GUDEL FlexxPump4 N Operating Manual Download Page 41

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Commissioning

5.1

Introduction

5.1.1

Safety

Only perform the tasks described in this chapter after you have read and un-
derstood the chapter "Safety".

It concerns your personal safety!

DANGER

Missing, defective, or modified safety equipment

Missing, defective, or modified safety equipment could lead to serious or fatal
injuries!

• Check the safety equipment at regular intervals.

• After working on the product, reattach all safety equipment correctly

• Ensure that the safety equipment function fault-free during operation

• Do not dismantle, bridge, or modify any safety equipment

DANGER

Hazardous voltage

The product contains components that are energized with hazardous volt-
ages. Touching these components will cause an electric shock. Electric shocks
can be fatal!

Before working in the danger area:

• Switch off the superordinate main power supply

• Secure the superordinate power supply against being switched on again

(main switch of complete system)

• Ground the equipment

Commissioning

OPERATING MANUAL FlexxPump4 N Lubrication
System

3422906891_v1.0_

EN-US

Summary of Contents for FlexxPump4 N

Page 1: ...OPERATING MANUAL FlexxPump4 N Lubrication System Project Order Bill of materials Serial number Year of manufacture BETRIEBSANLE 3422906891_V1 0 B1X xxxxxxxxx xxxx 10xxxxxx 2021...

Page 2: ...t may deviate from the original In the case of special models options or technical changes the scope of deliv ery may differ from the descriptions here Reprinting the instructions in whole or in part...

Page 3: ...Revision history Version Date Description 1 0 13 04 2021 Basic version Tab 1 Revision history Revision history OPERATING MANUAL FlexxPump4 N Lubrication System 3422906891_v1 0_EN US 3...

Page 4: ...Revision history OPERATING MANUAL FlexxPump4 N Lubrication System 3422906891_v1 0_EN US 4...

Page 5: ...onitoring equipment 17 2 4 Personnel 18 2 4 1 Personal safety equipment 18 2 4 2 Personnel qualifications 20 2 4 2 1 Operating companies 21 2 4 2 2 Fitters 21 2 4 2 3 Commissioning technicians 21 2 4...

Page 6: ...ction class 29 3 3 1 4 Operating pressure 29 3 3 2 Splitter 30 3 3 2 1 Temperature ranges 30 3 3 2 2 Accuracy of the lubricant distribution 30 3 3 2 3 Minimum lubrication quantity 30 3 3 2 4 Maximum p...

Page 7: ...lexxPump4 N B 3 fold 45 5 4 3 2 FlexxPump4 N B 6 fold 46 5 4 3 3 FlexxPump4 N B 9 fold 47 5 4 3 4 FlexxPump4 N B 10 fold 48 5 4 4 Connecting electrical equipment 49 5 4 4 1 Connecting 49 5 5 Activatio...

Page 8: ...cations 78 6 3 Operating mode 78 6 4 Lubrication recommendation 79 6 4 1 General information 79 6 4 2 Basics 80 6 4 3 Minimum lubrication quantity 80 6 4 4 Calculation formulas 81 6 5 Menu 82 6 5 1 Ex...

Page 9: ...s 101 7 3 2 Maintenance tasks after 2 200 hours 104 7 3 2 1 Replacing lubricant cartridge 104 7 3 2 2 Checking the lubrication system 107 7 3 3 Maintenance tasks after 10 000 hours 111 7 3 3 1 Cleanin...

Page 10: ...onnel qualifications 133 9 2 Storage conditions 133 9 3 Decommissioning 134 9 3 1 Shutdown 134 9 3 2 Cleaning rust proofing 134 9 3 3 Identification 135 9 4 Recommissioning 135 9 4 1 1 Cleaning the ra...

Page 11: ...ts 147 12 2 Explanations regarding the spare parts list 153 12 2 1 Spare parts and wear items list 153 12 2 2 Position drawings 153 13 Torque tables 154 13 1 Tightening torques for screws 154 13 1 1 Z...

Page 12: ...Table of contents OPERATING MANUAL FlexxPump4 N Lubrication System 3422906891_v1 0_EN US 12...

Page 13: ...to this operating manual for the safe handling of the product Document Explanation Target readership FAQ FlexxPump Sales project man agement Software engineer Maintenance techni cian Service technicia...

Page 14: ...is an essential component of the product The manual must be available at the product operation site throughout the entire service life of the product If the product is sold the manual must be transfe...

Page 15: ...rs to hazards with a moderate risk of severe physical injury or potential fatality CAUTION CAUTION CAUTION refers to hazards with a slight risk of moderate physical injury NOTE NOTE NOTE identifies a...

