Perma STAR VARIO User manual

The Expert in Lubrication Solutions
Installation Guide
perma STAR VARIO

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Blattformat: DIN A1
Maßstab: 1:1
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4-6
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9
11
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Blattformat: DIN A3
Maßstab: 1:1
© 2017 perma-tec GmbH & Co. KG
The content of this document has been compiled by perma-tec with mediculous care. Never-the-less, we cannot rule out deviations and reserve the right to make technical changes
to the product without any advance notice. We do not assume any judicial responsibility or liability for any damages which may ensue as a result. Necessary modifications will be
included in subsequent editions.
Compiled and printed: 01/2017
1.
2.
3.
4.
5.
6.
Mounting types
Preparation of lubrication point
Basic Guidelines
Direct mounting
Remote mounting with tube
Mounting of oil filled units
Pressure testing
Activation und installation
Identification of lubrication system
Pressure test procedure

© 2017 - perma-tec GmbH&Co. KG | www.perma-tec.com | 3
Schlauchanschlüsse
This Installation guide provides instructions for the installation of perma STAR VARIO and helps in
preventing basic mounting errors. The guide should be used with the operating instructions.
Drawings are only examples. There are many other possibilities for mounting, depending on local
conditions.
Disclaimers of corresponding operating instructions apply.
Installation guides do not affect validation of the operating instructions.
1. Basic Guidelines
• perma STAR VARIO is a single-point lubrication system. You must use a separate lubrication
sysem for each lubrication point.
• The connection thread of perma STAR VARIO is BSP R¼ male thread.
• Replace the application‘s grease fitting with a suitable reducer. perma-tec offers a wide
assortment of reducers, extensions, tubes, brackets and other accessories. See our product
catalogue for the entire overview on perma accessories.
• Ensure that the lube point is prefilled with fresh lubricant before installation. perma-tec offers all
of its lubricants in 400 g cartridges for grease guns.
• Select the right lubricant for your application. perma-tec offers a wide variety of standard
lubricants for different applications. See our product catalogue for further information.
• All metal to metal connections must be glued together with Loctite® 243™.
• Fill grease lines and accessories with the same lubricant that is contained in the lubrication
system.
• When oil is used for lubrication, an oil retaining valve (104862) must be installed. This will prevent
oil leakage from the lubricator.
• For managing serveral lube points we recommend the use of a lubrication maintenance plan. You
can use the free perma MLP software (https://mlp.perma-tec.com) for online administration.
• Please check our product catalogue for more information on how to select suitable lubricant and
activation screw. You may also download our free perma SELECT APP which is a great tool for the
selection of the right lubrication system, lubricant and discharge period.

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2. Mounting types
2.1 Direct mounting
Direct mounting should be preferred for all lubrication points, to protect the lubrication system against
high pressure.
Reducer for thread
connection
Please use Support flange STAR Gen 2.0 G1/4
male x G1/4 female (109420) for all angled or
horizontal installations.
Installation of perma STAR VARIO is possible in all directions (indoors and outdoors).
Protection cap can only be used for vertical installations (outlet at the bottom) or horizontal
installations.
When using oil filled LCs, mounting angle may not exceed 45°.

© 2017 - perma-tec GmbH&Co. KG | www.perma-tec.com | 5
2.2 Remote mounting with tube
• Keep connection lines as short as possible and use tubes with an inside diameter of at least 6 mm.
Keep in mind that tube length and bore diameter of bearing housings affect pressure and discharge
period of the lubrication system.
• For installation of perma STAR VARIO use Mounting bracket 1-point G1/4 female (109663).
• Secure tubes with suitable fastenings (brackets, cable ties) to protect against damage and tearing.
• Depending on lubricant and ambient temperature, different tube lengths are possible, e. g.
 perma Multipurpose grease SF01: 5 m (+20 °C).
Reducer for thread connection
Remote mounting is recommended if,
• the ambient temperature of the lubrication point is permanently higher than +60 °C
• the lubrication point is exposed to high vibrations
• no direct access to lubrication point is possible due to safety issues (e. g. removal of protective
screens, safety walls or cages)
• it is difficult or dangerous to access the lubrication point
• the lubrication system is exposed to mechanical forces (e. g. falling rocks)
Mounting bracket STAR Standard Duty
1-point G1/4 female (109663)
Hose connector G1/4 male for hose iØ 9.5 mm -
push-lock (101554)
Heavy Duty hose up to +100 °C oØ 16 mm x iØ 9.5 mm
(101555)
Hose connector G1/4 male for hose iØ 9.5 mm -
push-lock (101554)
Support flange STAR Gen 2.0 G1/4 male x
G1/4 female (109420)
All metal to metal connections must be
glued together with Loctite® 243™.

