SAFEMATIC 361034B Instruction Manual

MULTILUBE
INSTALLATION AND MAINTENANCE
HINS4AEN.doc 24.08.2006 Rev. 4A
MULTILUBE –SYSTEM INSTALLATION AND MAINTENANCE
TABLE OF CONTENTS
1 PUMPING UNIT INSTALLATION......................................................................................................................1
1.1 Installing the supporting blocks and the pumping unit................................................................................1
1.2 Installing the main line on the pumping unit................................................................................................3
1.3 Installing the safety switch..........................................................................................................................4
2 EXTERNAL CONNECTIONS............................................................................................................................5
2.1 Removing the cover....................................................................................................................................5
2.2 Installing the cables and electrical connections..........................................................................................7
3 PUMPING UNIT MAINTENANCE.....................................................................................................................9
3.1 Removing the shell......................................................................................................................................9
3.2 Fastening of the shell................................................................................................................................10
4 REPLACING THE PUMP ELEMENT..............................................................................................................12
5 REPLACING THE LINE VALVE......................................................................................................................14
6 FILLING THE LUBRICANT RESERVOIR OF THE PUMPING UNIT .............................................................16
7 REMOVING AIR FROM THE PUMPING UNIT...............................................................................................17
8 CONTACT INFORMATION.............................................................................................................................17
9 INSTALLING SIM-CARD TO GSM-MODEM (OPTION).................................................................................18

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MULTILUBE –SYSTEM INSTALLATION AND MAINTENANCE
1 PUMPING UNIT INSTALLATION
1.1 Installing the supporting blocks and the pumping unit
Note Free space is required below the pumping unit for maintenance procedures.
See dimensional drawings 361034B and 361035B.
Installing the supporting block of pumping unit models MLP-4-X-XX-XX-XX:
1. Determine the location of the supporting block with the help of the dimensional drawings.
2. Install the supporting block in its place with cotter bolts M8x75 or with hexagonal screws
M8 (4 pcs) (Figure 1).
3. Install 2 pcs M8x25 hexagonal screws on the other side of the block.
4. Lift the pumping unit on the wall on the M8 hexagonal screws.
5. Install 2 pcs M8 hexagonal screws on the other side of the block.
6. Fasten the pumping unit on the supporting block by tightening the M8 hexagonal screws (4
pcs).
Figure 1. Supporting block installed on a wall
Hex.
screw
M8x25
Cotter bolt M8x75 or
hex. screw M8 (4 pcs)

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Pumping unit models MLP-10-X-XX-XX-XX include 2 pcs supporting blocks:
1. Determine the location of the supporting block with the help of the dimensional drawings.
2. Install the first supporting block in its place with cotter bolts M8x75 or with hexagonal
screws M8 (4 pcs) (Figure 1).
3. Install 2 pcs M8x25 hexagonal screws on the other side of the block.
4. Install the other supporting block on the pumping unit with M8 hexagonal screws.
5. Lift the pumping unit on the M8 hexagonal screws of the supporting block which is already
installed on the wall.
6. Mark the place of the other supporting block (Figure 2).
7. Lift the pumping unit down.
8. Uninstall the block from the pumping unit and install it on the wall with cotter bolts M8x75
or with hexagonal screws M8 (4 pcs) (Figure 3).
9. Lift the pumping unit on the wall on the M8 hexagonal screws.
10. Fasten the pumping unit on the supporting blocks by tightening the M8 hexagonal screws
(8 pcs).
Figure 2. Marking the place of the other supporting block
Figure 3. Supporting blocks
installed on a wall
Figure 4. Pumping unit installed
on the supporting
blocks

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1.2 Installing the main line on the pumping unit
In single-line models the main line is installed in the lower pressure connection (Figure 5). The
upper pressure connection remains plugged.
In dual-line models main lines are installed in both pressure connections (Figure 6).
Note Hose assembly is recommended in installation of main lines (e.g. Safematic
code 12653750). The following components are required between the
pumping unit and the hose assembly: male connector 12 L R1/4 ZN (e.g.
Safematic code 12805220) and gasket Usit 217-04 (e.g. Safematic code
11682550).
Figure 5. Single-line model
Figure 6. Dual-line model
Caution Support the connector body while tightening the connector nut to prevent
damage to the threads of the pumping unit (Figure 5).