Page 16: ...ng state of the art technology It was designed and constructed in accordance with the accepted safety regulations However some residual danger remains during its operation There is danger to the perso...

Page 17: ...reattach all safety equipment correctly Ensure that the safety equipment function fault free during operation Do not dismantle bridge or modify any safety equipment You will find information on the se...

Page 18: ...rules and local provisions must be observed and followed 2 4 1 Personal safety equipment The operator is responsible for providing specialists with personal safety equipment Safety OPERATING MANUAL F...

Page 19: ...ing work Always wear safety shoes Wear hearing protection during opera tion and when working with compressed air Always wear protective clothing Wear face protection when working with compressed air a...

Page 20: ...icians are allowed to work on the product Persons are authorized if they are familiar with the relevant safety regulations for their area of re sponsibility they have read and understood this manual t...

Page 21: ...at all times the technicians are kept up to date regarding best practice the technicians are informed about technical progress modifications and the like the contracted cleaning staff only work under...

Page 22: ...technicians The manufacturer s technician is employed on site at the premises of the manufacturer or representative has very good mechanical and or electrical knowledge has good software knowledge has...

Page 23: ...ty zone during the cleaning process 2 4 2 7 Service technicians The service technician was trained by the operating company or the manufacturer has very good mechanical and or electrical knowledge has...

Page 24: ...out the materials They are country specific Safety data sheets are issued for example for materials such as oils greases cleaning agents etc The operating company is responsible for obtaining safety d...

Page 25: ...age All risks are borne solely by the user 3 1 3 Non intended use The product is not intended for lubrication of runners bearings or other elements for lubrication of elements in or on automobiles for...

Page 26: ...erial number 20XXXXXX www gudel com G del AG Industrie Nord CH 4900 Langenthal A B C E D Fig 3 1 Type plate A Serial number D Pump type B Item number E Build year the first two digits of the se rial n...

Page 27: ...vel depends on the machine properties and the operating conditions Generally the emissions sound pressure level LpA is 80dB A measured at a distance of 1 m from the safety fence and 1 6 m above ground...

Page 28: ...connections A Hydraulic output B connector plug M12x1 Connections Hydraulic Two connections for lubrication lines diameter 6 3 mm Electrical the four pin connector in size M12x1 transmits the followi...

Page 29: ...nsport 10 to 60 C Standard operation 15 to 60 C Up to and at 85 condensation forma tion is not permissible Bearing 5 to 30 C Up to 75 Tab 3 2 Temperature ranges FlexxPump Application in a lower temper...

Page 30: ...lubrication quantity Splitters only function correctly if 0 5 cm3 of lubricant is produced at their input per lubrication cycle 3 3 2 4 Maximum pressure The maximum pressure at the input of splitters...

Page 31: ...ormation 2 45 A B C E D Fig 4 1 Configuration of FlexxPump N lubrication system A FlexxPump D Y piece runs the lubricant together B Connection cable E Splitter divides the lubricant C Lubrication line...

Page 32: ...ollowing components A B C D E F Fig 4 2 Detailed configuration of the FlexxPump4 N A Cover D Housing B Oil bellow E Supply and control unit connector plug C Retaining ring F Hydraulic output Design fu...

Page 33: ...tridge is empty and for each piston stroke This makes it possible to process such information further 4 2 2 FlexxPump The product is supplied by an external power source This magnetic peg is used to a...

Page 34: ...n be made and the magnetic pin has previously been recognized Changes can be made On The green LED flashes every 5 s when the FlexxPump is switched On and no error is at hand The FlexxPump is ready fo...

Page 35: ...during the dispensing process 1 2 The FlexxPump shows which hydraulic output the lu bricant is being pumped from during the dispensing process Tab 4 3 Explanation of special characters Submenu INF men...

Page 36: ...ressure in bar is displayed in the LCD during the manually triggered active RUN command special dose Tab 4 6 Explanation of RUN menu PRO menu Submenu Display in LCD Explanation Pro h1 240 Changeable p...

Page 37: ...Cancel FIL command while in progress Tab 4 8 Explanation of FIL menu Malfunctions Display in LCD Explanation Designation E1 Empty status of lubricant car tridge Error E1 E2 Overpressure Error E2 E3 U...

Page 38: ...Magnetic peg C LCD Set the desired menu item as follows using the magnetic peg 1 Rotate the magnetic peg to OPEN position 2 Remove the magnetic peg out of the opening in the covering 3 Touch the acti...

Page 39: ...r 2 fold Lubricant quantity lubricant quantity lubricant quantity lubricant quantity Fig 4 6 Function Splitter 3 fold 4 2 4 Y segment The quantity of the lubricant at the inputs is combined at the out...

