Bijur Delimon FZ-A Operating Manual Download Page 1

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BIJUR DELIMON INTERNATIONAL

Operating manual

FZ-A pump

BA_2020_1_GB_FZ-A (rev. B)
Last updated: April 2020

Summary of Contents for FZ-A

Page 1: ...1 BIJUR DELIMON INTERNATIONAL Operating manual FZ A pump BA_2020_1_GB_FZ A rev B Last updated April 2020 ...

Page 2: ...2 Personnel qualification and training 10 2 13 3 Providing personal protective equipment 10 2 13 4 Instructing external assembly fitters 10 2 13 5 Testing and ensuring proper use 10 2 13 6 How to behave in emergency situations 10 2 14 Dangers if the safety instructions are not observed 10 2 15 Residual risks 11 3 Product description 11 3 1 Introduction 11 3 2 Revision level 11 3 3 Technical data 1...

Page 3: ...er s settings 32 5 7 2 Checks before commissioning for the first time 32 5 7 3 Measures during commissioning 32 5 8 Determining running and break times 33 5 9 Examples of applicable lubrication systems 33 5 9 1 Multi line system 33 5 9 2 Progressive system 33 6 Operation 34 6 1 Operating safety 34 6 2 Operating modes 34 6 3 The pump s or lubrication system s control unit 34 6 4 Topping up the lubr...

Page 4: ...vent the hazards that may occur during transport assembly commissioning operation maintenance repair and disassembly Qualified electrician A person with suitable technical training knowledge and experience who can recognise and prevent the hazards that can be caused by electricity Operator A trained person who based on their knowledge and experience is capable of commissioning and operating the pr...

Page 5: ...section carefully to understand the safety instructions throughout this document and on the product itself 2 1 Intended use The pump described below is intended for commercial use to supply lubricant to industrial machines and systems The pump may only be used by qualified operators The pump is deemed as functional when connected to a power supply The following is also required for intended use o ...

Page 6: ...ions Other signs Warning slipping hazard Wear safety goggles Warning tripping hazard Wear hearing protection Warning substances that are harmful to health Wear safety boots CE mark Warning flammable substances Wear safety gloves Waste electrical and electronic equipment symbol Warning possibility of hand injuries Wear face protection Warning possibility of hand injuries due to pulling in Wear a sa...

Page 7: ...is working o Never use parts of the pump or the connected central lubrication system as a standing or climbing aid 2 5 Safety instructions for maintenance inspection and assembly work o The operation maintenance inspection and assembly personnel must be appropriately qualified for this work o The personnel s area of responsibility competence and supervision must be regulated by the operating compa...

Page 8: ...oir lid o Risk of hand injuries due to the scraper and agitator in the reservoir Never reach into the reservoir while the pump is running o When the pump is being driven by a pendulum lever there is a particular risk of injury in the pendulum lever area while the pump is running o The pendulum lever drive must be suitably covered during operation to protect against unintentional contact 2 8 Notes ...

Page 9: ... the entire system Do not mix lubricants This has an impact on the lubricating properties and pumpability and thus on the central lubrication system s function When handling lubricants the relevant safety data sheets and if applicable the hazard labels on the packaging must be observed 2 10 2 Lubricant ageing If lubricants are stored in reservoirs or lines for an extended period of time e g due to...

Page 10: ...e required level of knowledge as the operating company s own personnel This includes all of the product information and safety instructions described in this document as well as safety regulations and accident prevention regulations issued by the operating company 2 13 5 Testing and ensuring proper use The operating company shall ensure that the pump is being used as intended by taking suitable pe...

Page 11: ...rts kits have been adapted accordingly and can be found under the FZAETB00xx order numbers Compatibility with the existing rev A pumps is guaranteed Please refer to the overview of spare parts kits in the annex for further details Revision B can be recognised by the code number The revision letter A in sixth place has been replaced by B The rest of the item code remains unchanged So you can easily...

Page 12: ...o With the drive running max 10 rpm o With the pendulum lever drive max 6 rpm Number of pendulum strokes max 300 rpm please enquire for higher rotation speeds rotation speeds 1 and downstream distributors Please refer to section 3 7 10 for further details and ratio dependent maximum rotation speeds Sound pressure level 70 dB A Approved lubricants Grease up to NLGI grade 2 DIN 51818 oil with an ope...

