Lincoln industrial ZPU 75 User manual

Owner Manual
Operating Instructions and Service Parts List
1115a95
Owner Manual
ZPU 75
1.1A-38001-C00
Subject to change without notice
High Pressure Barrel Pump
Model ZPU 75
LINCOLN GmbH  Postfach 1263  D-69183 Walldorf  el [phone]  Fax [phone]

1.1A-38001-C00
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LINCOLN GmbH  Postfach 1263  D-69183 Walldorf  el [phone]  Fax [phone]
If persons who are charged with work with the pump/lubrication
system do not have a good command of the english language, it
is the users responsibility to take the necessary action to make
the User Manual, particularly the Operating Instructions, under-
standable to these persons
The User Manual must be read and used by all persons who are
charged with work with the pump/lubrication system, e g
 Operation, including adjustment, troubleshooting during
operation, elimination of production waste, maintenance,
disposal of process materials
 Maintenance (inspection, repairs)
Transport
This Owner manual is intended to familiarize the user with the
pump/lubrication system and to enable him to use its various fea-
tures
The Operating Instructions contain important information for
safe, correct and economic operation of the pump/lubrication sy-
stem Their observance will help avoid hazards, reduce repair
costs and downtime, increase the reliability and prolong the ser-
vice life of the pump/lubrication system
These Operating Instructions must be completed to include the
respective national regulations concerning the prevention of ac-
cidents and protection of the environment
The User Manual must always be available on the site where the
pump/lubrication system is in operation
Preface to the Owner manual
Item Page
Preface / Table of Contents
Table of Contents
Item Page
1 Safety Instr ctions ......................................... 3
2 Description ....................................................... 5
2 1 General 5
2 2 Appropriate Use 5
2 3 Technical Data 5
2 4 Structure 6
2 5 Electrical Equipment 7
2 6 Mode of Operation 7
3 Erection and Assembly .................................. 8
3 1 Erection of the Pump 8
3 2 Electrical Connection 8
4 Operating Instr ctions ................................... 9
4 1 Commissioning 9
4 2 Maintenance and Repairs 9
4 3 Troubleshooting 10
4 4 Adjustments 11
5 Spare Parts List ............................................. 12
6 Accessories ................................................... 18
6 1 Pressure switch 18
6 2 Motordata sheet ZPU 75 19
7 Declaration ..................................................... 19

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The Operating Instructions include general instructions which
must be followed when a pump/pump unit is installed, operated
or serviced Therefore, it is absolutely necessary for the fitter and
the specialist/user to read the Operating Instructions before a unit
is installed and commissioned The Operating Instructions must
always be available on the site where the machine/system is er-
ected
All general safety instructions contained in this main chapter on
safety must be observed as well as all special safety instructions
given in other main chapters
Hazard warnings in the Operating Instr ctions
The notes referring to safety contained in the Operating Instruc-
tions whose failure to observe may result in personal injury are
marked by the following symbol
Safety symbol acc. to DIN 4844-W9
The symbol warns of an electrical hazard
Safety symbol acc. to DIN 4844-W8
If ignoring the safety note might result in machine damages and
malfunction, the word
is added
Warnings directly fixed to the machine must always be observed
and must be kept in completely legible condition
1 Safety Instructions
Safety Instructions
10013a94
10014a94
Staff Q alification and Training
The staff responsible for operation, maintenance, inspection and
installation must be adequately qualified for these jobs The user
must properly regulate the field of responsibility and supervision
of the personnel If the personnel is not in command of the ne-
cessary expertise, they must receive appropriate training and in-
structions
If necessary, this can be done by the manufacturer/supplier on
behalf of the machine user Furthermore, the user must ensure
that the contents of the Operating Instructions are fully under-
stood by the personnel
Hazards res lting from fail re to observe the safety instr c-
tions
Failure to heed the safety warnings may result in damage to
equipment and the environment and/or personal injury
Failure to observe the safety notes may result in the loss of all
claims for damage
As an example, in the following we list some dangers which may
result from failure to observe the warnings:
 failure of machine/system to fulfill important functions
 failure of specified methods for maintenance and repair
 personal injury due to electrical, mechanical and chemical
influences
 danger to the environment due to leakage of harmful
materials
Safety-Conscio s Working
The safety instructions given in the Operating Instructions, the
prevailing national regulations for the prevention of accidents and
any internal working and shop regulations and accident preventi-
on measures of the user must be observed
Safety Instructions for the User/Operator
 If warm or cold machine parts may involve hazards, the
customer must protect them against accidental contact
 Do not remove protection devices for moving parts while the
machine is in operation
 Leakages of harmful materials must be disposed of so as to
jeopardize neither persons nor the environment The require-
ments of the law must be satisfied
 Danger caused by electrical current must be excluded (for
details refer to the applicable specifications of VDE and the
local power supply companies)
CAUTION

