GUDEL FlexxPump 402 User manual

402
402 B
+_
OPERATING MANUAL
Automatic lubrication system
FlexxPump 402 / 402B
Project / Order:
Bill of materials:
Serial number:
Year of manufacture:
BETRIEBSANLEITUNG AUTOMATIC LUBRICATION SYSTEM FLEXXPUMP 402 / 402B 90071992656444683_V9.0_EN-US
B1X.xxxxxxxxx-xxxx
09xxxxxx
2019

© GÜDEL
Translation of the original instructions
This manual contains standard illustrations that may deviate from the original.
In the case of special models, options, or technical changes, the scope of deliv-
ery may differ from the descriptions here. Reprinting the instructions, in whole
or in part, requires our permission. Subject to change due to technical im-
provements.
90071992656444683_v9.0_EN-US

Revision history
Version Date Description
9.0 10/28/2019 New:
• Packaging symbols
ÜChapter5.2.1,244
• Repairing damaged packaging
ÜChapter5.2.2,245
• Declaration of conformity for TriboServ
ÜChapter,2151
Entire manual updated.
8.0 02/27/2019 Updated:
• Checking the lubrication system
Ü257
• Maintenance tasks Ü278
• Recommissioning Ü2114
New:
• Other applicable documentation
ÜChapter1.1,214
7.0 10/19/2018 Updated:
• Product identification Ü228
• Display elements Ü239
• Switch on the FlexxPump Ü261
• Lubrication quantity Ü268
• Set lubrication cycle Ü270
• Malfunctions / Troubleshooting Ü2106
Revision history
OPERATING MANUAL Automatic lubrication system
FlexxPump 402 / 402B
90071992656444683_v9.0_EN-US
3

