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1

General

Read the entire manual before working with the product. The manual con-
tains important information for your personal safety. The manual must be
read and understood by all persons who work on the product in any of the
product life phases.

1.1

Further applicable documentation

All documents delivered with this manual are further applicable documenta-
tion. They must be observed in addition to this operating manual for the safe
handling of the product.

Document

Explanation

Target readership

• Sales / project man-

agement

• Software engineer
• Maintenance techni-

cian

• Service technician
• Fitter
• Operating company
• Electrical engineer

only available in German,
French and English

Sales / project manage-
ment

Racks / Pinions Cata-
log

Only available in English
and Russian

Sales / project manage-
ment

Quick guide to
checking lubrication
system

• Maintenance techni-

cian

• Service technician
• Fitters

General

OPERATING MANUAL FlexxPump4 N Lubrication
System

3422906891_v1.0_

EN-US

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Содержание FlexxPump4 N

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

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

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

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

Страница 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...

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

Страница 175: ......

Страница 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...

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

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