Page 13: ... Hz 334 254 8 litres 559 188 764 Reduction gear and motor 290 or 500 V 50 Hz 335 255 15 litres 582 280 855 Reduction gear and motor flange coupling Ø 11 154 74 30 litres 651 309 995 Reduction gear shaft diameter 16 130 50 Reduction gear 160 Pendulum lever 141 Free shaft end shaft Ø 20 141 Detailed dimensions for the individual drive variants can also be found section 3 drive pos 5 drive pos 1 ...

Page 14: ... two different pump bodies for the FZ pump depending on the number of outlets selected 3 6 2 Drive variants The FZ pump is configured with a flange mounted three phase motor as standard If the drive is to be provided by the customer the FZ pump offers additional options with interfaces to external mechanical drives Lubricant reservoir available in different sizes Flange motor Reduction gear availa...

Page 15: ...uced by larger reservoir volumes into account On the other hand the lubricant s dwell time in the reservoir must also be taken into consideration An insufficient lubricant replacement frequency may have a negative effect on the lubricating and feeding properties The available installation space is also a selection criterion For 15 and 30 litre reservoirs we advise using a reservoir support if the ...

Page 16: ...quest Automatic filling e g with an external drum pump can be achieved by combining a level switch and filling valve We generally recommend pressure limitation at each outlet to protect the pump and downstream components which may only be approved for 160 bar Filling valve Ultrasonic level switch Pressure limitation valve 160 or 200 bar ...

Page 17: ...spindle During the suction stroke the lubricant flows from the suction chamber S into the piston s vertical grooves and into the ring channels R During the pressure stroke the lubricant is fed from the ring channel and into the pressure channel D and then into the outlet openings via a vertical groove 3 7 2 Outlet location and labelling The FZ A pump can be configured with up to 12 outlets Dependi...

Page 18: ...ody Arrows indicate the corresponding setting spindle for each outlet to adjust the metering volume If there are more than 6 outlets two outlets are positioned in pairs one on top of another 24 mm apart In this case the outlet volume can only be adjusted in pairs This means that regulation at outlet 1 also inevitably applies to outlet 7 below too Setting spindle s Outlet numbering Example Pump bod...

Page 19: ...es min x 0 1 cm3 3 7 4 Adjusting the delivery volume The FZ A pump has 1 to 6 setting spindles depending on the configuration If there are more than 6 outlets a setting spindle controls the delivery volume of the two outlets positioned one above the other Engraved arrows clearly indicate the spindle outlet association The top and bottom outlets cannot therefore be regulated independently of each o...

Page 20: ...ate either in a clockwise or an anti clockwise direction with the same power Depending on the drive different ratios are required to obtain the desired delivery volume and to maintain the feed piston s maximum rotation speed There are four different drive shafts with different ratios that can also be combined with a reduction gear This is necessary for example for a high flange motor drive speed 3...

Page 21: ... shaft speed range can be between 1 320 and 1 380 rpm which has a minor effect on the delivery volume Our standard motor s relevant shaft speed is 1 360 rpm at 50 Hz and 1 670 rpm at 60 Hz with which the following volume calculations were carried out Example FZA12B11AA00 Drive shaft Max drive speed Ratio 95 1 950 rpm Ratio 215 1 2 150 rpm Ratio 345 1 3 450 rpm Reduction gear 1 Ratio 215 1 2 Ratio ...

Page 22: ...uperior machine If the design prerequisites are met the FZ pump can be synchronised to the running times of the machine system to be lubricated without an electrical control unit The pendulum lever is moved back and forth by a suitable component of the machine to be lubricated using an eccentric tappet crank and rod whereby the worm wheel is always rotated in the same direction using the switching...

Page 23: ...amage possible The feed piston s maximum rotation speed with the pendulum lever drive is 6 rpm Example FZA01B01AA00 Drive shaft Max pendulum strokes Ratio 3 1 18 min Ratio 12 1 72 min Ratio 25 1 150 min Ratio 50 1 300 min Sketch of the sample drive ...