Page 40: ...Design function OPERATING MANUAL FlexxPump4 N Lubrication System 3422906891_v1 0_EN US 40...

Page 41: ...ty equipment correctly Ensure that the safety equipment function fault free during operation Do not dismantle bridge or modify any safety equipment DANGER Hazardous voltage The product contains compon...

Page 42: ...ty data sheets Oils and greases must be disposed of as hazardous waste even if the total quantity is small NOTE Improper transport Improper handling of the crates can lead to transport damage Do not t...

Page 43: ...panying documents Check the product for damage Report transport damage promptly Interfaces Check whether the necessary interfaces are present and ready for use The following interfaces are needed Lubr...

Page 44: ...3085 A B C Fig 5 1 Installing the lubricant pump A Installation site B Lubricant pump C Screw Install the lubricant pump as follows 1 Mount lubricant pump with two screws M6 L 35 mm The lubricant pump...

Page 45: ...cation system with 3 lubrication points D003487 A B C D F E Fig 5 2 Design FlexxPump4 N B 3 fold A Lubricating pinion not included in the scope of delivery D Splitter B Lubricating element not include...

Page 46: ...n not included in the scope of delivery E 2 Axis not included in the scope of de livery B Lubricating element not included in the scope of delivery F Lubrication line diameter 6 3 mm C FlexxPump4 N B...

Page 47: ...elivery F 2 FlexxPump4 N B B Lubricating element not included in the scope of delivery G 3 Axis not included in the scope of de livery C 1 FlexxPump4 N B H 2 Axis not included in the scope of de liver...

Page 48: ...elivery F 2 Axis not included in the scope of de livery B Lubricating element not included in the scope of delivery G 2 FlexxPump4 N B C 1 Axis not included in the scope of de livery H Lubrication lin...

Page 49: ...deviation of the electrical circuit Use only fuses with specified amperage Wire the plug according to the diagram Replace the damaged electric cable or plugs promptly Have electricians carry out the...

Page 50: ...age 24 VDC brown 2 Input signal of external control unit white 3 Ground GND 0 V blue 4 Output signal to external control unit black Tab 5 2 Connection assignment in pulse mode Connect the product as f...

Page 51: ...play in LCD Function Output signal PIN 4 OFF switched off low permanent On switched on high permanent E1 Oil bellow empty 0 5 Hz square wave signal permanent E2 Overpressure low permanent E3 Undervolt...

Page 52: ...ed Yes Set flag for machine stop Start lubrication cycle Successful no timeout Yes No Reset warning Reset flag for machine stop Set warning message Reset corresponding warning message as soon as OK ag...

Page 53: ...gh Signal 2 seconds Trigger single dose 12 high Signal 12 seconds Fill lubricant lines bleed FlexxPump FIL menu 14 high Signal 14 seconds Acknowledge error Tab 5 4 External control unit input signals...

Page 54: ...Commissioning OPERATING MANUAL FlexxPump4 N Lubrication System 3422906891_v1 0_EN US 54...

Page 55: ...5 8 Switching time diagram Trigger single dose The signal indicated at PIN 2 triggers a single dose The single dose lasts at least 22 seconds The output signal at PIN 4 in normal operation is High 20...

Page 56: ...Commissioning OPERATING MANUAL FlexxPump4 N Lubrication System 3422906891_v1 0_EN US 56...

Page 57: ...7 s 0 16 cm 1 1 or 1 2 Repeat 40x 3 s min 706 s pause 1 1 1 2 1 1 1 2 Fig 5 9 Switching time diagram Fill lubricant lines bleed FlexxPump The signal indicated at PIN 2 starts the filling process The f...

Page 58: ...Commissioning OPERATING MANUAL FlexxPump4 N Lubrication System 3422906891_v1 0_EN US 58...

Page 59: ...stem at PIN 4 sends a Low 0 V signal which lasts longer than 3 seconds The output signal at PIN 4 in normal operation is High 20 30 V The signal will switch to Low 0 V while the lubrication system s m...

Page 60: ...Commissioning OPERATING MANUAL FlexxPump4 N Lubrication System 3422906891_v1 0_EN US 60...

Page 61: ...Input signal received high permanent 01 50 Dispensing process low 10 18 s E1 Oil bellow empty 0 5 Hz square wave signal permanent E2 Overpressure low permanent E3 Undervoltage overvolt age low permane...

Page 62: ...Commissioning OPERATING MANUAL FlexxPump4 N Lubrication System 3422906891_v1 0_EN US 62...

Page 63: ...s supply of 24 VDC voltage Any information saved will not be lost when the lubrication system is switched off The output sig nal at PIN 4 in normal operation is High 20 30 V The lubrication system has...