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1.3 Installing the safety switch
Warning Pumping unit models with power input 230 V or 115 V have to be equipped
with a safety switch (e.g. Safematic code 10543062).
Installing the safety switch:
1. Install the safety switch next to the pumping unit (Figure 7).
2. Feed cable into the safety switch as shown in Figure 8.
3. Electrical connections are made according to a separate electrical drawing which is
delivered with the pumping unit.
Warning Electrical connections may only be made by a qualified electrician.
Figure 7. Safety switch next to
the pumping unit
Figure 8. Cable inside the
safety switch

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2 EXTERNAL CONNECTIONS
2.1 Removing the cover
Warning The reservoir MAY NOT BE OPENED when the pumping unit is installed
and operational (Figure 9). The risk is that the pumping unit may fall down
and damage.
Figure 9. The reservoir of the pumping unit may not be opened

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Maintenance of the pumping unit and external electrical connections:
1. Open the screw (Figure 10).
2. Remove the cover plate and gasket (Figure 11).
3. Open the nut (Figure 12).
4. Remove the nut and the star washer (Figure 13).
5. Remove the cover (Figure 14).
Figure 10. Open the screw
Figure 11. Remove the cover
plate and gasket
Figure 12. Open the nut
Figure 13. Remove the nut and
the star washer
Figure 14. Remove the cover

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2.2 Installing the cables and electrical connections
Warning Electrical connections to the terminal blocks may only be made by a
qualified electrician.
1. Remove the cover, see paragraph 2.1 .
2. Remove the protective plug of the cable gland (Figure 15).
3. Bend the cable end a little curved (Figure 16). This makes the feeding of the cable easier.
4. Push the cable through the cable gland to the terminal block (Figures 17 and 18).
5. Put an appropriate screwdriver in the upper opening of the terminal block.
Caution Do not twist the screwdriver, only put it in the opening.
6. The cable to be connected is put in the lower opening. The cable is locked when the
screwdriver is detached from the upper opening (Figure 19).
Figure 15. Removing the
protective plug
Figure 16. Feeding the cable
Figure 17. Feeding the cable
through the cable
gland
Figure 18. Cable at the terminal
block

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Figure 19. Connecting the wires to the terminal block

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3 PUMPING UNIT MAINTENANCE
3.1 Removing the shell
1. Remove the cover, see paragraph 2.1 .
2. Disconnect the protective grounding wire (Figures 20 and 21).
3. Remove the shell by gently pulling downwards (Figure 22).
4. Disconnect the cable of user interface from the circuit board (Figures 23 and 24).
Figure 20. Detach the fastening
of the protective
grounding wire
Figure 21. Disconnect the
protective grounding
wire
Figure 22. Removing the shell
Figure 23. Cable of user
interface IF-103
Figure 24. Disconnecting the
cable of user interface
IF-103
Figure 25. Pumping unit without
the shell for
maintenance

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3.2 Fastening of the shell
1. Connect the cable of user interface IF-103.
2. Ensure with the help of screwdriver that the rubber seal is set correctly
(Figures 26 and 27).
Warning Make sure that the protective grounding wire of the shell is connected
(Figure 28).
3. Install the cover (Figure 29).
Figure 26. Make sure that the
rubber seal is set
correctly inside the
shell
Figure 27. Make sure that the
rubber seal is set
correctly outside the
shell
Figure 28. Connecting the
protective grounding
wire
Figure 29. Installing the cover

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Warning A star washer DIN 6798 must be installed against the cover. This ensures
the protective grounding of the cover.
4. Place the star washer DIN 6798 against the cover (Figure 30).
5. Fasten the nut (Figure 31).
6. Fasten the gasket and the cover plate (Figure 32).
Figure 30. Place the star washer
Figure 31. Fasten the nut
Figure 32. Gasket and cover plate

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4 REPLACING THE PUMP ELEMENT
1. Remove the shell, see paragraph 3.1 .
2. Ensure that the reservoir is empty. If there is grease in the reservoir (Figure 33), empty the
reservoir by opening the filling connector (Figures 34 and 35) or the hexagonal plug of the
pump block (Figure 36).
3. Move the rubber seal on the side and open the pump element with 27 mm socket or socket
wrench, Safematic code 11790058 (Figure 37).
4. Remove the element.
Note Install the lengthening piece from the end of the element to the new
element. The lengthening piece is glued to the element, open in vice bench
(Figure 38).
5. Install the new element in its place. Ensure that the rubber seal is installed correctly
according to figure 39.
6. Fasten the shell, see paragraph 3.2 .
Figure 33. Checking the
reservoir
Figure 34. Opening the filling
connector
Figure 35. Opening the filling
connector
Figure 36. Opening the plug of
the pump block

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Figure 37. Moving the rubber
seal
Figure 38. Pump element and
lengthening piece
Figure 39. Installing the rubber
seal