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Safety Instr ctions for Maintenance, Inspection and In-
stallation Services
The user must make sure that all maintenance, inspection and
installation work is executed by authorized and qualified ex-
perts who have throroughly read the Operating Instructions
On no account may work be done on the machine while the
machine is in operation Follow all instructions for shutting
down the machine as described in the Operating Instructions
Decontaminate pumps and pump units delivering harmful
materials
Reassemble all safety and protection devices immediately af-
ter completion of the cleaning procedure
Dispose of material harmful to the environment in accordance
with the applicable official regulations
Before putting the pump/pump unit into operation, ensure that
all points given in the chapter Commissioning are observed
Una thorized Modification and Spare Parts Prod ction
Alteration and modifications of the machine are only allowed if
approved by the manufacturer Original spare parts and ac-
cessories authorized by the manufacturer ensure safe opera-
tion If other parts are used, the manufacturer may be re-
leased from its liability for the resulting consequences
Inadmissible Operating Modes
The operational safety of the supplied product is only granted
if the product is operated according to the instructions given in
chapter 1 - General - of the Operating Instructions The max
ratings listed in the Technical Data sheet must never be ex-
ceeded
Commissioning of the product (pump/pump unit) within the
European Union is forbidden until it has been decided that the
machine in question meets the requirements of the EU guide-
lines
Safety Instructions

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1.1A-38001-C00
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LINCOLN GmbH  Postfach 1263  D-69183 Walldorf  el [phone]  Fax [phone]
2 Description
Description
2.1 General
This Owner manual only refers to high-pressure barrel pumps of
the series ZPU 75
It is intended for the personnel charged with the installation, ope-
ration and maintenance of the pump
If faults should occur although the Operating Instructions have
been followed, please contact our Service Department below:
LINCOLN GMBH
Abt Zentraler Kundendienst
Postfach 1263
D-69183 Walldorf
Tel : [phone]
Fax: [phone]
2.2 Appropriate Use
The high-pressure barrel pump model ZPU 75 is designed for
use in centralized lubrication systems only
Take care that the max ratings mentioned in the Technical Data ,
particularly the max operating pressure of 300 bar, ist not excee-
ded
Any other use is not in accordance with the instructions and will
result in the loss of claims for guarantee and liability
The pump is mainly used as a supply pump for two-line lubricati-
on systems
If an electro-hydraulic pressure switch and a control unit are in-
stalled on the pump, it can also be used as a lubricating unit
2.3 Technical Data
Lubricant output 6 dm³/h
Drive: flanged gear motor, construction V 1,
protection IP 65,
power 0 25 kW, speed 23 5 rpm,
voltage: 220/380 V, 50 Hz (other ra-
tings on request)
Sense of rotation: lefthand (seen from the top of the
motor fan impeller)
Operating pressure: 300 bar
Working pressure set
on pressure switch 280 bar
Suitable lubricants: grease of NLGI grades 1, 2 and 3 acc
to DIN 51825
(NLGI grade 3 on request)
Ambient temperature: - 20° C to + 60° C
Safety valve: set to 300 bar, tamper-proof
Barrel size: lidded barrels acc to DIN 6644
see model designation
Connection thread: pressure line: 3/4" BSP
relief line: 3/4" BSP
Sound level: <70 dB(A)
Weights: ZPU75-570 : 72 kg
ZPU75-400 : 55 kg
(weight of the pump without stand and
without guide tube)

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2.4 Structure
Fig. 2.4.1: structure of the high-presure barrel pump ZPU 5
1114a95
Description
Item Designation
1 stand
2 winch
3 low level control
4 drive motor
5 pump
6 guide
7 follower plate

