GUDEL 404DLS User manual

404 DLS
OPERATING MANUAL
Automatic lubrication system
FlexxPump 404DLS
Project / Order:
Bill of materials:
Serial number:
Year of manufacture:
BETRIEBSANLEITUNG AUTOMATIC LUBRICATION SYSTEM FLEXXPUMP 404DLS72057594178931083_V7.0_EN-US
B1X.xxxxxxxxx-xxxx
09xxxxx
2018

© 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.
72057594178931083_v7.0_EN-US

Revision history
Version Date Description
7.0 01.06.2018 Valid as of FlexxPump serial number
1601929
Updated:
• Actuate ÜChapter6.4,243
• Lubrication recommendation Ü255
New:
• Splitter Ü229
ÜChapter5.2.3.1,233
6.0 12.04.2018 Updated:
• Lubrication check Ü261
5.0 12.12.2017 Updated:
• Lubrication check Ü261
4.0 08.08.2017 Added:
• Lubrication check Ü261
3.0 27.02.2017 Corrected:
• Standards and guidelines of the Declara-
tion of conformity ÜChapter1,211
2.0 29.11.2016 Updated:
• New signatures on Declaration of con-
formity ÜChapter1,211
• Entire manual updated
1.0 29.07.2016 Basic version
Table-1 Revision history
Revision history
OPERATING MANUAL Automatic lubrication system
FlexxPump 404DLS
72057594178931083_v7.0_EN-US
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Revision history
OPERATING MANUAL Automatic lubrication system
FlexxPump 404DLS
72057594178931083_v7.0_EN-US
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Table of contents
1 EC declaration of conformity 11
2 General 13
2.1 Further applicable documentation................ .................13
2.2 Purpose of the document..................... ......................13
2.3 Explanation of symbols/abbreviations.............................. 14
3 Safety 15
3.1 General ...............................................................15
3.1.1 Product safety .........................................................15
3.1.2 Personnel qualifications..................................................16
3.1.2.1 Operating companies....................................................16
3.1.2.2 Transport specialists....................................................17
3.1.2.3 Fitters ................................ .................................17
3.1.2.4 Commissioning technicians ...................... .......................17
3.1.2.5 Operators .............................. ...............................17
3.1.2.6 Manufacturer's technicians.............................................. 18
3.1.2.7 Maintenance technicians.................................................18
3.1.2.8 Service technicians .......................... ...........................19
3.1.2.9 Disposal specialists.......................... ...........................19
3.1.3 Disregarding safety regulations.......................................... 20
3.1.4 Installation instructions..................................................20
3.2 Hazard symbols in the manual .....................................21
3.2.1 Hazard warnings .......................................................21
3.2.2 Explanation of warning symbol.......................................... 22
3.3 Fundamentals of safety..............................................23
3.3.1 Product-specific hazards.................................................23
3.3.2 Material safety data sheets (MSDS)...................................... 24
Table of contents
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4 Product description 25
4.1 Use ................................. ..................................25
4.1.1 Intended use............................. ..............................25
4.1.2 Non-intended use.......................................................25
4.2 Product designation........................ .........................26
4.3 Technical data........................... ............................27
4.3.1 FlexxPump..............................................................27
4.3.1.1 Dimensions and connections 404DLS................. ..................27
4.3.1.2 Temperature ranges.................................................... 28
4.3.1.3 IP protection class ..................................................... 28
4.3.1.4 Operating pressure......................................................28
4.3.2 Splitter .................................................................29
4.3.2.1 Temperature ranges.................................................... 29
4.3.2.2 Accuracy of the lubricant distribution................. ..................29
4.3.2.3 Minimum lubrication quantity..................... ......................29
4.3.2.4 Maximum pressure.......................... ...........................29
4.3.3 Lubricant amount .......................................................29
4.3.4 Shelf life of Güdel H1 lubricant.......................................... 29
5 Design, function 31
5.1 Design................................................................ 31
5.1.1 Detailed design of FlexxPump 404DLS ...................................32
5.2 Function .............................................................33
5.2.1 Functional description...................................................33
5.2.2 FlexxPump..............................................................33
5.2.2.1 404DLS................................................................ 33
5.2.3 Splitter .................................................................33
5.2.3.1 Function............................... ................................33
Table of contents
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6 Commissioning 35
6.1 Introduction .........................................................35
6.1.1 Safety.................................................................. 35
6.1.1.1 Personnel qualifications..................................................35
6.2 Transport ............................................................ 35
6.3 Installing .............................................................36
6.3.1 Prerequisites............................................................36
6.3.2 Installing the FlexxPump.................................................37