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2.3 Mounting of oil filled units
2.3.2 Remote mounting
Oil brush Ø20 mm G1/4 female
(101396)
2.3.1 Direct mounting
perma STAR VARIO is not equipped with an oil retaining valve in the outlet. Usage of an external oil
retaining valve is recommended.
Remote installations of oil filled perma STAR VARIO require an oil retaining valve at the lowest
point of the application. This will prevent oil leakage from the lubrication system.
Oil retaining valve G1/4 male x G1/4
female up to +60 °C (104862)
Bracket (104864)
Support flange STAR Gen 2.0 G1/4
male x G1/4 female (109420)
Mounting bracket STAR Standard Duty
1-point G1/4 female (109663)
Tube connector G1/4 male for tube oØ 8 mm straight
(101496)
Tube up to +80 °C oØ 8 mm x iØ 6 mm (101393)
Bracket (104864)
Tube connector G1/4 male for tube oØ
8 mm straight (101496)
Oil retaining valve G1/4 male x G1/4
female up to +60 °C (104862)
Oil brush 40 x 30 mm G1/4
female (101397)
Support flange STAR Gen 2.0 G1/4 male x G1/4 female
(109420)
All metal to metal connections
must be glued together with
Loctite® 243™.
All metal to metal connections
must be glued together with
Loctite® 243™.

© 2017 - perma-tec GmbH&Co. KG | www.perma-tec.com | 7
3. Preparation of lubrication point
2. Remove grease nipple or plug screw of connecting thread and check thread size.
3. Insert reducer and install tube and necessary accessory parts.
1. Prior to installation, lubrication point must be cleaned to protect against contamination.

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4. Lubrication point, accessory parts and tubes must be pre-filled with lubricant.
This enables the lubricant to immediately reach the lubrication point.
5. Prefill lubrication point and all grease lines for remote installation.
6. Use a tube prefill adapter to prefill lubrication point and grease lines.
Grease gun
(101455)
Hose with rotary joint, slide and hydraulic
coupling for grease gun (110199)
Tube prefill adapter
Tube prefill adapter for tube oØ 8 mm (101526)
Tube prefill adapter for tube oØ 6 mm (101532)
Hose prefill adapter for Heavy Duty hose (107633)
Tube prefill adapter for VA-flex tubes (107634)

© 2017 - perma-tec GmbH&Co. KG | www.perma-tec.com | 9
4. Pressure testing
For pressure testing please use perma STAR VARIO with Accessory set for pressure test (101480).
Be sure to use the same lubricant for both, prefilling and LC of perma STAR VARIO.
perma STAR VARIO
Gauge
Stop valve
Accessory set for
pressure test
Check counter pressure at lubrication point before installing the lubrication system to guarantee
correct function.
Most bearings require 0.5 - 2 bar pressure (without extension tubes). perma STAR VARIO can be
used for these lubrication points.
Accessory set for pressure test (101480)
(order lubrication system separately)

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4.1 Pressure test procedure
1. Remove grease nipple.
2. Screw reducer onto lube point and connect pressure testing set.
3. Connect perma STAR VARIO to the open outlet.
4. Turn machines on to ensure that lube point is in use and measuring of corresponding counter
pressure is possible (Caution: Observe accident prevention regulations).
5. Open stop valve.
6. Push SET button on perma STAR VARIO for approx. 10 seconds until
PU lights up on display to trigger an additional discharge/purge.
7. Watch the pressure on the gauge during the additional discharge.
If pressure exceeds 6 bar the lubricator will shut off automatically.
8. If pressure doesn‘t rise any more during the additional discharge,
max injection pressure has been reached. In order to find out the
required system pressure you must wait another 5 minutes. The
gauge will then show the system pressure
9. If system pressure exceeds 2 bar you need to „purge“ the lube point
by using a mechanical grease gun. Proceed with steps 6 and 7.
10. If counter pressure doesn‘t decrease you need to either select a different lubricant or a different
lubricator. Please ask perma-tec to assist you in this matter

© 2017 - perma-tec GmbH&Co. KG | www.perma-tec.com | 11
Manufactured by: perma-tec GmbH & Co. KG
Hammelburger Str. 21 | 97717 EUERDORF
www.perma-tec.com | Tel.: [phone]
Made in Germany
STAR
120
Lubricant Cartridge
120 cm³ / 4.06 fl.oz. (US)
Art. No. 100724 | SM-1709-37337
perma Multipurpose grease SF01
04/17 | 10/17
5. Activation und installation
6. Identification of lubrication system
Installation date and ex-
change date
(to be added by operator)
Art. No. | Serial number
(Product designation –
year/week of manufacture
– internal no.)
Lubricant designation
Start up as following (also refer to operating instructions):
1. Assemble all components (drive, battery pack, LC)
2. Turn the threaded ring on the LC unit until the small white arrow mark is fully visible
3. Select LC size
4. Select discharge period (1 to 12 months)
5. Remove plug and screw lubricator into lube point
The label of the lubrication system shows product-code, manufacturing date, traceability number, lub-
ricant code and part number.

2017/01 · Version: 2.1 en