Page 64: ...Commissioning OPERATING MANUAL FlexxPump4 N Lubrication System 3422906891_v1 0_EN US 64...

Page 65: ...output signal at PIN 4 in normal oper ation is High 20 30 V The signal will switch to Low 0 V while the lubrication system s motor is actually running This usually takes between approx 7 and 17 second...

Page 66: ...Commissioning OPERATING MANUAL FlexxPump4 N Lubrication System 3422906891_v1 0_EN US 66...

Page 67: ...s Hydraulic output t V Duration 3 s 1 1 1 2 1 1 1 2 Fig 5 13 Switching time diagram General error In case of general errors the lubrication system at PIN 4 sends a Low 0 V signal which lasts longer t...

Page 68: ...parameters Replace defective electronic components Switch on lubrication system Acknowledge error if necessary E4 internal error Disassemble entire lubrication system with screwed on lubricant cartri...

Page 69: ...face with magnetic peg 2 38 2 Remove magnetic peg from magnetic surface as soon as the LCD shows On and the yellow LED lights up 3 Wait until the green LED and the LCD flash 2x If an error is not dete...

Page 70: ...uted while the FlexxPump is in emptying time mode the set emptying time is shortened 2 x FIL 40 x On FIL 01 01 2 x CLr CLr Fig 5 15 Execute FIL menu Execute the FIL menu as follows Prerequisite There...

Page 71: ...gnetic peg 2 38 2 Remove the magnetic peg from the active surface once a dispensing process is completed and the LCD displays CLr 3 Wait until the green LED and the LCD flash twice The FlexxPump cance...

Page 72: ...Commissioning OPERATING MANUAL FlexxPump4 N Lubrication System 3422906891_v1 0_EN US 72...

Page 73: ...g pinion if necessary then pre lubricate Lubricating element lubricating pinion saturated with lubricant and intact Yes No Does lubricant flow out at lubrication point Yes No Other lubrication points...

Page 74: ...I II III IV VI VII V VIII 404 DLS 402 402 B _ Commissioning OPERATING MANUAL FlexxPump4 N Lubrication System 3422906891_v1 0_EN US 74...

Page 75: ...g surfaces of the roller and pinion need to be covered completely by a lubricating film Cleaning agents mild universal cleaner free from aromatic compounds e g Motorex OPAL 5000 Tab 5 8 Lubricant Clea...

Page 76: ...Commissioning OPERATING MANUAL FlexxPump4 N Lubrication System 3422906891_v1 0_EN US 76...

Page 77: ...Compare current FlexxPump Chapter 6 6 5 2 90 setting with the values needed for the lubrication points 2 79 3 Make changes in PRO menu in case of deviations Chapter 6 6 2 2 85 The settings have been...

Page 78: ...her operating modes are to be considered as supplementary information The product has three operating modes Draining time mode Et Draining time mode Et allows you to set the stroke rate c and the drai...

Page 79: ...o be lu bricated A precise recommendation on the lubrication quantity needed can not be made because that depends on various factors The calculations listed here are based on empirical values and lead...

Page 80: ...oint U Recommended lu brication quantity Pt The recommended lubrication quantity Pt can be found in the following table System Size 1 4 Size 5 7 3 lubrication points e g EP TMF TMO 0 9 cm3 100 km 1 2...

Page 81: ...ues need to be calculated for P1 Value Formula Unit Running performance of the axle per day V vm x t x POT x 0 036 km day Recommended lubrication quantity per day P V x Pt 100 cm3 day Emptying time of...

Page 82: ...D display The control arrow displays the fixed ba sic structure of the menus Control arrow The action arrow indicates the result af ter touching the active surface with the magnetic peg Action arrow U...

Page 83: ...for the FlexxPump is structured as follows OFF InF SEt On OFF On OFF run run Men OFF Pro FIL OFF Pro Men FIL Men On InF Men SEt Men Fig 6 1 Menu navigation Operation OPERATING MANUAL FlexxPump4 N Lub...

Page 84: ...s switched OFF The control system reverts to OFF mode after a completed function The standard SET menu setting which G del requires calls for draining time mode as the operating mode and a bellow volu...

Page 85: ...yellow LED lights up 5 3 Wait until the green LED and the LCD flash 2x The SET menu has been set up and the operating mode and bellow volume have been set according to G del standards 6 6 2 PRO menu...

Page 86: ...2 x Pro On Pro 01 c01 02 2 x 04 c02 2 x c03 03 04 c03 c30 36 Fig 6 3 PRO menu in emptying time mode Operation OPERATING MANUAL FlexxPump4 N Lubrication System 3422906891_v1 0_EN US 86...