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2.5 Electrical Equipment
Flanged gear motor: technical data in enclosed sheet
Electric low level control: position switch with roller lever ac-
tuator (data sheet enclosed)
Pressure switch: position switch with plunger actua-
tor (data sheet enclosed)
2.6 Mo e of Operation
The pump supplies the lubricant directly from the original drum
and sinks together with the follower plate with the grease level
decreasing
The flanged gear motor drives a stirring paddle which delivers
the lubricant to the suction boreholes of the pump element Via
an eccentric pin the rotating movement is simultaneously conver-
ted into an oscillating movement of the drive of the pump ele-
ment
The pump element operates as a piston pump with 2 pistons ope-
rating in opposite direction which alternately suck in lubricant and
deliver it via the outlet borehole to the pressure line
The outlet channels of the high-pressure pistons are controlled
via a floating valve piston
The lubricant supplied by the pump element is directed via 2
check valves to a connection block which is installed on the stand
A safety valve is installed in the pressure line channel
A pressure gauge and a pressure switch are installed in the con-
nection block for the pressure monitoring and control
A stand with winch is used for facilitating the barrel change
Model Designation
Examples of model designations
ZPU75 570G 400
ZPU75 400F 500
Basic model
Diameter of the follower plate:
Diameter 570 for 200-l barrels
Diameter 400 for 50 kg barrels
Voltage of drive motor:
400=230/400V, 50Hz
500=500V, 50Hz
Description

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Erection and Assembly
3 Erection and ssembly
3.1 Erection of Pump
The pump stand must be securely fixed on the floor
Requirements on the place of installation
 protected from dust and dirt
 safe against atmospheric influences
 enough space for replacing the barrels and executing the
maintenance work
 even, solid and vibration-free place of erection
3.2 Electrical Connection
All electrical work should be undertaken
only by qualified personnel
Electrical connection of the drive motor:
 terminal diagramm in cover of terminal box
 fuse protection in conformity with the national regulations in
force Nominal current consumption mentioned in enclosed
motor data sheet
 please note sense of rotation: lefthand (seen from the top of
the motor fan impeller)
Electrical connection of pressure switch and low level control
 in accordance with enclosed terminal diagram and circuit
diagram
 The switch on the control unit of the pump must be comple-
ted by a main circuit breaker (emergency circuit breaker) on
the control box

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Operating Instructions
4.1 Commissioning
Lift the pump until a full barrel can be pushed under the pump
Remove lid of barrel
Take care that no impurities or foreign particles enter the bar-
rel The grease surface must be even
Let pump down until the follower plate lies on the grease level
NOTE: When descending the um , move it to and fro to avoid
air bubbles forming between follower late and grease level.
Loosen winch eyelet from pump support
Fasten barrel by means of barrel holder (item 52)
Venting and connection of the tube lines
Switch pump on (drive shaft rotates lefthand) and let it run until
the lubricant emerges from the pressure line connecton wit-
hout air bubbles
NOTE: If no lubricant emerges, this indicates that there are still
air bubbles between the follower late and the grease level.
They can be removed by o ening a venting borehole (during
normal o eration closed with s indle item 53).
Then,connect the tube lines of the pump
All system components connected
downstream of the pump (change-over
valve, lubricant metering devices, tube
lines, tube fittings, hoses) must be de-
signed for the max operating pressure
of the system
Barrel change
When the follower plate has reached the barrel bottom, there
follows an electric low level signal via the telescopic rod with
switching ring (item 49) which actuates a limit switch
If the low level signal should be given earlier, the switching
ring may be installed at a lower point
Turn spindle (item 53) clockwise to vent the area beneath the
follower plate
Hang up winch eyelet on pump holder
Remove the pump from the emptied barrel by means of the
winch
Note: If the follower late has settled on the drum bottom it can
be vented by tilting the s indle for easier loosening.
Remove the empty barrel and replace it by
a full one
Then, proceed as described under para-
graph 4 1 (Commissioning)
Replace the barrel in due time (a full barrel should always be
available)
Avoid dust in the pump area
4 Operating Instructions
CAUTION
CAUTION
4.2 Maintenance an Repairs
Before executing any repair on the
pump, take care of the following:
 Switch drive motor off and secure it
against inadvertent restart
Risk of injury by the stirring paddle
 Disconnect pressure connection fitting
of pump to decrease the pressure in the pump and system
down to 0 (observe pressure gauge)
Risk of injury by lubricant splashing
 Dont let the pump run after it has been removed from the
barrel
The repair work should be executed only by qualified person-
nel using original spare parts
Under the condition that the pump only supplies clean lubri-
cant, it does not need any particular maintenance The pump
element is lodged in a chamber together with the eccentric
shaft and they are protected by a cover This chamber is con-
nected with the grease lying beneath the follower plate via
the overflow tube (item 32) so that the element and the drive
are lubricated by the supplied medium
This chamber is filled in the factory with 1 5 kg CEPATTYN KG
10 to allow the pump running in and the initial pump operati-
on After big repair work, e g replacement of the pump ele-
ment, the chamber must be refilled
Maintenance work
 If there are problems with the pressure build up, replace the
check valve
The pump is equipped with 2 check valves: item 7, fitted to
connection block 1 and item 11, fitted to connection block 2
In case of malfunctioning, clean both check valves and
replace them, if necessary
Note: To remove the second check valve, remove the cover.
Lubrication instructions
Flanged gear motor, construction V 1
Gear type G 100
The flanged gear motors are filled in the factory with the initial
lubricant quantity This quantity is generally sufficient for
about 10 000 operating hours under normal working conditi-
ons Refilling is not necessary since overfilling might lead to
inadmissible temperature rises
When the lubricant is changed - every 10 000 operating hours
- the gear must be cleaned thoroughly
Lubricant quantity: 420 cm³
Sorts of grease: Deutsche Calypsol D 4024
(first filling in factory)
Other sorts of grease: Aral FDP 00
BP Energrease HT0
Esso Fibrax EP-370
Mobil Multiplex 44
Shell Spezialgetriebefett H

