Perma STAR CONTROL - User Manual

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01/2022
07/2022
360°
www.perma-tec.com
perma STAR CONTROL - Quick Start Guide
1. Predefi ne installation / Select lubricant, discharge period + connecting parts
2. Prepare lube-point
Clean lube-point Remove grease fi tting
Add reducer, support fl ange
and tubes (if required)
For remote mounting:
Prefi ll lube-point and any grease lines / connections
(use the same grease that is contained in the lubrication system)
For direct mounting:
Prefi ll lube-point and any connecting parts
(use the same grease that is contained in the lubrication system)
3. Activation / Installation of lubrication system
Pressure check: Lube-point / all connecting parts
2022/01 · Version: 1.2 · en
Select a suitable lubricant
for perma STAR LC unit
→ e. g. perma Multipurpose grease SF01
Select discharge period
→
e. g. with perma SELECT APP
(refer to our product catalog for details)
Possible mounting positions:
(Oil fi lled LC
+/- 45°)
Assemble drive
and LC
Tighten threaded ring hand tight until
the white triangle is completely visible
Note activation /
exchange date
on label
Confi guration can be
found on the back page Remove plug
Connect the cable to the
drive by screwing it on
Remove cap and screw
the lubrication system into
the lubrication point
Reducer
Remote mounting for lube-points with vibration,
limited mounting space, high temperature
Direct mounting
Examples: Bearing lubrication
Mounting bracket
STAR Standard Duty
1-point G1/4 female
(109663)
Hose connector G1/4 male for
hose iØ 9.5 mm - push-lock
(101554)
Heavy Duty hose up to
+100 °C oØ 16 mm x iØ 9.5 mm
(101555)
Hose connector G1/4 male for
hose iØ 9.5 mm - push-lock
(101554)
Support fl ange STAR
G1/4 male x G1/4 female
(109420)
Support fl ange STAR
Reducer
Add sealant
(e. g.
Loctite® 243™)

Summary

Predefine Installation and Lubricant Selection

Bearing Lubrication Examples

Examples of direct and remote mounting for bearing lubrication.

Lubricant and Discharge Period Selection

Guidance on selecting lubricant type and discharge period.

Possible Mounting Positions

Overview of various possible mounting positions for the device.

Prepare Lube-Point

Cleaning and Fitting Preparation

Steps for cleaning the lube-point and removing grease fittings.

Adding Components and Prefilling

Add reducer, support flange, tubes and prefill lube-points and lines.

Pressure Check

Perform a pressure check on the lube-point and all connecting parts.

Activation and Installation

Assemble Drive and LC

Assemble the drive and LC and tighten the threaded ring.

Marking and Final Connection

Note activation date, remove plugs/caps, and connect the drive cable.

Device Configuration

Mode, Size, and Discharge Settings

Configure operating mode, LC size, discharge period, and volume per impulse.

Electrical Connection Details

Information on electrical connection, signal output, and parallel wiring.

Quick Reference and Indicators

Power Supply and Purge Feature

Information on power supply indication and how to use the purge feature.

LED and LCD Screen Combinations

Explanation of LED/LCD displays for normal operation, run cycle, and errors.

Overview

1. Function Description
2. Usage Features
3. Maintenance Features

The perma STAR CONTROL is a lubrication system designed for precise and controlled delivery of lubricants to various points, particularly in bearing lubrication. It offers flexibility in installation, allowing for both direct and remote mounting, and provides clear visual feedback on its operational status.

Function Description

The perma STAR CONTROL's primary function is to deliver lubricant to a designated point over a selected period or in specific impulse volumes. It is designed to ensure continuous and accurate lubrication, which is crucial for the longevity and performance of machinery. The system can be configured to operate in either "TIME" mode, where lubricant is discharged over a set duration (e.g., months or weeks), or "IMPULSE" mode, where a specific volume of lubricant is discharged per impulse. This flexibility allows the system to adapt to different lubrication requirements and operational conditions.

The device consists of a drive unit and a lubricant cartridge (LC). The drive unit controls the discharge of lubricant from the LC. Connecting parts such as mounting brackets, support flanges, hoses, and connectors are used to establish the path from the lubrication system to the lube-point. For remote mounting, especially in environments with vibration, limited space, or high temperatures, specific components like heavy-duty hoses and remote mounting brackets are utilized to ensure reliable lubricant delivery.