Version Date Description
6.0 06/05/2018 Updated:
• Error message E3 Ü2108
• Lubrication recommendation Ü265
New:
• Splitter Ü234
ÜChapter4.2.3.1,241
Removed:
• Transport information for lithium battery
(new different battery type)
5.0 12/12/2017 Updated:
• Lubrication check Ü257
4.0 08/08/2017 Added:
• Lubrication check Ü257
3.0 02/27/2017 Corrected:
• Standards and guidelines of the Declara-
tion of conformityDeclaration of con-
formity, declaration of incorporation
2.0 11/29/2016 Updated:
• New signatures on Declaration of con-
formityDeclaration of conformity, decla-
ration of incorporation
• Entire manual updated
1.0 07/28/2016 Basic version
Table-1 Revision history
Revision history
OPERATING MANUAL Automatic lubrication system
FlexxPump 402 / 402B
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Table of contents
1 General 13
1.1 Further applicable documentation................ .................14
1.2 Purpose of the document..................... ......................15
1.3 Explanation of symbols/abbreviations.............................. 16
2 Safety 17
2.1 General ...............................................................17
2.1.1 Product safety .........................................................17
2.1.2 Personnel qualifications..................................................18
2.1.2.1 Operating companies....................................................19
2.1.2.2 Transport specialists....................................................19
2.1.2.3 Fitters ................................ .................................19
2.1.2.4 Commissioning technicians ...................... .......................20
2.1.2.5 Operators .............................. ...............................20
2.1.2.6 Manufacturer's technicians.............................................. 20
2.1.2.7 Maintenance technicians.................................................21
2.1.2.8 Service technicians .......................... ...........................21
2.1.2.9 Disposal specialists.......................... ...........................21
2.1.3 Disregarding safety regulations.......................................... 22
2.1.4 Installation instructions..................................................22
2.2 Hazard symbols in the manual .....................................23
2.2.1 Hazard warnings .......................................................23
2.2.2 Explanation of warning symbol.......................................... 24
2.3 Fundamentals of safety..............................................25
2.3.1 Product-specific hazards.................................................25
2.3.2 Material safety data sheets (MSDS)...................................... 26
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3 Product description 27
3.1 Use ................................. ..................................27
3.1.1 Intended use............................. ..............................27
3.1.2 Non-intended use.......................................................27
3.2 Product designation........................ .........................28
3.2.1 Type plate .............................. ...............................28
3.2.2 Position of the type plate................................................29
3.3 Technical data........................... ............................30
3.3.1 FlexxPump..............................................................31
3.3.1.1 Dimensions and connections 402 ................... ....................31
3.3.1.2 Dimensions and connections 402B.......................................32
3.3.1.3 Temperature ranges.................................................... 33
3.3.1.4 IP protection class ..................................................... 33
3.3.1.5 Operating pressure......................................................33
3.3.2 Splitter .................................................................34
3.3.2.1 Temperature ranges.................................................... 34
3.3.2.2 Accuracy of the lubricant distribution................. ..................34
3.3.2.3 Minimum lubrication quantity..................... ......................34
3.3.2.4 Maximum pressure.......................... ...........................34
3.3.3 Lubricant amount .......................................................34
3.3.4 Shelf life of Güdel H1 lubricant.......................................... 34
4 Design, function 35
4.1 Design................................................................ 35
4.1.1 Detailed design of FlexxPump 402 .......................................36
4.1.2 Detailed design of FlexxPump 402B.................. ...................37
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4.2 Function ............................................................. 38
4.2.1 Functional description...................................................38
4.2.2 FlexxPump..............................................................38
4.2.2.1 402.....................................................................38
4.2.2.2 402B ...................................................................38
4.2.2.3 Display elements........................... ............................39
4.2.2.4 Control elements .......................................................40
4.2.3 Splitter .................................................................41
4.2.3.1 Function............................... ................................41
5 Commissioning 43
5.1 Introduction .........................................................43
5.1.1 Safety.................................................................. 43
5.1.2 Personnel qualifications..................................................43
5.2 Transport ............................................................ 44
5.2.1 Packaging symbols...................................................... 44
5.2.2 Repairing damaged packaging............................................45
5.3 Installing .............................................................46
5.3.1 Prerequisites............................................................46
5.3.2 Installing the FlexxPump.................................................47
5.3.3 Connect hydraulics......................................................48
5.3.3.1 402/402B 3-fold.........................................................48
5.3.3.2 402/402B 6-fold.........................................................49
5.3.3.3 402/402B 10-fold........................................................50
5.3.4 Connecting electrical equipment.........................................51
5.3.4.1 Connecting 402.........................................................52
5.3.4.2 Connecting 402B........................................................53
5.3.5 Actuate................................................................ 54
5.3.5.1 FlexxPump 402 .........................................................54
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5.4 Initial commissioning................................................ 55
5.4.1 Checking the lubrication system .........................................57
5.4.2 Switching on the FlexxPump 402/402B...................................61
5.4.2.1 Lubrication cycle........................... ............................62
5.4.2.2 Special dispensing .......................................................62
6 Operation 63
6.1 General ...............................................................63
6.2 Personnel ............................................................ 63
6.3 Safety .................................................................64
6.4 Setting the lubrication cycle........................................ 65
6.4.1 Lubrication recommendation ..................... ......................65
6.4.1.1 General information.................................................... 65
6.4.1.2 Basics.................................................................. 66
6.4.1.3 Calculation formulas.................................................... 67
6.4.2 Lubrication quantity.....................................................68
6.4.3 Minimum lubrication quantity..................... ......................69
6.4.4 Setting the lubrication cycle..............................................70
6.5 Malfunctions ............................ .............................71
6.6 Switching off FlexxPump 402/402B................ .................72
7 Maintenance 73
7.1 Introduction .........................................................73
7.1.1 Safety.................................................................. 73
7.1.2 Personnel qualifications..................................................74
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7.2 Consumables and auxiliary agents..................................75
7.2.1 Cleaning agents .........................................................75
7.2.1.1 Table of cleaning agents .................................................75
7.2.2 Lubricants .............................................................75
7.2.2.1 Lubrication .............................................................76
Automatic lubrication system........................................ 76
7.2.2.2 Lubricant table............................ .............................77
7.3 Maintenance tasks......................... ..........................78
7.3.1 Replacing the cartridge........................ .........................79
7.3.2 Replacing the battery 402B ...................... .......................81
7.3.3 Checking the lubrication system .........................................85
7.3.4 Checking automatic lubrication system.................................. 89
7.3.5 Replacing the FlexxPump....................... ........................90
7.3.5.1 Disassembling the FlexxPump............................................90
7.3.5.2 Installing the FlexxPump.................................................91
7.3.5.3 Connect hydraulics......................................................92
402/402B 3-fold..................................................... 92
402/402B 6-fold..................................................... 93
402/402B 10-fold....................................................94
7.3.5.4 402.....................................................................95
Connecting electrical equipment.....................................95
7.3.5.5 Checking the lubrication system .........................................97
7.3.5.6 Switching on the FlexxPump 402/402B................ .................101
7.4 Maintenance table..................................................103
8 Repairs 105
8.1 Introduction ........................... ............................ 105
8.1.1 Safety................................ .................................105
8.1.2 Personnel qualifications................................................ 105
8.2 Repairs .............................................................. 106
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8.3 Malfunctions / Troubleshooting....................................106
8.3.1 Display element and malfunctions...................................... 106
8.3.2 Empty E1 .............................................................107
8.3.3 Overcurrent E2........................... ............................107
8.3.4 Operating voltage too low E3..........................................108
8.3.5 Internal electrical error E4..............................................108
8.3.6 Internal mechanical error E5..................... ......................109
8.3.7 System malfunction....................................................109
8.3.8 Functional check .......................................................110
8.4 Service departments...............................................110
9 Decommissioning, storage 111
9.1 Introduction ........................... ............................ 111
9.1.1 Personnel qualifications................................................ 111
9.2 Storage conditions .................................................112
9.3 Decommissioning......................... ......................... 113
9.3.1 Shutdown.............................. ...............................113
9.3.2 Cleaning, rust-proofing.................................................113
9.3.3 Identification.......................................................... 113
9.4 Recommissioning......................... ..........................114
10 Disposal 117
10.1 Introduction ........................... ............................ 117
10.1.1 Safety................................ .................................117
10.1.2 Personnel qualifications................................................ 117
10.2 Disposal .............................................................118
10.3 Waste management compliant assemblies........... ............119
10.3.1 Disassembly ...........................................................119
10.3.2 Material groups .......................................................120
10.4 Disposal facilities, authorities......................................120
Table of contents
OPERATING MANUAL Automatic lubrication system
FlexxPump 402 / 402B
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