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4.3 Troubleshooting
Note: The following only describes um failures. Failures due to
electrical malfunctioning or system malfunction are indicated in
the System Descri tion.
 Fault: pump does not supply the lubricant
 Ca se:
 Grease barrel empty
 Pump sucks in air
 Suction boreholes clogged (are located near the axle of the
stirring paddle)
 Fault: pump runs, but there is no pressure rise
 Ca se:
 Check valves clogged or defective
 Pump element item 4 damaged or worn
 Change-over valve malfunctioning or failure in the system
connected downstream
All repairs which are beyond the personnels knowledge must be
executed by Lincolns specialists For this, either send the defec-
tive pump back to the Repair Department of our Walldorf factory
or call a specialist for the repair on site
.
 Remedy:
Replace barrel and then proceed as described under item
4 1
Vent area beneath the follower plate Screw in spindle (a few
rotations) Move pump to and fro Turn spindle back
Remove pump from barrel by means of the winch Clean the
boreholes and remove the contaminated grease
 Remedy:
 Replace check valves First, replace upper check valve item
11 and check its function If there is still no pressure rise,
also replace check valve item 7
Note: For re lacing check valve item 7, loosen bulkhead
fitting item 31 and hexagon socket screws item 10.
 Replace pump element This should be undertaken only by
qualified personnel having special knowledge
Note: The um element cannot be re aired since its istons
are recision-fitted in our factory.
 See paragraph Failures of the change-over valve and
System Description
Service Address:
LINCOLN GmbH
Abt Zentraler Kundendienst
Postfach 1263
D-69183 Walldorf
Tel [phone]
Fax [phone]
Operating Instructions

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4.4 A justments
The shut-off pressure of the electro-hydraulic pressure switch is
set in the factory to 280 bar
If this pressure must be decreased or increased, take care - in
the case of an increase - that it does not exceed the admissible
pump pressure of 300 bar
The pressure switch and its adjustment are described on page
18 para 6 1
Operating Instructions

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LINCOLN GmbH  Postfach 1263  D-69183 Walldorf  el [phone]  Fax [phone]
High-press re Central L brication P mp ZPU 75
with Stand and Guide for 200 - barrel
1044a95
Spare Parts Drawing and Spare Parts List
5 Spare Parts Drawing and Spare Parts List