Page 87: ...and the yellow LED lights up 4 3 Wait until the green LED and the LCD flash twice 5 Set the number of strokes 5 1 Touch the active surface with the magnetic peg 2 38 5 2 Remove the magnetic peg from...

Page 88: ...bricant quantity calculator The details on other operating modes are to be considered as supplementary information The function is only available if the FlexxPump is switched On The control system rev...

Page 89: ...until the green LED and the LCD flash twice The PRO menu is executed and the pause time and number of strokes are set If the FlexxPump is ready for operation battery and lubricant cartridge are in se...

Page 90: ...mode after a completed function 2 x InF OFF InF n41 06 c01 400 A B C D Fig 6 5 INF menu in draining time mode A FlexxPump firmware version C Stroke rate value set B Draining time value set in months...

Page 91: ...ed as supplementary information The function is only available if the FlexxPump is switched OFF The control system reverts to OFF mode after a completed function 2 x InF OFF InF n41 h06 c01 400 A B C...

Page 92: ...onsidered as supplementary information The function is only available if the FlexxPump is switched OFF The control system reverts to OFF mode after a completed function 2 x InF OFF InF n41 PUL 400 A B...

Page 93: ...executed while the FlexxPump is in emptying time mode the set emptying time is shortened 2 x run run On 01 Fig 6 8 RUN menu Execute the RUN menu as follows Prerequisite There is no malfunction at the...

Page 94: ...te The FlexxPump is switched On and the green LED flashes every 5 s 1 Touch magnetic surface with magnetic peg 2 38 2 Remove magnetic peg from magnetic surface as soon as the LCD shows OFF and the yel...

Page 95: ...nal spare parts 2 145 Tightening torques Unless otherwise indicated adhere to the tightening torques of G del Chapter 13 2 154 7 1 1 Safety Only perform the tasks described in this chapter after you h...

Page 96: ...f the total quantity is small 7 1 2 Personnel qualifications Only appropriately trained and authorized technicians are allowed to work on the product 7 2 Consumables and auxiliary agents 7 2 1 Cleanin...

Page 97: ...l G del lu bricants If special lubricants have been delivered ex works at the request of the cus tomer you can find the relevant specifications in the spare parts list Alternative manu facturers The f...

Page 98: ...rication system FlexxPump Oil Tab 7 2 Lubricant Lubrication system FlexxPump Fig 7 2 Pre lubricating rails and racks Lubrication ex works Specifica tions Lubri cant quantity Location of appli cation C...

Page 99: ...ump Oil Tab 7 4 Lubricant Lubrication system FlexxPump Temperature range 30 C to 20 C The following lubricants are intended for use in the lubrication system at a temperature range 30 C to 20 C Fig 7...

Page 100: ...g rails and racks Oil G del H1 NSF no 146621 Cannot be deter mined Lubrication system FlexxPump Oil Rivolta F L 125 Cannot be deter mined Lubrication system FlexxPump Oil Rivolta F L 500 Cannot be det...

Page 101: ...h the drives are located in the control system Duty cycle The maintenance intervals refer to the effective operating hours of the prod uct at a duty cycle ED of 100 The duty cycle always refers to the...

Page 102: ...product Avoid in particular Operation near or above the permissible performance limits High acceleration and resulting vibrations and operating forces Abrasive and or corrosive environmental conditio...

Page 103: ...years Tab 7 8 Maintenance intervals in shift operation 5 days a week Operating hours 1 shift opera tion 2 shift opera tion 3 shift opera tion 150 every 18 days every 9 days every 6 days 2 000 every 9...

Page 104: ...bricant cartridges contain lubricant residues Oils and greases are harmful to the environment Dispose of the lubricant cartridge in an environmentally friendly manner Replace the component every 2 000...

Page 105: ...g B Lubricant cartridge E Casing C Cover Lubrication ex works Specifications Lubricant quan tity Chapter 7 2 2 1 2 98 Chapter 7 2 2 1 2 98 400 ml Tab 7 10 Lubricant Lubrication system FlexxPump Mainte...

Page 106: ...nt cartridge in the direction of the arrow and remove it 4 Turn the new lubricant cartridge in the direction of the arrow by 2 full rotations Label of the lubricant cartridge has to be aligned with th...

Page 107: ...ing pinion if necessary then pre lubricate Lubricating element lubricating pinion saturated with lubricant and intact Yes No Does lubricant flow out at lubrication point Yes No Other lubrication point...

Page 108: ...I II III IV VI VII V VIII 404 DLS 402 402 B _ Maintenance OPERATING MANUAL FlexxPump4 N Lubrication System 3422906891_v1 0_EN US 108...