Page 24: ...me A screen plate is installed in the reservoir base to protect the pump suction chamber against coarse dirt WARNING Hand injury due to the rotating scraper Never reach into the reservoir while the pump is running There is a risk of hands and fingers being crushed and cut off Top up the lubricant only when the pump is at a standstill and secured against being switched back on again No unauthorised...

Page 25: ...ating voltage UB 20 V 252 V DC AC 47 Hz 63 Hz Detection range 60 mm 550 mm Power consumption Approx 70 mA at 30 V DC all relays in the operating position Reference value 100 mm x 100 mm Switching output 1 3 Relay Sound beam s opening angle Approx 5 at 6 dB sound pressure Contact material Gold plated silver alloy Converter frequency Approx 380 kHz Max switching voltage 150 V DC 252 V AC Repeatabili...

Page 26: ...r valve code no 38132 1241 assembly w screw connections 38132D009 Example FZ pump with 6 pre installed pressure limitation valves ATTENTION Pump and system component damage possible The maximum operating pressure for the FZ pump is 200 bar When selecting or setting the pressure limitation valve the maximum permissible operating pressure of all connected system components must be taken into account...

Page 27: ... If the FZ pump is used for a progressive system overpressure can be detected early on by exceeding a programmed monitoring time using a downstream monitored lubricant distributor A separate operating manual with the code PL_20XX_X_E_38132 is supplied with the pressure limitation when ordered 3 7 14 Filling valve accessories Each variant of the reservoir has a 1 filling connection at the bottom A ...

Page 28: ...A B C D 30 l reservoir reservoir support with base plate 450 x 450 mm E 15 l reservoir reservoir support with base plate 450 x 450 mm F Accessories Without accessories 00 Level switch filling valve 01 02 Level switch and filling valve 03 1 x pressure limitation 160 200 bar d 10 mm 20 36 2 x pressure limitation 160 200 bar d 10 mm 21 37 3 x pressure limitation 160 200 bar d 10 mm 22 38 4 x pressure...

Page 29: ...mp vertically reservoir lid at the top 4 3 Storage conditions o Storage preferably in original packaging o Store vertically reservoir lid at the top o Use an oil tight base or reservoir o Select a storage location that is protected against dust moisture extreme temperature fluctuations vibrations and other mechanical effects o Observe the approved temperature range 5 Assembly installation and comm...

Page 30: ... for M10x1 5 8 8 screws is 49 Nm 5 4 Assembling lubrication lines and system components Before commissioning the pump the outlet lines and if necessary other system components such as lubricant distributors are installed Please note the following in this respect o The pipe installation may only be carried out by qualified specialists using suitable standard tools o Long lines especially lubricatio...

Page 31: ...cally using the filling connection Proceed as follows when filling using the reservoir lid Use a suitable filling pump with a hose Ø 10 With the pump switched off push the hose into the reservoir close to the screen plate in the reservoir base Fill the reservoir to 1 4 full Remove the hose Switch on the pump and let it run with the max delivery volume setting spindle stage 4 Let the pump run until...

Page 32: ...y volume all setting spindles in position 4 o Pre set level switch switching points if the level switch is available suitable for the selected reservoir size o Pre set pressure limitation valves according to the order 160 or 200 bar 5 7 2 Checks before commissioning for the first time Checklist before commissioning o Is there visible damage or is assembly improper or unfinished loose parts o Are t...

Page 33: ...ambient conditions This is why the values must be determined under given conditions during commissioning and why the programming must be adjusted if necessary A separate system description is available for further details about controlling progressive systems 5 9 Examples of applicable lubrication systems The FZ pump is suitable for directly supplying up to 12 lubrication points multi line system ...

Page 34: ...the lubricant Following commissioning lubricant must always be topped up in good time before the reservoir is emptied Otherwise air may enter the system which in turn will lead to malfunctions There is also a risk of the bearings being undersupplied undetected Topping up time When using a level switch and control unit recommended an automatic warning is issued when the defined minimum level is rea...

Page 35: ...s or at least every three months It must also always be ensured that the signage is legible and that heavy contamination is removed in good time Gears The gears are filled with lubricant grease Gearmaster LX00 Lubritech or similar by the manufacturer The filling must only be replaced when disassembling and cleaning the gears To do this open the sealing plugs shown in green in the figure below 7 1 ...

