Perma CLASSIC - User Manual

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Manual44 pages

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Summary

Predefine Installation and Lubricant Selection

Bearing Lubrication Examples

Illustrates direct and remote mounting examples for bearing lubrication.

Select Suitable Lubricant

Guidance on choosing the correct lubricant for the perma CLASSIC system.

Select Activator Screw

Instructions for selecting the appropriate activator screw.

Prepare Lube-Point

Clean Lube-Point

Step to clean the lubrication point before installation.

Remove Grease Fitting

Procedure for removing the existing grease fitting.

Add Reducer and Tubes

Guidance on adding reducers and tubes as needed for the setup.

Prefill Lube-Point and Connections

Instructions for prefilling lube-points and connecting parts.

Pressure Check

Performing a pressure check on the lube-point and connections.

Activate Lubrication System

Gas Generator Status

Indicates the status of the gas generator.

Record Activation Date

Advise to record activation and exchange dates on the label.

Remove Plug

Step to remove the plug before activation.

Predefine Installation and Lubricant Selection (FUTURA)

Bearing Lubrication Examples (FUTURA)

Illustrates direct and remote mounting examples for bearing lubrication.

Select Suitable Lubricant (FUTURA)

Guidance on choosing the correct lubricant for the perma FUTURA system.

Select Activator Screw (FUTURA)

Instructions for selecting the appropriate activator screw.

Prepare Lube-Point (FUTURA)

Clean Lube-Point (FUTURA)

Step to clean the lubrication point before installation.

Remove Grease Fitting (FUTURA)

Procedure for removing the existing grease fitting.

Add Reducer and Tubes (FUTURA)

Guidance on adding reducers and tubes as needed for the setup.

Prefill Lube-Point and Connections (FUTURA)

Instructions for prefilling lube-points and connecting parts.

Pressure Check (FUTURA)

Performing a pressure check on the lube-point and connections.

Activate Lubrication System (FUTURA)

Gas Generator Status (FUTURA)

Indicates the status of the gas generator.

Record Activation Date (FUTURA)

Advise to record activation and exchange dates on the label.

Remove Plug (FUTURA)

Step to remove the plug before activation.

The perma CLASSIC and perma FUTURA are single-point lubrication systems designed for reliable and continuous lubrication of bearings and other components. These devices are suitable for both direct mounting and remote mounting applications, offering flexibility in various industrial settings.

Function Description

The core function of both perma CLASSIC and perma FUTURA is to provide a steady and controlled supply of lubricant to a designated lube-point over a predefined period. This ensures optimal lubrication, reduces friction, and extends the lifespan of machinery. The systems operate on an electrochemical principle, where a gas generator produces pressure to dispense the lubricant. This continuous lubrication helps prevent premature wear, reduces maintenance costs, and minimizes downtime.

Important Technical Specifications

While specific technical specifications like lubricant volume and exact pressure ranges are not explicitly detailed in the provided manual, several key components and their characteristics are highlighted:

Mounting Bracket: A universal mounting bracket (part number 109685) is available for CLASSIC, FUTURA, FLEX, and NOVA 1-point systems, featuring a G1/4 female connection. This suggests a standardized interface for various perma lubrication units.
Reducers:
- Reducer G1/4 male x 1/4" NPT female (part number 901000): This reducer facilitates connection between different thread sizes, allowing for adaptation to various lube-point interfaces.
- Additional reducers are available and their selection depends on the grease fitting size of the lube-point, indicating a need for compatibility.
Hose Connectors:
- Hose connector 1/4" NPT male for hose iØ 3/8" - push-on (part number 902160): This connector is designed for easy and secure attachment of lubrication hoses.
- Hose connector 1/4" NPT male for hose iØ 3/8" - push-on (part number 901007): Another push-on connector for 3/8" inner diameter hoses.
Heavy Duty Hose: A heavy-duty hose (part number 901006) with an inner diameter of 3/8" is specified, capable of withstanding temperatures up to 260 °F / 127 °C. This indicates suitability for demanding environments with elevated temperatures.
Activator Screws: The systems utilize activator screws to set the discharge period. The manual illustrates options for 1, 3, 6, and 12 months, providing flexibility in lubrication intervals. The perma SELECT APP is suggested for selecting the appropriate activator screw, implying a digital tool for configuration.
Lubricant Compatibility: The manual emphasizes selecting a "suitable lubricant" for perma CLASSIC/FUTURA, suggesting that these systems are designed to work with a range of greases and oils, but proper selection is crucial for optimal performance.

Usage Features

The perma CLASSIC and perma FUTURA systems offer several features that enhance their usability and adaptability:

Direct Mounting: The devices can be directly mounted onto the lube-point, providing a compact and straightforward lubrication solution. This is ideal for applications where space is not a constraint and the lube-point is easily accessible.
Remote Mounting: For lube-points with vibration, limited mounting space, or high temperatures, remote mounting is a key feature. This allows the lubrication unit to be positioned in a more accessible or protected location, connected to the lube-point via hoses and reducers. This significantly expands the range of applications where these systems can be effectively used.
Adjustable Discharge Period: The ability to select discharge periods of 1, 3, 6, or 12 months using different activator screws provides flexibility in tailoring the lubrication schedule to specific application requirements and lubricant consumption rates.
Ease of Installation: The "Quick Start Guide" format suggests a focus on straightforward installation. The step-by-step instructions, including preparing the lube-point and activating the system, are designed for user-friendliness.
Visual Confirmation of Operation: The "Gas generator OK" indicator (implied by the green light in the diagram) provides a visual cue that the system is functioning correctly, enhancing user confidence.
Sealant Application: The instruction to "Add sealant" when connecting reducers and tubes highlights the importance of leak-free connections for efficient lubricant delivery.

Maintenance Features

Maintenance for the perma CLASSIC and perma FUTURA systems is primarily focused on preparation and replacement, minimizing ongoing intervention:

Lube-point Preparation: Before installation, the lube-point must be cleaned, and the existing grease fitting removed. This ensures a clean and unobstructed path for the new lubricant.
Prefilling: A critical maintenance step is prefilling the lube-point and all connecting parts (hoses, reducers) with the same grease contained in the lubrication system. This prevents air pockets and ensures immediate lubricant delivery upon activation, which is vital for preventing initial dry running.
Pressure Check: After installation and prefilling, a pressure check of the lube-point and all connecting parts is recommended. This verifies the integrity of the system and ensures proper lubricant flow, preventing potential issues during operation.
Activation and Date Marking: The activation process involves inserting the activator screw, which triggers the gas generator. Users are instructed to "Note activation / exchange date on label," facilitating tracking of the service life and scheduling of timely replacements. This is a key feature for proactive maintenance.
System Replacement: As single-point lubricators with a predefined discharge period, these systems are designed for replacement once the lubricant is fully dispensed. The "Remove plug" step likely refers to the final removal of the spent unit. This "set and forget" approach simplifies maintenance routines, as there is no need for refilling or complex servicing of the unit itself.
Troubleshooting Guidance: While not detailed, the reference to "perma CLASSIC/FUTURA installation guide for details" for pressure checks implies that more comprehensive troubleshooting and maintenance information is available in a full manual.