Page 109: ...g surfaces of the roller and pinion need to be covered completely by a lubricating film Cleaning agents mild universal cleaner free from aromatic compounds e g Motorex OPAL 5000 Tab 7 11 Lubricant Cle...

Page 110: ...Maintenance OPERATING MANUAL FlexxPump4 N Lubrication System 3422906891_v1 0_EN US 110...

Page 111: ...spection point Description Measures Contamination Check the components for contamination Lubricant pump Lubrication lines Other components Immediately clean away any contamination Loss of lubricant Ch...

Page 112: ...cating film on rails and racks leads to damage to the product This results in operational failure Ensure that there is always a lubricating film on rails and racks during oper ation Perform the descri...

Page 113: ...necting cable 3 Disconnect the lubrication lines from the hydraulic outputs 4 Loosen the screws 5 Remove the lubricant pump The lubricant pump has been removed Replacing the lubricant pump Replace the...

Page 114: ...85 A B C Fig 7 7 Installing the lubricant pump A Installation site B Lubricant pump C Screw Install the lubricant pump as follows 1 Mount lubricant pump with two screws M6 L 35 mm The lubricant pump h...

Page 115: ...system with 3 lubrication points D003487 A B C D F E Fig 7 8 Design FlexxPump4 N B 3 fold A Lubricating pinion not included in the scope of delivery D Splitter B Lubricating element not included in t...

Page 116: ...t included in the scope of delivery E 2 Axis not included in the scope of de livery B Lubricating element not included in the scope of delivery F Lubrication line diameter 6 3 mm C FlexxPump4 N B 6 fo...

Page 117: ...very F 2 FlexxPump4 N B B Lubricating element not included in the scope of delivery G 3 Axis not included in the scope of de livery C 1 FlexxPump4 N B H 2 Axis not included in the scope of de livery D...

Page 118: ...very F 2 Axis not included in the scope of de livery B Lubricating element not included in the scope of delivery G 2 FlexxPump4 N B C 1 Axis not included in the scope of de livery H Lubrication line d...

Page 119: ...e deviation of the electrical circuit Use only fuses with specified amperage Wire the plug according to the diagram Replace the damaged electric cable or plugs promptly Have electricians carry out the...

Page 120: ...external control unit white 3 Ground GND 0 V blue 4 Output signal to external control unit black Tab 7 15 Connection assignment in pulse mode Connect the product as follows Prerequisite The hydraulics...

Page 121: ...shows On and the yellow LED lights up 3 Wait until the green LED and the LCD flash 2x If an error is not detected On will be shown on the LCD and the green LED will light up every 5 s The FlexxPump i...

Page 122: ...Maintenance OPERATING MANUAL FlexxPump4 N Lubrication System 3422906891_v1 0_EN US 122...

Page 123: ...pinion if necessary then pre lubricate Lubricating element lubricating pinion saturated with lubricant and intact Yes No Does lubricant flow out at lubrication point Yes No Other lubrication points av...

Page 124: ...I II III IV VI VII V VIII 404 DLS 402 402 B _ Maintenance OPERATING MANUAL FlexxPump4 N Lubrication System 3422906891_v1 0_EN US 124...

Page 125: ...g surfaces of the roller and pinion need to be covered completely by a lubricating film Cleaning agents mild universal cleaner free from aromatic compounds e g Motorex OPAL 5000 Tab 7 16 Lubricant Cle...

Page 126: ...Maintenance OPERATING MANUAL FlexxPump4 N Lubrication System 3422906891_v1 0_EN US 126...

Page 127: ...kalub FLC 8 H1 mild universal cleaner free from aro matic compounds e g Motorex OPAL 5000 Chapter 7 3 2 2 2 107 Cleaning and checking lubri cation system 10 000 12 Service technicians The manufacturer...

Page 128: ...Maintenance OPERATING MANUAL FlexxPump4 N Lubrication System 3422906891_v1 0_EN US 128...

Page 129: ...ion to ensure uniform lubrication A B C D E F G Fig 9 7 Replacing the lubricating pinion A Lubrication point E Fastening screw B Screw F Lubricating pinion C Hexagonal socket wrench G Carriage D Cover...

Page 130: ...described in this chapter after you have read and un derstood the chapter Safety 2 15 It concerns your personal safety DANGER Hazardous voltage The product contains components that are energized with...

Page 131: ...p propriate measures Observe the country specific safety data sheets Oils and greases must be disposed of as hazardous waste even if the total quantity is small 8 1 2 Personnel qualifications Only app...

Page 132: ...brication system Check supply voltage and com pare with specified parameters Replace defective electronic com ponents Switch on lubrication system Acknowledge error if necessary E4 internal error Disa...

