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
OPERATING MANUAL Lubrication system
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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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