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High-press re Central L brication P mp ZPU 75
with Stand and Guide for 200 - barrel
Item Designation Qty Part Number
12 check valve 1 505-30447-1
16 pressure gauge 0-600 bar,
DIA 100 1 234-13101-2
18 flanged gear motor 0 25 kW, 1 245-13557-1
25 min
-1
,220/380 V, 50 Hz
or
flanged gear motor 0 25 kW,
25 min
-1
,500 V, 50 Hz 1 245-13518-6
26 pressure switch 1 623-25452-2
45 limit switch for low level control 1 236-13244-2
46 control box for 380 V, 50 Hz 1 664-36029-7
220 V, 50 Hz 664-36029-8
500 V, 50 Hz 664-36029-9
48 winch mechanism 1 223-13041-9
49 actuating ring for low level control 1 408-20487-1
50 stand with guide 1
51 protective hose DIA 60, 1250 long 1 225-12502-1
52 barrel holding bracket 1 408-20488-1
53 stop cock (for venting) 1
54 high-pressure hose 1 225-12325-7
NW 8 x 1840 long
pipe connectors DIA 10
55 high-pressure hose 1 225-12325-6
NW 8 x 1640 long
pipe connectors DIA 10
Spare Parts Drawing and Spare Parts List

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LINCOLN GmbH  Postfach 1263  D-69183 Walldorf  el [phone]  Fax [phone]
High-press re Central L brication P mp ZPU 75
with Stand and Guide for 200 l- barrel
1045a95
Spare Parts Drawing and Spare Parts List

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LINCOLN GmbH  Postfach 1263  D-69183 Walldorf  el [phone]  Fax [phone]
High-press re Central L brication P mp ZPU 75
with Stand and Guide for 200 l- barrel
Item Designation Qty Part Number
2 pressure gauge, 0-600 bar,
DIA 100 1 234-13101-4
3 pressure switch, set to 280 bar 1 523-31315-1
10 gasket 1 306-17877-1
11 check valve 1 505-30447-1
12 safety valve, set to 300 bar 1 624-25466-1
Spare Parts Drawing and Spare Parts List

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High-press re Central L brication P mp ZPU 75
Sectional View of Cover with Pump Element and Coupling
1046a95
Spare Parts Drawing and Spare Parts List

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High-press re Central L brication P mp ZPU 75
Sectional View of Cover with Pump Element and Coupling
Item Designation Qty Part Number
30 hexagon head screw M8 x 20 C 4 200-12553-4
washer DIA 8 4 4 209-13077-1
31 bulkhead union SV 10 LC 1 223-12368-8
32 cover 1 407-20400-1
33 hexagon nut M12 C 1 207-12138-5
34 roller pivot (no spare part) 1 407-20398-1
35 roller 1 407-20392-1
36 pump element assembly 1 507-30469-2
37 fixed paddle 2 407-20424-1
38 flat head screw M5 x 16 C 2 202-12415-2
39 hexagon head screw M8 x 20 C 2 200-12553-4
tooth lock washer DIA 8 4 2 210-12161-8
40 hexagon socket head screw 4 201-12016-4
M5 x 12 C
Spare Parts Drawing and Spare Parts List
Item Designation Qty Part Number
1 flanged gear motor 0 25 kW 1 245-13557-1
25 min
-1
, 220/380 V, 50 Hz or
flanged gear motor 0 25 kW,
25 min
-1
, 500 V, 50 Hz 245-13518-6
3 gasket DIA 110 x DIA 160 x 1 1 306-17856-1
4 key 6 x 6 x 36 2 214-12175-2
5 eccentric shaft with eccentric pin 1 507-30472-1
6 connectioin pipe DIA 10 x 2 1 105-35019-4
7 check valve 1 505-30447-1
8 hexagon socket head screw 4 201-12021-1
M8 x 55 C
9 hexagon socket head screw 4 201-12021-9
M8 x 45 C
10 hexagon head screw
M8 x 18 for 200 l or 50 l barrel 14 201-12020-3
M8 x 40 for 35 l barrel 201-12021-5
tooth lock washer DIA 8,4 14 210-12161-8
11 closure plug (draining) 3/8" BSP 1 203-12075-3
12 junction block 1 407-20399-1
13 O-ring 7 5 x 2 1 219-12222-6
14 grooved thrust ball bearing 1 250-14001-1
DIA 17 x DIA 35 x 12
15 stirring paddle
for 200 l barrel 1 407-20409-1
for 50 l barrel 407-20410-1
for 35 l barrel 407-20411-1
16 washer 1 407-20423-1
17 flat head screw M6 x 20 C 1 202-12049-6
tooth lock washer DIA 6 4 1 210-12160-1
18 protection plug 1 233-13100-4
(remove at commissioning)
19 gasket DIA 135 x DIA 120 x 1 1 306-17892-1
20 gasket DIA 242 x DIA 300 x 1 1 306-17869-1
21 follower plate 1
22 hexagon nut 1/2  BSP 1 207-12143-5
23 overflow pipe 1 407-20428-1
24 coupling M42, D1 = 20, D2 = 25 1 252-14030-1
25 sealing washer 1 306-17815-1
DIA 26 6 x DIA 34 x 1
26 closure plug (filling) 3/4" BSP 1 203-12077-1
27 hexagon head screw M6 x 16 C 6 200-13017-9
tooth lock washer DIA 6 4 8 210-12161-9
28 bracket 1 407-20412-1
29 control box for 380 V, 50 Hz 1 664-36029-8
220 V, 50 Hz 664-36029-7
500 V, 50 Hz 1 664-36029-9

