GUDEL FlexxPump4 N User manual

OPERATING MANUAL
FlexxPump4N Lubrication
System
Project / Order:
Bill of materials:
Serial number:
Year of manufacture:
BETRIEBSANLEITUNG FLEXXPUMP4N LUBRICATION SYSTEM3422906891_V1.0_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.
3422906891_v1.0_EN-US

Revision history
Version Date Description
1.0 13.04.2021 Basic version
Tab.-1 Revision history
Revision history
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Revision history OPERATING MANUAL FlexxPump4N Lubrication System
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Table of contents
1 General 13
1.1 Further applicable documentation................ .................13
1.2 Purpose of the document..................... ......................14
1.3 Explanation of symbols/abbreviations.............................. 14
2 Safety 15
2.1 Hazard symbols in the manual .....................................15
2.1.1 Warning notes............................ .............................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....................................................21
2.4.2.2 Fitters ................................ .................................21
2.4.2.3 Commissioning technicians ...................... .......................21
2.4.2.4 Operators .............................. ...............................22
2.4.2.5 Manufacturer's technicians.............................................. 22
2.4.2.6 Maintenance technicians.................................................23
2.4.2.7 Service technicians .......................... ...........................23
2.4.2.8 Disposal specialists.......................... ...........................23
2.5 Product-specific hazards ............................................ 24
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 FlexxPump4N dimensions and connections.............. ...............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 configuration of the FlexxPump4N .............................32
4.2 Function .............................................................33
4.2.1 Functional description...................................................33
4.2.2 FlexxPump..............................................................33
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4.2.2.1 Display elements........................... ............................33
LED ................................................................34
Character display.................................................... 34
Submenu............................................................ 35
Malfunctions ........................................................37
4.2.2.2 Control elements .......................................................38
4.2.3 Splitter .................................................................39
4.2.4 Y-segment.............................. ...............................39
5 Commissioning 41
5.1 Introduction .........................................................41
5.1.1 Safety.................................................................. 41
5.1.2 Personnel qualifications..................................................42
5.2 Intermediate storage................................................42
5.3 Transport ............................................................ 43
5.4 Installing .............................................................43
5.4.1 Prerequisites............................................................43
5.4.2 Installing the lubricant pump.............................................44
5.4.3 Connect hydraulics......................................................45
5.4.3.1 FlexxPump4 N/B 3-fold..................................................45
5.4.3.2 FlexxPump4 N/B 6-fold..................................................46
5.4.3.3 FlexxPump4 N/B 9-fold..................................................47
5.4.3.4 FlexxPump4 N/B 10-fold................................................ 48
5.4.4 Connecting electrical equipment.........................................49
5.4.4.1 Connecting .............................................................49
5.5 Activation in draining time mode or hour mode.................. 51
5.5.1 Output signals in draining time mode or hour mode.......... ...........51
5.6 Activate in pulse mode.............................................. 51
5.6.1 Suggested solution: Programming software...............................52
5.6.2 Input signals and external control system................................ 53
5.6.2.1 Trigger single dose.......................... ...........................55
5.6.2.2 Fill lubricant lines / bleed FlexxPump.....................................57
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5.6.2.3 Reset the error .........................................................59
5.6.3 Output signals and external control system..............................61
5.6.3.1 Switching on and off.................................................... 63
5.6.3.2 Empty .................................................................65
5.6.3.3 General error.......................................................... 67
5.7 Initial commissioning................................................ 69
5.7.1 Switch on FlexxPump....................................................69
5.7.2 Execute FIL menu.......................................................70
5.7.2.1 Cancel FIL menu ........................... ............................71
5.7.3 Checking the lubrication system .........................................73
5.7.4 Check settings............................ .............................77
6 Operation 78
6.1 General ...............................................................78
6.2 Personnel qualifications...................... .......................78
6.3 Operating mode.......................... ...........................78
6.4 Lubrication recommendation .......................................79
6.4.1 General information.................................................... 79
6.4.2 Basics.................................................................. 80
6.4.3 Minimum lubrication quantity..................... ......................80
6.4.4 Calculation formulas.................................................... 81
6.5 Menu ................................ .................................82
6.5.1 Explanation of symbols........................ .........................82
6.5.2 Menu navigation........................................................ 83
6.6 Sub-menu............................................................ 84
6.6.1 SET menu.............................................................. 84
6.6.2 PRO menu in emptying time mode...................................... 85
6.6.3 PRO menu in hour mode................................................88
6.6.4 PRO menu in pulse mode................................................89
6.6.5 INF menu in draining time mode.........................................90
6.6.6 INF menu in hour mode.................................................91
6.6.7 INF menu in pulse mode................................................ 92
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6.6.8 RUN menu .............................................................93
6.7 Switch off FlexxPump....................... ........................94
7 Maintenance 95
7.1 Introduction .........................................................95
7.1.1 Safety.................................................................. 95
7.1.2 Personnel qualifications..................................................96
7.2 Consumables and auxiliary agents..................................96
7.2.1 Cleaning agents .........................................................96
7.2.1.1 Table of cleaning agents .................................................96
7.2.2 Lubricants .............................................................97
7.2.2.1 Lubrication .............................................................98
Standard............................................................ 98
Temperature range 0°C to +5°C..................................... 99
Temperature range -30°C to -20°C..................................99
7.2.2.2 Lubricant table........................................................ 100
7.3 Maintenance tasks..................................................101
7.3.1 Maintenance intervals..................................................101
7.3.2 Maintenance tasks after 2,200 hours ...................................104
7.3.2.1 Replacing lubricant cartridge..................... ......................104
7.3.2.2 Checking the lubrication system .......................................107
7.3.3 Maintenance tasks after 10,000 hours...................................111
7.3.3.1 Cleaning and checking lubrication system................................111
7.3.4 Maintenance tasks after 20,000 hours...................................113
7.3.4.1 Replacing the lubricant pump ...........................................113
Removing the lubricant pump.......................................113
Replacing the lubricant pump .......................................113
Installing the lubricant pump........................................114
Connect hydraulics.................................................115
Connecting electrical equipment....................................119
Switch on FlexxPump...............................................120
Checking the lubrication system.....................................123
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7.4 Maintenance table..................................................127
7.5 Feedback on the instructions...................................... 129
8 Repairs 130
8.1 Introduction ........................... ............................ 130
8.1.1 Safety................................ .................................130
8.1.2 Personnel qualifications................................................ 131
8.2 Repairs .............................................................. 131
8.3 Malfunctions / Troubleshooting....................................132
9 Decommissioning, storage 133
9.1 Introduction ........................... ............................ 133
9.1.1 Personnel qualifications................................................ 133
9.2 Storage conditions .................................................133
9.3 Decommissioning......................... ......................... 134
9.3.1 Shutdown.............................. ...............................134
9.3.2 Cleaning, rust-proofing.................................................134
9.3.3 Identification.......................................................... 135
9.4 Recommissioning......................... ..........................135
9.4.1.1 Cleaning the rails and racks............................................ 136
9.4.1.2 Pre-lubricating rails and racks.......................................... 137
10 Disposal 139
10.1 Introduction ........................... ............................ 139
10.1.1 Safety................................ .................................139
10.1.2 Personnel qualifications................................................ 139
10.2 Disposal .............................................................140
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