GUDEL FlexxPump4 D User manual

OPERATING MANUAL
Lubrication system
FlexxPump4D
Project / Order:
Bill of materials:
Serial number:
Year of manufacture:
BETRIEBSANLEITUNG LUBRICATION SYSTEM FLEXXPUMP4D9007202674126091_V2.0_EN-US
B1X.xxxxxxxxx-xxxx
10xxxxxx
2021

© 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.
9007202674126091_v2.0_EN-US

Revision history
Version Date Description
2.0 04.03.2021 Added:
• Transport Ü236
• Input signals external control
ÜChapter5.5.2,246
• Output signals external control
ÜChapter5.5.3,253
• Maintenance intervals Ü276
Structure modified:
• Actuate ÜChapter5.5,244
• Maintenance tasks Ü276
1.0 26.11.2020 Basic version
Tab.-1 Revision history
Revision history
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Revision history OPERATING MANUAL Lubrication system FlexxPump4D
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Table of contents
1 General 11
1.1 Further applicable documentation................ .................11
1.2 Purpose of the document..................... ......................12
1.3 Explanation of symbols/abbreviations.............................. 13
2 Safety 15
2.1 Hazard symbols in the manual .....................................15
2.1.1 Hazard warnings .......................................................15
2.1.2 Explanation of warning symbol.......................................... 16
2.2 Product safety ........................... ............................16
2.3 Danger areas ........................... .............................17
2.3.1 Safety and monitoring equipment ................... ....................17
2.4 Personnel ............................................................ 18
2.4.1 Personal safety equipment...............................................18
2.4.2 Personnel qualifications..................................................20
2.4.2.1 Operating companies....................................................20
2.4.2.2 Fitters ................................ .................................21
2.4.2.3 Commissioning technicians ...................... .......................21
2.4.2.4 Operators .............................. ...............................21
2.4.2.5 Manufacturer's technicians.............................................. 22
2.4.2.6 Maintenance technicians.................................................22
2.4.2.7 Service technicians .......................... ...........................23
2.4.2.8 Disposal specialists.......................... ...........................23
2.5 Product-specific hazards ............................................ 23
2.6 Material safety data sheets (MSDS)................................ 24
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3 Product description 25
3.1 Use ................................. ..................................25
3.1.1 Lifetime................................................................ 25
3.1.2 Intended use............................. ..............................25
3.1.3 Non-intended use.......................................................25
3.2 Product designation........................ .........................26
3.2.1 Type plate .............................. ...............................26
3.2.2 Position of the type plate................................................27
3.3 Technical data........................... ............................27
3.3.1 FlexxPump..............................................................28
3.3.1.1 Dimensions and connections FlexxPump4 D..............................28
3.3.1.2 Temperature ranges.................................................... 29
3.3.1.3 IP protection class ..................................................... 29
3.3.1.4 Operating pressure......................................................29
3.3.2 Splitter .................................................................30
3.3.2.1 Temperature ranges.................................................... 30
3.3.2.2 Accuracy of the lubricant distribution................. ..................30
3.3.2.3 Minimum lubrication quantity..................... ......................30
3.3.2.4 Maximum pressure.......................... ...........................30
3.3.3 Lubricant amount .......................................................30
3.3.4 Shelf life of Güdel H1 lubricant.......................................... 30
4 Design, function 31
4.1 Design................................................................ 31
4.1.1 Detailed design of FlexxPump4D................... ....................32
4.2 Function .............................................................33
4.2.1 Functional description...................................................33
4.2.2 FlexxPump..............................................................33
4.2.3 Splitter .................................................................33
4.2.4 Y-segment.............................. ...............................34
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5 Commissioning 35
5.1 Introduction .........................................................35
5.1.1 Safety.................................................................. 35
5.1.2 Personnel qualifications..................................................36
5.2 Intermediate storage................................................36
5.3 Transport ............................................................ 36
5.4 Installing .............................................................37
5.4.1 Prerequisites............................................................37
5.4.2 Installing the lubricant pump.............................................38
5.4.3 Connect hydraulics......................................................39
5.4.3.1 FlexxPump4 D 3-fold....................................................39
5.4.3.2 FlexxPump4 D 6-fold....................................................40
5.4.3.3 FlexxPump4 D 9-fold....................................................41
5.4.3.4 FlexxPump4 D 10-fold.................................................. 42
5.4.4 Connecting electrical equipment.........................................43
5.4.4.1 Connecting .............................................................43
5.5 Actuate ...............................................................44
5.5.1 Suggested solution: Programming software...............................45
5.5.2 Input signals and external control system................................ 46