6.3.3 Connect hydraulics......................................................38
6.3.3.1 404DLS 3-fold ......................................................... 38
6.3.3.2 404DLS 6-fold ......................................................... 39
6.3.3.3 404DLS 10-fold .........................................................40
6.3.4 Connecting electrical equipment.........................................41
6.3.4.1 Connecting the 404DLS.................................................42
6.4 Actuate ...............................................................43
6.4.1 Recommended solution, software programming............ .............44
6.4.2 Switching the FlexxPump on and off......................................45
6.4.3 Lubrication .............................................................47
6.4.4 Filling hydraulic lines / venting the FlexxPump............................ 49
6.4.5 Error message: Empty...................................................51
6.4.6 Error message: General..................................................53
6.4.7 Lubrication recommendation ..................... ......................55
6.4.7.1 General information.................................................... 55
6.4.7.2 Basics.................................................................. 56
6.4.7.3 Minimum lubrication quantity..................... ......................56
6.4.7.4 Calculation formulas.................................................... 57
6.5 Initial commissioning................................................ 59
6.5.1 Carrying out a lubrication check.........................................61
Table of contents
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7 Operation 66
7.1 General ...............................................................66
7.2 Personnel ............................................................ 66
7.3 Safety .................................................................67
8 Maintenance 69
8.1 Introduction .........................................................69
8.1.1 Safety.................................................................. 69
8.1.2 Personnel qualifications..................................................69
8.2 Consumables and auxiliary agents..................................70
8.2.1 Cleaning agents .........................................................70
8.2.1.1 Table of cleaning agents .................................................70
8.2.2 Lubricants ............................................................. 70
8.2.2.1 Lubrication .............................................................71
Automatic lubrication system........................................ 71
8.2.2.2 Lubricant table............................ .............................72
8.3 Maintenance tasks......................... ..........................73
8.3.1 Checking automatic lubrication system.................................. 73
8.3.2 Replacing the cartridge........................ .........................74
8.4 Maintenance table......................... ..........................77
9 Repairs 79
9.1 Introduction .........................................................79
9.1.1 Safety.................................................................. 79
9.1.2 Personnel qualifications..................................................79
9.2 Malfunctions / Troubleshooting.................. ...................80
9.3 Service departments................................................ 80
Table of contents
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10 Decommissioning, storage 81
10.1 Introduction .........................................................81
10.1.1 Personnel qualifications..................................................81
10.2 Storage conditions ...................................................81
10.3 Decommissioning....................................................82
10.3.1 Shutdown.............................................................. 82
10.3.2 Cleaning, rust-proofing........................ .........................82
10.3.3 Identification............................................................82
10.4 Recommissioning.................................................... 83
11 Disposal 85
11.1 Introduction .........................................................85
11.1.1 Safety.................................................................. 85
11.1.2 Personnel qualifications..................................................85
11.2 Disposal .............................................................. 86
11.3 Waste management compliant assemblies........................ 86
11.3.1 Disassembly ........................................................... 86
11.3.2 Material groups .........................................................87
11.4 Disposal facilities, authorities................... ....................87
12 Accessories 89
12.1 PLC connecting cable ....................... ........................89
13 Spare parts supply 91
13.1 Service departments................................................ 93
13.2 Explanations regarding the spare parts list........................ 99
13.2.1 Parts list............................... ................................99
13.2.2 Position drawings .......................................................99
Table of contents
OPERATING MANUAL Automatic lubrication system
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14 Torque tables 100
14.1 Tightening torques for screws................... ................... 100
14.1.1 Zinc plated screws ......................................................101
14.1.2 Black screws ............................................................102
14.1.3 Stainless steel screws ...................................................103
Illustrations 105
List of tables 107
Index 109
Appendix
Layout
Spare parts lists
Table of contents
OPERATING MANUAL Automatic lubrication system
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