Page 36: ...e or a collection basin for lubricant drops escaping for a short time Carefully loosen the union screw s at each pump outlet until lubricant escapes make gradual half turns with brief interruptions Carefully loosen the union screw s until no further lubricant escapes Important Only small volumes of lubricant escape during the relief process Depending on the system pressure and the medium s viscosi...

Page 37: ...m the power supply and secure it against being switched back on again before starting cleaning Electrical and live parts may only be cleaned by a qualified electrician Do not touch electrical or live parts with wet hands or cloths Wear PPE WARNING Fire hazard Do not use flammable substances for cleaning CAUTION Skin irritation possible Avoid contact between the skin and lubricants at all costs Wea...

Page 38: ... and eliminate them if necessary Setting spindle s or feed piston s worn Contact Customer Service send the pump in Level switch malfunction Lubricant residues on the level switch Clean the level switch Too much lubricant in the reservoir Keep a minimum distance of 60 mm between the sensor and lubricant filling The pressure limitation valve opens The system pressure is too high e g due to blockages...

Page 39: ...assemble the connecting lines at the outlets and secure them against leakage Loosen the pump s fixing screws and prepare the pump for transport if necessary roughly empty the reservoir ensure that no lubricant escapes during transport When transporting the pump observe the safety instructions in section 2 under all circumstances Remove lubricant residues in the pump at a suitable place and take pr...

Page 40: ...ELIMON INTERNATIONAL 12 Annexes 12 1 Declaration of conformity 12 2 Overview of the spare parts kits 12 3 Illustration of the FZ pump s symbols according to DIN ISO 1219 1 2 3 Annex 12 1 Declaration of conformity ...

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Page 42: ...7 SP kit pump body FZ A 3 outlets 0 1 cm3 FZAETB0008 SP kit pump body FZ A 4 outlets 0 1 cm3 FZAETB0009 SP kit pump body FZ A 5 outlets 0 1 cm3 FZAETB0010 SP kit pump body FZ A 6 outlets 0 1 cm3 FZAETB0011 SP kit pump body FZ A 7 outlets 0 1 cm3 FZAETB0012 SP kit pump body FZ A 8 outlets 0 1 cm3 FZAETB0013 SP kit pump body FZ A 9 outlets 0 1 cm3 FZAETB0014 SP kit pump body FZ A 10 outlets 0 1 cm3 ...

Page 43: ...B0026 SP kit drive option pendulum lever i 3 1 FZAETB0027 SP kit drive option pendulum lever i 12 1 FZAETB0028 SP kit drive option pendulum lever i 25 1 FZAETB0029 SP kit drive option pendulum lever i 50 1 FZAETB0030 SP kit drive option reduction gear free shaft end AL1 i 95 1 FZAETB0031 SP kit drive option reduction gear free shaft end AL1 i 215 1 FZAETB0032 SP kit drive option reduction gear fre...

Page 44: ... drive option reduction gear motor flange AL1 i 345 1 FZAETB0058 SP kit drive option reduction gear motor flange AL1 i 710 1 FZAETB0059 SP kit drive option reduction gear motor flange AL1 i 1420 1 FZAETB0060 SP kit drive option reduction gear motor flange AL1 i 2880 1 FZAETB0061 SP kit drive option reduction gear motor flange AL5 i 95 1 FZAETB0062 SP kit drive option reduction gear motor flange AL...

Page 45: ...kits FZ A FZ B FZAETA0073 FZAETB0073 SP kit maintenance kit reservoir FZAETA0074 FZAETB0074 SP kit maintenance kit sealings FZBETB0001 SP kit pump body FZ B 1 outlet 1 2 cm3 FZBETB0002 SP kit pump body FZ B 2 outlets 0 6 cm3 Annex 12 2 spare part SP kits for FZ pumps as of March 2020 ...

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Page 47: ...47 BIJUR DELIMON INTERNATIONAL Annex 12 3 Illustration of the FZ pump s symbols according to DIN ISO 1219 1 2 3 Note This drawing is also available as a dwg file on request ...

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