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Appendi
1005a94
6 ppendix
6.1 Pressure Switch
Adjustment of pressure switch:
Before adjusting the pressure switch, switch off current supp-
ly to lubrication pump
After loosening counter nut SW 27, re-adjust the spring tensi-
on
On turning set screw SW 24 clockwise, the compression
spring is tensed and the switching pressure is increased In-
verse procedure will result in a pressure decrease
Scope of delivery:
As illustrated, please indicate the piston diameter when orde-
ring
To be supplied by customer:
Wiring of limit switch to switch cabinet by means of oil-resi-
sting cable 3 x 1 5 mm²
Pessure range Pressure Compression Part Num
reducer spring
Piston and Wire DIA
cylinder DIA
160 - 400 bar 6 mm 4 0 mm 623-25461-2
Connection thread 3/8" BSP
Limit switch: 1 NC contact, 1 NO contact

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LINCOLN GmbH  Postfach 1263  D-69183 Walldorf  el [phone]  Fax [phone]
Voltage 220-240/380-415V 243-277/420-480V 290/500V Units
Motor man fact rer ABM ABM
Motor type G100F/4D71A-4 G100F/4D71A-4
Freq ency f 50 60 50 [Hz]
Nominal power P 0,25 0,21 0,25 [kW]
Nominal speed n 1380/25 1690/31 1360/25 [min -1]
Rated torq e M 95 95 95 [Nm]
Nominal c rrent IN1,2 ___ _____ [A] at 220-240 V
0,70 ___ _____ [A] at 380-415 V
___ 1,04 _____ [A] at 243-277 V
___ 0,60 _____ [A] at 420-480 V
1,0 [A] at 290 V
0,58 [A] at 500 V
Starting c rrent/
ratio IA/IN3,9 4,8 3,6 [A]
Power factor cos j0,7 0,7 0,74
Efficiency h61 [% ]
Frame size 63
Type of constr ction B14
Type of protection IP 65
Ins lation class F
Weight 13 13 [kg]
Flange Ø 160 [mm]
Shaft end Ø 25 x 60 [mm]
Part-No. 245-13575-4 245-13518-6
6.2 Motor ata sheet ZPU 75
The m lti-range motors can be connected
at the following networks:
220/380 V ± 5%, 50Hz
230/400 V ± 10%, 50Hz
240/415 V ± 5%, 50Hz
254/440 V ± 5%, 60Hz
265/460 V ± 5%, 60Hz
480 V ± 5%, 60 Hz
Other voltages and/or special designs as well as other manu-
factures available on request
The 290/500 V-motor can be connected to the following net-
work::
290/500 V ± 10%, 50Hz

1.1A-38001-C00
Subject to change without notice
Owner Manual
Operating Instructions & Service Parts List
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LINCOLN GmbH  Postfach 1263  D-69183 Walldorf  el [phone]  Fax [phone]
Appendi
7. Declaration by the
manufacturer as defined by machinery
directive 89/392/EEC nnex II B
Herewith we declare that the supplied model of
Pump Typ ZPU 75...
is intended to be incorporated into machinery covered by this
directive and must not be put into service until the machinery
into which it is to be incorporated has been declared in con-
formity with the provisions of the directive
A lied harmonized standards in articular
EN 292 T1/T2
prEN 809
EN 563
29.12.1994