5.5.2.1 Lubrication .............................................................47
5.5.2.2 Filling lubrication lines / Venting FlexxPump4D.......................... 49
5.5.2.3 Reset the error .........................................................51
5.5.3 Output signals and external control system.............................. 53
5.5.3.1 Switching on and off.................................................... 55
5.5.3.2 Empty .................................................................57
5.5.3.3 General error.......................................................... 59
5.5.4 Lubrication recommendation ..................... ......................61
5.5.4.1 General information.................................................... 61
5.5.4.2 Basics.................................................................. 62
5.5.4.3 Minimum lubrication quantity..................... ......................62
5.5.4.4 Calculation formulas.................................................... 63
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5.6 Initial commissioning................................................ 64
5.6.1 Checking the lubrication system .........................................65
6 Operation 70
6.1 General ...............................................................70
6.2 Personnel qualifications...................... .......................70
7 Maintenance 71
7.1 Introduction .........................................................71
7.1.1 Safety.................................................................. 72
7.1.2 Personnel qualifications..................................................72
7.2 Consumables and auxiliary agents..................................73
7.2.1 Cleaning agents .........................................................73
7.2.1.1 Table of cleaning agents .................................................73
7.2.2 Lubricants ............................................................. 73
7.2.2.1 Lubrication .............................................................74
Standard............................................................ 74
Temperature range 0°C to +5°C..................................... 75
Temperature range -30°C to -20°C.................................. 75
7.2.2.2 Lubricant table............................ .............................76
7.3 Maintenance tasks......................... ..........................76
7.3.1 Maintenance intervals....................................................76
7.3.2 Maintenance tasks after 2,200 hours .....................................79
7.3.2.1 Replacing lubricant cartridge.............................................79
7.3.2.2 Checking the lubrication system .........................................83
7.3.3 Maintenance tasks after 10,000 hours................. ..................87
7.3.3.1 Cleaning and checking lubrication system................................ 87
7.3.4 Maintenance tasks after 20,000 hours................. ..................89
7.3.4.1 Replacing the lubricant pump ..................... ......................89
Removing the lubricant pump........................................ 89
Replacing the lubricant pump ........................................ 89
Installing the lubricant pump......................................... 90
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Connect hydraulics..................................................91
Connecting electrical equipment.....................................95
Checking the lubrication system...................................... 97
7.4 Maintenance table..................................................101
7.5 Feedback on the instructions......................................103
8 Repairs 104
8.1 Introduction ........................... ............................ 104
8.1.1 Safety................................ .................................104
8.1.2 Personnel qualifications................................................ 105
8.2 Repairs .............................................................. 105
8.3 Malfunctions / Troubleshooting....................................106
9 Decommissioning, storage 107
9.1 Introduction ........................... ............................ 107
9.1.1 Personnel qualifications................................................ 107
9.2 Storage conditions .................................................107
9.3 Decommissioning......................... ......................... 108
9.3.1 Shutdown.............................. ...............................108
9.3.2 Cleaning, rust-proofing.................................................108
9.3.3 Identification.......................................................... 108
9.4 Recommissioning......................... ..........................109
9.4.1.1 Cleaning the rails and racks............................................ 110
9.4.1.2 Pre-lubricating rails and racks.......................................... 111
10 Disposal 113
10.1 Introduction ........................... ............................ 113
10.1.1 Safety................................ .................................113
10.1.2 Personnel qualifications................................................ 113
10.2 Disposal .............................................................114
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10.3 Waste management compliant assemblies........... ............114
10.3.1 Disassembly ...........................................................114
10.3.2 Material groups .......................................................116
10.4 Disposal facilities, authorities......................................116
11 Accessories 117
11.1 PLC connecting cable .............................................. 117
12 Spare parts supply 119
12.1 Service departments....................... ........................121
12.2 Explanations regarding the spare parts list.......................127
12.2.1 Spare parts and wear items list..........................................127
12.2.2 Position drawings .....................................................127
13 Torque tables 128
13.1 Tightening torques for screws................... ................... 128
13.1.1 Zinc plated screws ......................................................129
Illustrations 131
List of tables 133
Index 135
Appendix
Layout
Spare parts lists
Declaration of conformity for TriboServ
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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.
