Perma STAR VARIO User manual

The Expert in Lubrication Solutions
perma STAR VARIO
Pocket Guide

The perma STAR VARIO is set and controlled via a simple to navigate menu
using a single SET button. The menu is intuitive and requires minimal
manipulation after the initial setting.
Features which support simple operation and error
minimisation include:
Initial set screen
A new lubricator displays on the LCD. This forces users to set the time
and LC (lubricant canister) size before the lubricator can be turned on.
Automatic restart
When the LC and battery set is changed the lubricator automatically
restarts meaning that there is no need to use the SET button when servicing
lubricators.
Battery insertion
and initial assembly
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21 3
Insert battery set into the underside of the DRIVE. It will click into place.
The DRIVE will perform a self-test, during which the LED system
will change from red to green to orange and the drive motor will run
continuously.
Sit the DRIVE on top of the LC so that the socket of the DRIVE engages
correctly with the hexagonal head of the LC spindle.
Secure it by rotating the collar until it comes to its stop point.
When correctly assembled
the white triangle markings
around the DRIVE will be
visible as shown.
A
B
CLICK!
= OK
OK
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New DRIVE which
has not been set
The LC SIZE, TIME interval type (months or weeks) and TIME setting must be
assigned for each new DRIVE before rst use.
A B
Insert a new battery set. The
lubricator will perform a self-test
and display .
=
=
=
=
The lines at the bottom of the
display indicate the SIZE options
of 60, 120, 250 and 500cm3.
Press the SET button for 5
seconds and the lines will begin
to ash.
Release and press the button to
scroll through the SIZE options.
Stop at the desired size.
Setting
for the rst time
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The setting will now be displayed
and after 8 seconds the lubricator
will perform its initialisation run
cycle.
At the end of the run cycle the
display will return to the allocated
setting.
C E
After the SIZE has been
assigned, wait for 'm' (months)
to be displayed. Press the button
to toggle between 'm' (months)
and 'w' (weeks). Stop at the
desired TIME interval type.
D
Press and release the button to
scroll through the TIME options.
Stop at the desired setting.
Wait for the screen to go to the
off status .
Press the SET button for 1
second to turn the lubricator
ON.
26
12
months
weeks Example - 120cm3 set to 3 months.
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A B
Changing the setting
after initial programming
After initial programming, the assigned settings can be changed at anytime from
either the ON or OFF status.
Press the SET button for 5
seconds.
Press and release the SET button
to scroll to the new SIZE setting
=
=
=
=
26
12
months
weeks
Wait for the TIME interval type to
start ashing.
Select the new TIME interval
type.
Wait for the TIME setting to start
ashing.
Select the new TIME setting.
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The lubricator can be turned OFF at anytime except during a run cycle.
If a lubricator is turned OFF for a period of time it will retain memory of its
operational status and recommence the lubricant delivery program from
that point when turned back ON.
It is important to note that turning the lubricator OFF and ON does not reset
the memory of the grease volume remaining. The only way to reset the
memory is to remove and re-insert the battery set.
off
A B
Turning OFF and ON
Press the SET button for 1
second to turn the DRIVE OFF.
The off screen will be displayed.
Press the SET button for 1
second to restart the lubricator.
The programmed setting will be
shown.
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Dispensing rates
Weekly settings
1 8.57 17.14 35.71 71.43
2 4.29 8.57 17.86 35.71
3 2.86 5.71 11.90 23.81
4 2.14 4.29 8.93 17.86
5 1.71 3.43 7.14 14.29
6 1.43 2.86 5.95 11.90
7 1.22 2.45 5.10 10.20
8 1.07 2.14 4.46 8.93
9 0.95 1.90 3.97 7.94
10 0.86 1.71 3.57 7.14
11 0.78 1.56 3.25 6.49
12 0.71 1.43 2.98 5.95
13 0.66 1.32 2.75 5.49
Time
setting,
weeks
Daily dispensing rate, cm³ per day
60cm³ 120cm³ 250cm³ 500cm³
The dispensing rate data tabled below applies to the perma STAR VARIO
and STAR VARIO BLUETOOTH®. Details on the dwell time between lubricant
delivery cycles are available upon request.
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Time
setting,
weeks
Daily dispensing rate, cm³ per day
60cm³ 120cm³ 250cm³ 500cm³
14 0.61 1.22 2.55 5.10
15 0.57 1.14 2.38 4.76
16 0.54 1.07 2.23 4.46
17 0.50 1.01 2.10 4.20
18 0.48 0.95 1.98 3.97
19 0.45 0.90 1.88 3.76
20 0.43 0.86 1.79 3.57
21 0.41 0.82 1.70 3.40
22 0.39 0.78 1.62 3.25
23 0.37 0.75 1.55 3.11
24 0.36 0.71 1.49 2.98
25 0.34 0.69 1.43 2.86
26 0.33 0.66 1.37 2.75
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Dispensing rates
Monthly settings
The dispensing rate data tabled below applies to the perma STAR VARIO
and STAR VARIO BLUETOOTH®. Details on the dwell time between lubricant
delivery cycles are available upon request.
1 2.0 4.0 8.3 16.45
2 1.0 2.0 4.2 8.22
3 0.67 1.3 2.8 5.48
4 0.50 1.0 2.1 4.11
5 0.40 0.80 1.7 3.29
6 0.33 0.67 1.4 2.74
7 0.29 0.57 1.2 -
8 0.25 0.50 1.0 -
9 0.22 0.44 0.93 -
10 0.20 0.40 0.83 -
11 0.18 0.36 0.76 -
12 0.17 0.33 0.69 -
Time
setting,
months
Daily dispensing rate, cm³ per day
60cm³ 120cm³ 250cm³ 500cm³
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NBCF perma FLEX is made in Germany and supports our corporate
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The NBCF perma FLEX is ideal when a compact, lightweight,
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LUBRICATING
THE WHEELS OF
RESEARCH
© 2022 – HTL perma Australia Pty Ltd | www.perma.com.au | 11