Page 133: ...mables may leak during the entire service life of the product These leaking liquids are harmful to the environ ment Observe the specified maintenance intervals and service intervals When anchoring the...

Page 134: ...brication lines and the gearbox when shutting down the product To shut down the product proceed as follows 1 Switch off lubrication system 2 Remove lubrication cartridge 3 Remove connecting cable 4 Di...

Page 135: ...mmissioning After cleaning work on the product or a downtime of one to four weeks carry out the following jobs Check the lubrication system 2 111 Check lubrication film on rails and racks and pre lubr...

Page 136: ...racks Wear appropriate protective clothing Fig 9 1 Cleaning rails and racks Cleaning agents mild universal cleaner free from aromatic compounds e g Motorex OPAL 5000 Tab 9 1 Cleaning agents Rails and...

Page 137: ...racks and pinions Pre lubricate the rails and racks as follows Prerequisite The rails and racks have been cleaned 1 Switch off the system and secure it with a padlock against being switched on again...

Page 138: ...tion system If the machine downtime is longer than one year carry out the following tasks Rinse the lubrication lines with fresh lubricant Replace the lubricating elements and lubricating pinion Repla...

Page 139: ...entire service life of the product These leaking liquids are harmful to the environ ment Observe the specified maintenance intervals and service intervals When anchoring the product ensure that the b...

Page 140: ...les 10 3 Waste management compliant assemblies 10 3 1 Disassembly DANGER Hazardous voltage The product contains components that are energized with hazardous volt ages Touching these components will ca...

Page 141: ...to the drinking water supply Take ap propriate measures Observe the country specific safety data sheets Oils and greases must be disposed of as hazardous waste even if the total quantity is small Disa...

Page 142: ...llecting point disposal in accordance with the safety data sheets 2 24 Batteries Battery collection Metals Scrap metal collection Electrical material Electrical waste Tab 10 1 Disposal material groups...

Page 143: ...ength 10 m 0200517 Length 20 m Tab 11 1 PLC connecting cable The PLC connecting cables are equipped with three colored LEDs LED color Meaning Green Voltage on PIN 1 Yellow Signal on PIN 4 White Signal...

Page 144: ...Accessories OPERATING MANUAL FlexxPump4 N Lubrication System 3422906891_v1 0_EN US 144...

Page 145: ...12 Spare parts supply Spare parts supply OPERATING MANUAL FlexxPump4 N Lubrication System 3422906891_v1 0_EN US 145...

Page 146: ...Spare parts supply OPERATING MANUAL FlexxPump4 N Lubrication System 3422906891_v1 0_EN US 146...

Page 147: ...epartment For all other countries not included in the following list please contact the service department in Switzerland Customer with special agreements should contact the service department specifi...

Page 148: ...l Jier Automation Ltd A Zone 16th Floor JIER Building 21th Xinxi Road 250022 Jinan China 86 531 81 61 6465 service gudeljier com India G del India Pvt Ltd Gat No 458 459 Mauje Kasar Amboli Pirangut Ta...

Page 149: ...rkstrasse 26 Industrie Nord 4900 Langenthal Switzerland 41 62 916 91 70 service ch gudel com Finland Greece Norway Sweden Switzerland Turkey Bosnia and Herzegovina G del GmbH Sch neringer Strasse 48 4...

Page 150: ...tralogistics G del Intralogistics GmbH Gewerbegebiet Salzhub 11 83737 Irschenberg Germany 49 8062 7075 0 service intralogistics de gudel com Italy G del S r l Via per Cernusco 7 20060 Bussero Mi Italy...

Page 151: ...swerkstrasse 26 Industrie Nord 4900 Langenthal Switzerland 41 62 916 91 70 service ch gudel com Tab 12 4 Service departments for all other countries Inquiries outside of business hours If you have ser...

Page 152: ...Spare parts supply OPERATING MANUAL FlexxPump4 N Lubrication System 3422906891_v1 0_EN US 152...

Page 153: ...Z e g a i r r a C 900 406015 10 00 Worm gear unit AE060 L left Ratio i 10 00 AE060 2 Stk E 910 406089 Motor flange 060 18x116x116 130 110 8030 018a 2 Stk E 1000 0910499 Mechanical multi limit switch...

Page 154: ...ions Screws without screw lock can come loose Secure screw connections on moving parts with Loctite medium strength 243 Apply the adhesive on the nut thread not on the screw Torque tables OPERATING MA...