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 Control
Requirements
Only available in Eng-
lish
Software engineer
General
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Document Explanation Target readership
Lubrication quantity
calculator
• Only available in
English
• Only available as Mi-
crosoft Excel
• Sales / project man-
agement
• Software engineer
Software modules for
standard control sys-
tems
Only available as ZIP
file
Software engineer
Tab.1-1 Other applicable documentation
1.2 Purpose of the document
This manual describes the following product life phases of the product:
• 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 operation site throughout the
entire service life of the product. If the product is sold, the manual must be
transferred to the new owner.
General OPERATING MANUAL Lubrication system FlexxPump4D
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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
Tab.1-2 Explanation of symbols/abbreviations
General
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General OPERATING MANUAL Lubrication system FlexxPump4D
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2 Safety
2.1 Hazard symbols in the manual
2.1.1 Hazard warnings
The hazard warnings are defined for the following four types of danger levels:
DANGER
DANGER
DANGER identifies a hazard with high risk that could lead to serious injury
or death.
WARNING
WARNING
WARNING identifies a hazard with medium risk that could lead to moderate
injury.
CAUTION
CAUTION
CAUTION identifies a hazard with low risk that could lead to slight injury.
NOTE
NOTE
NOTE identifies a hazard that can lead to property damage.
Safety
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2.1.2 Explanation of warning symbol
Hazard warnings for personal injuries contain the symbol of the correspond-
ing hazard.
Symbol Explanation of symbols
Hazards due to general causes
Hazards due to environmental pollution
Hazards due to dangerous electrical voltage
Tab.2-1 Explanation of warning symbol
2.2 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.
Use When operating the product, observe this manual and ensure that the prod-
uct is always in perfect working order.
The product must never be modified or used in a manner contrary to its in-
tended use. Ü225
Safety OPERATING MANUAL Lubrication system FlexxPump4D
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2.3 Danger areas
The danger area is the area at a product and/or in its surroundings where
there is a potential of danger to the life or health of persons, or to the envi-
ronment, or damage to property. The operator must secure the danger area
(protective fence/sensors). No person is allowed access to the danger area.
All safety provisions and hazard symbols at the product must be obeyed. The
general safety provisions must be observed and complied with.
2.3.1 Safety and monitoring equipment
DANGER
Missing safety and monitoring equipment
Missing or changed safety and monitoring equipment could lead to serious or
fatal injuries!
• Do not dismantle, bridge, or change any safety or monitoring equipment
• After commissioning, attach all safety and monitoring equipment correctly
• Ensure that the safety and monitoring equipment is closed during opera-
tion
You will find information on the separating safety and monitoring equipment
in the documentation of the entire plant.
The operator is responsible for ensuring safe conditions in the vicinity of the
product. In particular, he must ensure compliance with the general safety reg-
ulations, guidelines and standards. Before commissioning, the operator must
check if all the safety measures have been met. They must cover all hazards.
This is the only way to ensure that application of the product conforms to CE
regulations.
According to the machinery directive, the safety and monitoring equipment
must:
• Correspond to best practices
• Comply with the required safety category
Safety
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2.4 Personnel
The generally accepted occupational safety rules must be observed and imple-
mented.
2.4.1 Personal safety equipment
The operator is responsible for providing specialists with personal safety
equipment.
Safety OPERATING MANUAL Lubrication system FlexxPump4D
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Fig.2-1 PSA (personal safety equipment)
Always wear safety helmet Wear fall protection system when work-
ing from 2 m height.
Always wear protective goggles
Wear welding goggles during welding
work
Always wear safety shoes
Wear hearing protection during opera-
tion and when working with compressed
air
Always wear protective clothing
Wear face protection when working with
compressed air and hot oil
Wear safety gloves when dismantling hot
parts and when working with lubricants
and detergents
Safety
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2.4.2 Personnel qualifications
DANGER
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.
2.4.2.1 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
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