It is recommended to always write the installation date on the cartridge of
perma STAR VARIO lubricators. This provides valuable information to personnel
involved in lubricator inspections. In particular, if a lubricator is found to be
empty, the recorded date allows the period for which lubricant has not been
delivered to be determined, which in turn allows the equipment maintainer to
determine the appropriate maintenance action.
For occasions where an installation date has not been recorded the perma STAR
VARIO* provides a count of the number of days for which the cartridge has been
empty.
*This feature is only available for perma STAR VARIO drive units with software version 3.4
onwards.
Contact your supplier of perma products for more information.
Days since empty count
Days since empty count
Information from empty lubricators
When the lubricant cartridge is empty the lubricator display screen shows LC
and the LEDs ash red every 2 seconds.
When LC is displayed the time setting and count of the number of days that the
cartridge has been empty can be obtained. This information assists equipment
maintainers to make decisions about the most appropriate action when
lubricators are found to be empty, especially when lubricant cartridges have not
been clearly marked with the installation date.
To conrm the lubricator time setting press and hold the SET button for 1
second, then release the SET button to conrm the number of days since empty.
The display will automatically alternate between 'rd' and the day count, up to
a maximum of 99 days. After alternating between 'rd' and the day count eight
times the display will return to 'LC'. rd = days count since red.
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Press SET for 1 second Setting 6 months
Empty for 2 days
Alternating
Information from empty lubricators
Example - A 250cc lubricator is found to be empty, displaying LC, with no
date markings on the lubricant cartridge. By holding the SET button down
for 1 second it is conrmed that the time setting is 6 months and that the
lubricator has been empty for 2 days. The display sequence is shown below.
This information would indicate to the equipment maintainer that no special
action is required other than the normal lubricator servicing procedure.
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Lubricator status
Dwell
What is on the display?
The display shows the time setting and the LC size. For the example shown, the
time setting is 3 months and the LC size is 250cm3.
What is the light sequence?
Single green ash every 7 seconds.
The line
indicates the
LC size
The digit
shows the
time setting
What is happening?
The lubricator is in between lubricant delivery cycles. The time between cycles
depends on the lubricator setting.
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Lubricator status
Run
What is happening?
The DRIVE system is dispensing lubricant.
What is on the display?
'ru' stands for 'run' and indicates that lubricant is being dispensed. At the end
of the run cycle the lubricator will return to the dwell mode, displaying the time
setting and LC size.
What is the light sequence?
Single green ash every 1 second.
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Lubricator status
Purge
What is on the display?
'PU' stands for 'purge' and indicates that the purge cycle has been activated
and that lubricant is being dispensed.
What is the light sequence?
Single green ash every 1 second.
What is happening?
The purge cycle has been initiated by holding down the SET button for 10
seconds.
A full purge cycle delivers around 6cm3 of grease and can be interrupted at
anytime by pushing the SET button once.
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Lubricator status
Empty
What is on the display?
The display shows LC.
What is the light sequence?
Single red ash every 2 seconds.
What is happening?
The LC is empty and needs to be changed. If 'LC' is displayed but the LC is not
empty, check the following:
1. Check that the LC size setting correctly matches the actual LC size.
2. Ensure that new batteries are exchanged with every new LC. This is
necessary to reset the lubricator for the next service cycle.
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Lubricator status
Overload
What is on the display?
'OL' stands for 'overload' and indicates that resistance to lubricant delivery has
been too high.
What is the light sequence?
Double red ash every 7 seconds.
What is happening?
The resistance to lubricant dispensing has been too high for the DRIVE system
to overcome and as a consequence 'overload' has been registered. Lubricant
dispensing has stopped.
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A B
The grease point should be manually purged to check for blockages or
problems. If free delivery of grease cannot be re-established the root cause of
the high resistance must be investigated and rectied.
> A plug of grease caused by excessive oil bleed;
> Low temperatures which have affected lubricant pumpability;
> An extended shutdown during which the resistance to grease ow to idle
equipment has increased;
> Poor installation practices such as grease lines which are too narrow.
Possible causes of an overload
Overload is indicated by OL
on the display screen and red
ashing lights.
If a manual grease kit is in
place, close the valve so that
the lubricator is not damaged
during manual purging.
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E F
C D
Purge the lubrication point
using a manual grease gun
and conrm that grease can be
freely received.
After approx. 1 minute open the
ball valve. Reopening too quickly
can allow grease pressure
within the line to damage the
lubricator.
Press the SET button for 1
second to turn lubricator off.
Press for another second to turn
back on.
A short run cycle will begin
automatically.
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