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FlexxPump 402
GUDEL FlexxPump 402 - User Manual
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402
402 B
+
_
OPERATING MANUAL
Automatic lubrication system
FlexxPump 402 / 402B
Project / Order:
Bill of materials:
Serial number:
Year of manufacture:
BETRIEBSANLEITUNG
AUTOMATIC
LUBRICATION
SYSTEM
FLEXXPUMP
402
/
402B
90071992656444683_V9.0_EN-US
B1X.xxxxxxxxx-xxxx
09xxxxxx
2019
2
Table of Contents
Main Page
Table of Contents
5
Default Chapter
4
Table -1 Revision History
4
Table of Contents
5
Fig. 5 -6 Connecting 402
7
Table 8-1 Empty E1
10
General
13
Further Applicable Documentation
14
Document
14
Explanation of Symbols/Abbreviations
14
Table 1-1 Other Applicable Documentation
14
Table 1-2 Explanation of Symbols/Abbreviations
16
Safety
17
General
17
Product Safety
17
Personnel Qualifications
18
Operating Companies
19
Transport Specialists
19
Fitters
19
Technicians
20
Operators
20
Maintenance Technicians
21
Service Technicians
21
Disposal Specialists
21
Disregarding Safety Regulations
22
Installation Instructions
22
Manual
23
Hazard Warnings
23
Explanation of Warning Symbol
24
Safety
24
Product-Specific Hazards
25
Material Safety Data Sheets
26
(Msds)
26
Fig. 3 -1 Type Plate
28
Fig. 3 -2 Position of the Type Plate
29
Fig. 3 -3 Dimensions and Connections 402
31
Table 3-1 Operating Voltage
31
Fig. 3 -4 Dimensions and Connections 402B
32
Table 3-2 Temperature Ranges: Flexxpump
33
Table 3-3 Temperature Ranges: Splitter
34
Fig. 4 -1 Design of Flexxpump Lubrication System
35
Fig. 4 -2 Detailed Design of Flexxpump 402
36
Fig. 4 -3 Detailed Design of Flexxpump 402B
37
402B
38
Flexxpump
38
Function
38
Functional Description
38
Display Elements
39
Fig. 4 -4 Display Element and Malfunctions
39
Control Elements
40
Fig. 4 -5 Magnetic Peg
40
Fig. 4 -6 Function: Splitter, 2-Fold
41
Function
41
Splitter
41
Commissioning
43
Introduction
43
Personnel Qualifications
43
Safety
43
Fig. 5 -1 Transport Information
44
Packaging Symbols
44
Transport
44
Repairing Damaged Packaging
45
Installing
46
Prerequisites
46
Table 5-1 Interfaces
46
Fig. 5 -2 Installing the Flexxpump
47
Installing the Flexxpump
47
402/402B 3-Fold
48
Connect Hydraulics
48
Fig. 5 -3 Design 402/402B 3-Fold
48
402/402B 6-Fold
49
Fig. 5 -4 Design 402/402B 6-Fold
49
402/402B 10-Fold
50
Fig. 5 -5 Design 402/402B 10-Fold
50
Equipment
51
Connecting 402
53
Connecting 402B
53
Fig. 5 -7 Connecting 402B
53
Actuate
54
Flexxpump 402
54
Initial Commissioning
55
Checking the Lubrication
57
Table 5-3 Lubricants, Cleaning Agents: Prelubricate Guideways and Racks
60
Fig. 5 -8 Display Sequence of Display LCD
61
Switching on the Flexxpump
61
Fig. 5 -9 Lubrication Cycle
62
Lubrication Cycle
62
Special Dispensing
62
General
63
Operation
63
Personnel
63
Safety
64
Cycle
65
General Information
65
Lubrication Recommendation
65
Setting the Lubrication
65
Basics
66
Table 6-1 Average Lubricant Requirement Per Lubrication Point (U)
66
Calculation Formulas
67
Table 6-3 Calculation Formulas: Emptying Time of the Cartridge (P1)
67
Fig. 6 -1 Lubrication Quantity P2
68
Lubrication Quantity
68
Quantity
68
Fig. 6 -2 Example: Lubrication Quantity
69
Cycle
70
Setting the Lubrication
70
Table 6-4 Lubrication Cycle: Factory Settings for P1
70
Table 6-5 Lubrication Cycle: Factory Settings for P2
70
Fig. 6 -3 Set Lubrication Cycle
71
Malfunctions
71
Switching off Flexxpump
72
Introduction
73
Maintenance
73
Safety
73
Personnel Qualifications
74
Cleaning Agents
75
