Perma STAR VARIO User manual

The Expert in Lubrication SolutionsThe Expert in Lubrication Solutions
perma STAR VARIO
Installation Guide

2
© 2023 perma-tec GmbH & Co. KG
The content of this document has been compiled by perma-tec with meticulous care. Nevertheless, 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 modications will be included in subsequent editions.
Compiled and printed: 05|2023
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Page 4 - 6
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• Direct mounting
• Remote mounting with tube / hose
• Mounting of oil lled units
• Pressure test procedure
1. Basic guidelines
2. Mounting types
3. Preparation of lubrication point
4. Pressure testing
5. Activation and installation
6. Identication of lubrication system

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This installation guide provides instructions for the installation of perma STAR VARIO lubrication systems 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.
• 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 tting with a suitable reducer. perma offers a wide assortment of reducers, extensions,
tubes / hoses, brackets and other accessories. See our product catalogue for the entire overview on
perma accessories.
• Ensure that the lube point is prelled with fresh lubricant before installation. perma offers all of its lubricants in 400 g
cartridges for grease guns.
• Select the right lubricant for your application. perma 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 lubrication points we recommend the use of a lubrication maintenance plan. You can use the free
perma CONNECT (https://www.perma-tec.com/en/service/perma-connect-app/) software for online administration.
• Information about the selection of suitable lubricants can be found in our product catalogue. Selection is also possible
via the perma SELECT APP (https://www.perma-tec.com/en/service/perma-select-app/). This free software helps you
nd the most suitable lubrication system, the ideal lubricant and the right discharge period.
Basic guidelines

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Direct mounting should be preferred for all lubrication points, to protect the lubrication system against high pressure.
Reducer for thread connection
Please use Support ange STAR G1/4 male x G1/4 female
(109420) for all angled or horizontal installations and in
areas with mild vibrations.
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 lled LCs, mounting angle may not exceed 45°.
Mounting types
Direct mounting

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• Keep connection lines as short as possible and use tubes / hoses with an inside diameter of at least 6 mm. Keep in mind
that tube / hose 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 / hoses with suitable fastenings (brackets, cable ties, hose spiral guard) to protect against damage
and tearing.
• Depending on lubricant and ambient temperature, different tube / hose lengths are possible, e. g.
→ perma Multipurpose grease SF01: 5 m* / 3 m** (+20 °C)
→ perma Multipurpose oil S032: 5 m* / 3 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 difcult 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 (116624)
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 (116624)
Support ange STAR G1/4 male x G1/4 female (109420)
Remote mounting with tube / hose
*with Heavy Duty hose with NBR lining and fabric insert (101555) or VA-Flex tube stainless steel / PTFE (113864, 101549, 101550)
**with tube PA (101393) or hose PTFE (101394)
All metal to metal connections must
be glued together with Loctite® 243™

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Remote mounting
Oil brush Ø20 mm G1/4 female (101396)
Remote installations of oil lled perma STAR VARIO require an oil retaining valve at the lowest point of the application.
This will prevent oil leakage from the lubrication system.
Insert for bracket G1/4 male x G1/4 female
(104820)
Bracket (104864)
Support ange STAR 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 foam up to +80 °C 40 x 30 mm G1/4i
female thread on top + lateral thread (117435)
Support ange STAR G1/4 male x G1/4 female (109420)
An oil lled perma STAR LC is standardly equipped with an oil retaining valve in the outlet and a red sealing cap. Therefore,
an additional oil retaining valve is not necessary when mounting the lubrication system directly to an oil brush.
Mounting of oil lled units
Direct mounting
All metal to metal connections must
be glued together with Loctite® 243™

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2. Remove grease nipple or plug screw of connecting thread and check thread size.
3. Insert reducer and install tube / hose and necessary accessory parts.
1. Prior to installation, lubrication point must be cleaned to protect against contamination.
Determine thread size at the
lubrication point with perma tting
thread tester Art. No. 110374
Preparation of lubrication point

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4. Lubrication point, accessory parts and tubes / hoses must be pre-lled with lubricant.
This enables the lubricant to immediately reach the lubrication point.
5. Prell lubrication point and all grease lines for remote installation.
6. Use a tube prell adapter to prell lubrication point and grease lines:
KIT TUBE PREFILL ADAPTERS (117907)
Grease gun (101455)
Hose with rotary joint, slide and hydraulic coupling
for grease gun (110199)
Tube prell adapter

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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 / hoses). perma STAR VARIO can be used for these
lubrication points.
For pressure testing please use perma STAR VARIO with Accessory kit for pressure test (101480).
Be sure to use the same lubricant for both, prelling and LC of perma STAR VARIO.
perma STAR VARIO
Gauge
Stop valve
Accessory kit for
pressure test
Accessory kit for pressure test (101480)
(order lubrication system separately)
Pressure testing

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Pressure test procedure
1. Remove grease nipple.
2. Screw reducer onto lube point and connect pressure testing kit.
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 7.5 bar the lubrication system 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 nd 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 lubrication system.
Please ask perma-tec to assist you in this matter.

© 2022 | perma-tec GmbH&Co. KG | www.perma-tec.com | 11
Art. No. 100724 | SM-2227-37337
perma Multipurpose grease SF01
07/22 | 01/23
Installation date and exchange 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. Assembly
2. Screw control unit onto LC unit until arrow lines up
3. Note activation / exchange date on label
4. Select LC unit 60, 120, 250, 500 cc
5. Select weeks / months
6. Select discharge period
7. Remove plug
The label of the lubrication system shows product-code, manufacturing date, traceability number, lubricant code and
article number.
Activation and installation
Identication of lubrication system

perma-tec GmbH & Co. KG
Hammelburger Str. 21
97717 Euerdorf
GERMANY
Tel.: [phone] - 0
[email protected]om
www.perma-tec.com
2023/05 · en