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
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90071992656444683_v9.0_EN-US
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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
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11 Accessories 121
11.1 PLC connecting cable .............................................. 121
12 Spare parts supply 123
12.1 Service departments....................... ........................125
12.2 Explanations regarding the spare parts list.......................131
12.2.1 Parts list...............................................................131
12.2.2 Position drawings .....................................................131
13 Torque tables 132
13.1 Tightening torques for screws................... ................... 132
13.1.1 Zinc plated screws ......................................................133
13.1.2 Black screws ............................................................134
13.1.3 Stainless steel screws ...................................................135
Illustrations 137
List of tables 139
Index 141
Appendix
Layout
Spare parts lists
Declaration of conformity for TriboServ
Table of contents
OPERATING MANUAL Automatic lubrication system
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Table of contents
OPERATING MANUAL Automatic lubrication system
FlexxPump 402 / 402B
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1 General
Read the entire manual before working with the product. The manual con-
tains important information for your personal safety. The manual must be
read and understood by all persons who work on the product in any of the
product life phases.
General
OPERATING MANUAL Automatic lubrication system
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1.1 Further applicable documentation
All documents delivered with this manual are further applicable documenta-
tion. They must be observed in addition to this operating manual for the safe
handling of the product.
Document Explanation Target readership
FAQ: FlexxPump • Sales / project man-
agement
• Software engineer
• Maintenance techni-
cian
• Service technician
• Fitter
• Operating company
• Electrical engineer
Module Catalog only available in Ger-
man, French and Eng-
lish
Sales / project manage-
ment
Racks / Pinions Catalog Only available in Eng-
lish and Russian
Sales / project manage-
ment
Quick guide to check-
ing lubrication system
• Maintenance techni-
cian
• Service technician
• Fitters
Lubrication quantity
calculator
• Only available in
English
• Only available as Mi-
crosoft Excel
• Sales / project man-
agement
• Software engineer
Table1-1 Other applicable documentation
General
OPERATING MANUAL Automatic lubrication system
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1.2 Purpose of the document
This manual describes all the product life phases of the product:
• Transport
• Commissioning
• Operation
• Maintenance
• Repairs
• Disposal
The manual contains the information required for using the product as in-
tended. It is an essential component of the product.
The manual must be available at the product site throughout the entire ser-
vice life of the product. If the product is sold, the manual must be transferred
to the new owner.
General
OPERATING MANUAL Automatic lubrication system
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1.3 Explanation of symbols/abbreviations
The following symbols and abbreviations are used in this manual:
Symbol/Abbrevia-
tion
Use Explanation
Ü
For cross-reference See
2
Possibly for cross-ref-
erence
Page
Fig. Designation of graphics Figure
Table Designation of tables Table
In the tip Information or tip
Table1-2 Explanation of symbols/abbreviations
General
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2 Safety
2.1 General
Read the entire manual before working with the product. The manual con-
tains important information for your personal safety. The manual must be
read and understood by all persons who work on the product in any of the
product life phases.
2.1.1 Product safety
Residual danger The product is built using state-of-the-art technology. It was designed and
constructed in accordance with the accepted safety regulations. However,
some residual danger remains during its operation.
There is danger to the personal safety of the operator as well as for the prod-
uct and other property.
Operation When operating the product, always observe this manual and ensure that the
system is always in perfect working order.
Safety
OPERATING MANUAL Automatic lubrication system
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2.1.2 Personnel qualifications
WARNING
Lack of safety training
Incorrect behavior of untrained or insufficiently trained technicians can result
in severe or fatal injuries!
Before technicians work on safety-related aspects of the product:
• Ensure that the technicians are trained with regard to safety
• Train and instruct the technicians specifically for their area of responsibility
Only appropriately trained and authorized technicians are allowed to work on
the product.
Persons are authorized if:
• they are familiar with the relevant safety regulations for their area of re-
sponsibility
• they have read and understood this manual
• they meet the requirements for an area of responsibility
• they were assigned an area of responsibility by the operator
The technician is responsible to third parties in his area of responsibility.
During a training session or instruction, the technician may only work on the
product under the supervision of an experienced manufacturer's technician.
Safety
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2.1.2.1 Operating companies
The operating company is responsible for ensuring that:
• the product is used as intended
• the product is sufficiently lubricated at all times
• all safety aspects are complied with
• the product is put out of operation if the functioning of the safety equip-
ment is not fully guaranteed
• the technician working on the product is appropriately trained
• the technician is provided with personal protective equipment
• the operating manual is available to the technician at the operation site of
the product at all times
• the technicians are kept up-to-date regarding best practice
• the technicians are informed about technical progress, modifications, and
the like.
• the contracted cleaning staff only work under the supervision of a mainte-
nance technician
2.1.2.2 Transport specialists
The transport specialist:
• is able to transport loads safely
• is able to use slings safely and properly
• is able to secure the load properly
• has experience in transportation
2.1.2.3 Fitters
The fitter:
• has very good mechanical and/or electrical knowledge
• is flexible
• has assembly experience
Safety
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2.1.2.4 Commissioning technicians
The commissioning technician:
• has good programming knowledge
• has mechanical and/or electrical knowledge
• is flexible
The commissioning technician is responsible for the following tasks:
• commissioning the product
• testing the functions of the product
2.1.2.5 Operators
The operator:
• was trained and instructed by the operating company or the manufacturer
• has very good knowledge of the user interface and the operating elements
• has process knowledge which is specifically geared to the product
The operator is responsible for the following tasks:
• switching the control system of the product on and off
• creating production readiness
• monitoring the production process
• localizing minor malfunctions
2.1.2.6 Manufacturer's technicians
The manufacturer's technician:
• is employed on site at the premises of the manufacturer or representative
• has very good mechanical and/or electrical knowledge
• has good software knowledge
• has maintenance, service and repair experience
• has experience with Güdel products
The manufacturer's technician is responsible for the following tasks:
• performing mechanical and electrical maintenance work in accordance with
the manual
• performing mechanical and electrical service work in accordance with the
manual
• cleaning the product
• replacing spare parts
• localizing and fixing malfunctions
Safety
OPERATING MANUAL Automatic lubrication system
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