Page 155: ...9 12 9 M3 1 1 1 58 1 9 M4 2 6 3 9 4 5 M5 5 2 7 6 8 9 M6 9 13 2 15 4 M8 21 6 31 8 37 2 M10 43 63 73 M12 73 108 126 M14 117 172 201 M16 180 264 309 M20 363 517 605 M22 495 704 824 M24 625 890 1041 M27 9...

Page 156: ...Torque tables OPERATING MANUAL FlexxPump4 N Lubrication System 3422906891_v1 0_EN US 156...

Page 157: ...ump4 N B 6 fold 46 Fig 5 4 Design FlexxPump4 N B 9 fold 47 Fig 5 5 Design FlexxPump4 N B 10 fold 48 Fig 5 6 Connect 49 Fig 5 7 Flow diagram Programming software 52 Fig 5 8 Switching time diagram Trigg...

Page 158: ...ecking lubrication system 111 Fig 7 7 Installing the lubricant pump 114 Fig 7 8 Design FlexxPump4 N B 3 fold 115 Fig 7 9 Design FlexxPump4 N B 6 fold 116 Fig 7 10 Design FlexxPump4 N B 9 fold 117 Fig...

Page 159: ...Tab 5 1 Connection assignment in draining time mode or hour mode 50 Tab 5 2 Connection assignment in pulse mode 50 Tab 5 3 Output signals external control unit 51 Tab 5 4 External control unit input s...

Page 160: ...ction assignment in draining time mode or hour mode 120 Tab 7 15 Connection assignment in pulse mode 120 Tab 7 16 Lubricant Cleaning agents Pre lubricating rails and racks 123 Tab 7 17 Maintenance tab...

Page 161: ...nu 71 Multi dispensing 71 Checking Lubrication system 73 107 111 123 Cleaning 134 135 Lubrication system 111 Rack 136 Rail 136 Cleaning agents 96 Connect Product 49 119 Connecting Electrical equipment...

Page 162: ...reviations 14 Explanation of symbols 14 External control system Input signal 53 Output signal 61 F Feedback 129 Feedback on the instructions 129 FIL menu Cancel 71 Execute 70 Fill Lubricant lines 57 F...

Page 163: ...81 Lubricant quantity 30 maximum storage period 30 Replacing 104 Lubricant lines fill 57 Lubricant pump Installing 44 114 Removing 113 Replacing 113 Lubricant quantity Calculate 81 Lubricant cartridg...

Page 164: ...spare part 95 130 Output signal Draining time mode 51 External control system 61 Hour mode 51 Overpressure 67 Overvoltage 67 P Personnel qualifications 42 PLC Connecting cable 143 Pre lubricating Rac...

Page 165: ...ightening torque 154 Service departments 147 SET menu 84 settings check 77 Shelf life G del H1 lubricants 30 Shutdown 134 Product 134 Single dose trigger 55 Software Programming Lubrication system 52...

Page 166: ...rew 154 Zinc plated screw 155 Torques 154 Transport 43 Trigger Single dose 55 Troubleshooting 132 Type plate 26 U Undervoltage 67 Use 16 W Warning notes 15 Warning symbols 16 Wear items list 153 Y Y s...

Page 167: ...appendix of this operating manual contains the following documents Layout Spare parts lists Declaration of conformity for TriboServ Appendix OPERATING MANUAL FlexxPump4 N Lubrication System 342290689...

Page 168: ...Appendix OPERATING MANUAL FlexxPump4 N Lubrication System 3422906891_v1 0_EN US...

Page 169: ...Layout Appendix OPERATING MANUAL FlexxPump4 N Lubrication System 3422906891_v1 0_EN US...

Page 170: ...Appendix OPERATING MANUAL FlexxPump4 N Lubrication System 3422906891_v1 0_EN US...

Page 171: ...Spare parts lists Appendix OPERATING MANUAL FlexxPump4 N Lubrication System 3422906891_v1 0_EN US...

Page 172: ...Appendix OPERATING MANUAL FlexxPump4 N Lubrication System 3422906891_v1 0_EN US...

Page 173: ...Declaration of conformity for TriboServ See also 2 Declaration of conformity for TriboServ 175 Appendix OPERATING MANUAL FlexxPump4 N Lubrication System 3422906891_v1 0_EN US...

Page 174: ...Appendix OPERATING MANUAL FlexxPump4 N Lubrication System 3422906891_v1 0_EN US...

Page 175: ......

Page 176: ...r Date G DEL AG Industrie Nord CH 4900 Langenthal Switzerland Fax 41 62 916 91 50 E mail info ch gudel com www gudel com larwue 1 0 13 04 2021 OPERATING MANUAL FlexxPump4 N Lubrication System 34229068...

Page 177: ...G DEL AG Industrie Nord CH 4900 Langenthal Switzerland info ch gudel com www gudel com...

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