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5 REPLACING THE LINE VALVE
Warning Ensure that the pumping unit is turned off when replacing the line valve.
1. If there are a lot of impurities in the environment, do not replace the line valve while the
pumping unit is in its place. Remove the pumping unit (see paragraphs 1 and 2 ) and
replace the line valve in a clean environment.
2. Remove the cover and the shell (see paragraphs 2 and 3 ).
3. Open the fastening nut of the terminal block package and power supply unit (Figure 40).
4. Remove the nut and disconnect the protective grounding wire (Figure 41).
5. Remove the screw and disconnect the other protective grounding wire (Figure 42).
6. Move the terminal block package and power supply unit so that you are able to open the
nut of the line valve coil with fingers and to remove the nut and the coil (Figure 43 and 44).
7. Disconnect the thermostat wire (Figure 45).
8. Remove the terminal block package and the power supply unit (Figure 46).
9. Remove the line valve body with 27 mm socket or socket wrench (Safematic code
11790058) (Figure 47 and 48).
10. Install a new line valve.
11. Reassemble the pumping unit in reverse order.
Warning Ensure that the wires are not pressed or cut during the reassembly phase.
Figure 40. Open the nut
Figure 41. Disconnect the protective
grounding wire
Figure 42. Remove the screw
and disconnect the
other protective
grounding wire
Figure 43. Move the power supply unit
and terminal block package

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Figure 44. Open the nut of the
line valve coil
Figure 45. Disconnect the thermostat
wire
Figure 46. Remove the terminal
block package and
the power supply unit
Figure 47. Open line valve body
Figure 48. Remove line valve
body

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6 FILLING THE LUBRICANT RESERVOIR OF THE PUMPING UNIT
Lubricant reservoir of the pumping unit is filled through the filling connector which is equipped
with a filter.
Use of filling device (Safematic code 11600352; suitable for 20 l / 18 kg barrel)
Note Numbers in brackets are part numbers of drawing 461799A.
1. Ensure that the surroundings of the pumping unit are clean. Impurities in the system
prevent trouble-free operation and cause damage when reaching the lubrication point.
2. Remove the lid from the lubricant reservoir (1) and press the follower plate (2) tightly to the
reservoir above the lubricant. Follower plate is not used with fluid lubricants, as it does not
remain on the surface.
3. Place the lid (3) on top of the lubricant reservoir. Fasten the lid with wing screws (4) on the
lubricant reservoir.
4. Place the pump (5) through the lid into the follower plate central unit (6).
5. Connect the lubricant hose (7) to the pump.
6. Fill the lubricant hose by pumping by hand.
7. Connect the quick connector (8) to the lubricant hose.
8. Connect the quick connector to the pumping unit filling connector (9).
9. Fill the lubricant reservoir of the pumping unit by pumping slowly by hand.
10. Filling of the lubricant reservoir can be followed at the level indicator (10). To prevent
overfilling, the pumping unit is equipped with a safety valve (11).
11. Turn the pump handle (12) to upright position so that pressure discharges to the lubricant
reservoir.
12. Disconnect the quick connector from the pumping unit filling connector.
13. Fasten the protecting cap (13) of the pumping unit filling connector.
14. Fasten the protecting cap (14) of the filling device quick connector.
Caution Filter (15) of the filling connector has to be cleaned regularly and replaced if
necessary. Cleaning and replacing has to be performed when the reservoir
is empty.
Caution Do not fill the reservoir without the filter.
Caution The viscosity of used oil must be min. 46 cSt in pumping unit operation
temperature.

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7 REMOVING AIR FROM THE PUMPING UNIT
Remove air from the pumping unit, if there is air mixed with the lubricant e.g. in connection with
the filling of the lubricant reservoir.
Removing air from the pumping unit:
1. Disconnect the main line connections.
2. Start the pumping unit.
3. Open the pumping element deaerating screw.
4. Pump until only lubricant is coming out of the deaerating screw (no air).
5. Tighten the deaerating screw.
6. Connect the main line connections.
Figure 49. Opening the deaerating screw
8 CONTACT INFORMATION
Oy SKF Ab
P.O. BOX 80
40951 MUURAME
FINLAND
Tel. [phone]
Fax. [phone]
WWW: www.SKF.com

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9 INSTALLING SIM-CARD TO GSM-MODEM (OPTION)
User interface IF-103 of MultiLube MLP pumping unit can be replaced with SMS-MLP
equipment, which is installed inside the pumping unit. SIM-card is installed in the GSM-modem
of the pumping unit.
1. Remove the shell, see paragraph 3.1 (Figure 50).
2. Open the screws (Figure 51).
3. Detach the GSM-modem from the fastener (Figure 52).
4. Open the SIM-card slot by pressing the yellow button with a pen or other sharp object
(Figure 53).
5. Install the SIM-card in the GSM-modem (Figure 54).
6. Attach the GSM-modem in place.
7. Fasten the shell, see paragraph 3.2 .
Figure 50. Pumping unit without
the shell
Figure 51. Open screws M3x35
Figure 52. Detach GSM-modem Figure 53. Open SIM-card slot
Figure 54. Place the SIM-card in
the GSM-modem