Consumables and Auxiliary Agents
75
Lubricants
75
Table 7-1 Table of Cleaning Agents
75
Table of Cleaning
75
Fig. 7 -1 Automatic Lubrication System Flexxpump
76
Fig. 7 -2 Automatic Lubrication System Flexxpump
76
Lubrication
76
System
76
Table 7-2 Lubricants: Automatic Lubrication System Flexxpump
76
Table 7-3 Lubricants: Automatic Lubrication System Flexxpump: Prelubricate Guideways and Racks
76
Lubricant Table
77
Maintenance Tasks
77
Table 7-4 Lubricant Table
77
Replacing the Cartridge
79
Fig. 7 -3 Replacing the Cartridge
80
Table 7-5 Lubricants: Automatic Lubrication System Flexxpump
80
Replacing the Battery 402B
81
Fig. 7 -4 Replacing the Battery 402B
82
Checking the Lubrication
85
Table 7-6 Lubricants, Cleaning Agents: Prelubricate Guideways and Racks
88
Checking Automatic Lubrication
89
Fig. 7 -5 Inspect Automatic Lubrication System
89
System
89
Table 7-7 Cleaning Agents: Automatic Lubrication System: Pump, Lines, Other Components
89
Table 7-8 Inspection Table
89
Disassembling the
90
Replacing the Flexxpump
90
Fig. 7 -6 Installing the Flexxpump
91
Installing the
91
402/402B 3-Fold
92
Connect Hydraulics
92
Fig. 7 -7 Design 402/402B 3-Fold
92
402/402B 6-Fold
93
Fig. 7 -8 Design 402/402B 6-Fold
93
402/402B 10-Fold
94
Fig. 7 -9 Design 402/402B 10-Fold
94
Equipment
95
Checking the Lubrication
97
Table 7-9 Lubricants, Cleaning Agents: Prelubricate Guideways and Racks
100
402/402B
101
Fig. 7 -10 Display Sequence of Display LCD
101
Maintenance Table
103
System
103
Table 7-10 Maintenance Table
103
Introduction
105
Personnel Qualifications
105
Repairs
105
Safety
105
Malfunctions
106
Repairs
106
Empty E1
107
Overcurrent E2
107
Table 8-2 Overcurrent E2
107
Internal Electrical Error E4
108
Operating Voltage too Low E3
108
Table 8-3 Overcurrent E3
108
Table 8-4 Internal Electrical Error E4
108
Internal Mechanical Error E5
109
System Malfunction
109
Table 8-5 Internal Mechanical Error E5
109
Decommissioning, Storage
111
Introduction
111
Storage Conditions
112
Cleaning, Rust-Proofing
113
Decommissioning
113
Identification
113
Shutdown
113
Recommissioning
114
Disposal
117
Introduction
117
Personnel Qualifications
117
Safety
117
Disassembly
119
Waste Management Compliant
119
Disposal Facilities, Authorities
120
Material Groups
120
Table 10-1 Disposal: Material Groups
120
Accessories
121
PLC Connecting Cable
121
Table 11-1 PLC Connecting Cable
121
Table 11-2 PLC Connecting Cable: Meaning of the LED Color
121
Spare Parts Supply
123
Service Departments
125
Table 12-1 Service Departments Americas
126
Table 12-2 Service Departments in Asia
127
Table 12-3 Service Departments in Europe
129
Table 12-4 Service Departments for All Other Countries
129
Table 12-5 Service Departments Outside of Business Hours
129
Parts List
131
Position Drawings
131
Tightening Torques for Screws
132
Torque Tables
132
Table 13-1 Torque Table for Zinc-Plated Screws Lubricated with Molykote (Mos2) Grease
133
Zinc Plated Screws
133
Black Screws
134
Table 13-2 Torque Table for Black Oiled and Non-Lubricated Screws
134
Stainless Steel Screws
135
Table 13-3 Torque Table for Stainless Steel Screws Lubricated with Molykote (Mos2) Grease
135
Illustrations
137
List of Tables
139
Index
141
Appendix
145
Layout
147
Spare Parts Lists
149
Declaration of Conformity for Triboserv
151
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GUDEL FlexxPump 402 Specifications
General
Brand
GUDEL
Model
FlexxPump 402
Category
Lubrication systems
Language
English
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