The system incorporates a pressure check feature, which is essential for verifying the integrity of the lubrication path. This check ensures that the lube-point and all connecting parts are properly sealed and free from blockages, allowing for efficient lubricant flow.

Usage Features

The perma STAR CONTROL is designed for user-friendly operation, with several features facilitating easy setup and monitoring:

• Installation Flexibility: It supports both direct mounting, where the system is attached directly to the lube-point, and remote mounting, which is ideal for hard-to-reach or harsh environments. This adaptability ensures that the system can be integrated into a wide range of industrial applications.
• Lubricant Selection: Users can select a suitable lubricant for the perma STAR LC unit, such as perma Multipurpose grease SF01, to match the specific needs of their machinery.
• Discharge Period/Volume Configuration: The system allows for precise configuration of the discharge period in "TIME" mode (e.g., 1-12 months or 1-26 weeks for 500 cm³ LCs) or the discharge volume per impulse in "IMPULSE" mode (0.1 - 9.5 cm³). This granular control enables optimized lubrication tailored to specific operational demands.
• Intuitive Configuration Interface: The configuration process involves holding down a SET button to select the desired mode ("TIME" or "IMPULSE"), then pressing the SET button to choose the LC size (60, 120, 250, 500 cm³) and set the discharge period or impulse volume. This straightforward interface simplifies the initial setup.
• Visual Status Indicators (LED Light & LCD Screen): The device provides clear visual feedback through LED lights and an LCD screen, indicating its operational status:
  • Normal operation: Green LEDs flash every 7 seconds, and the LCD displays the Time/Impulse setting and volume.
  • Run cycle (lubricant being delivered): Green LEDs flash every second, and the LCD displays "ru."
  • Empty Lubricant Cartridge (LC): Red LEDs double flash every 2 seconds, and the LCD displays "LC," alerting the user to replace the cartridge.
  • Blockage / Back Pressure Overload (OL): Red LEDs double flash every 7 seconds, and the LCD displays "OL," indicating a potential issue in the lubrication line that requires attention.
  • Purge (PU): Green LEDs flash every second, and the LCD displays "PU" during the purge cycle.
• Signal Output: The system offers signal output capabilities, providing information on its status (OK/Err/LC) which can be integrated into broader control systems for remote monitoring and alerts.
• Parallel Connection: Multiple perma STAR CONTROL units can be connected in parallel, allowing for synchronized lubrication across several points from a single control interface.

Maintenance Features

The perma STAR CONTROL incorporates features that facilitate easy maintenance and ensure the continuous, reliable operation of the lubrication system:

• Lube-point Preparation: Before installation, the lube-point must be cleaned, and the grease fitting removed. This ensures a clean and unobstructed path for the new lubricant.
• Prefilling: For both direct and remote mounting, it is crucial to prefill the lube-point and any connecting parts with the same grease contained in the lubrication system. This prevents air pockets and ensures immediate lubricant delivery upon activation.
• Sealant Application: Adding sealant (e.g., Loctite® 243TM) to threaded connections helps prevent leaks and ensures a secure, pressure-tight system.
• Reducer, Support Flange, and Tubes: The system allows for the addition of reducers, support flanges, and tubes as required, providing flexibility in adapting to various installation scenarios and ensuring proper support for the lubrication lines.
• Assembly and Activation: The assembly of the drive and LC unit is straightforward, requiring the threaded ring to be tightened hand-tight until a white triangle is completely visible. This ensures a secure connection.
• Activation/Exchange Date Labeling: The system includes a label for noting the activation and exchange dates, aiding in tracking maintenance schedules and ensuring timely cartridge replacement.
• Plug Removal: Before connecting the lubrication system, a plug must be removed, preparing the unit for operation.
• System Installation: The cap is removed, and the lubrication system is screwed into the lubrication point, establishing the connection for lubricant delivery.
• Cable Connection: The cable is connected to the drive by screwing it on, providing power and control to the unit.
• Purge Function: The system features a purge function, accessible by holding down the SET button for 10 seconds. This function runs for three complete revolutions of the drive spindle, delivering approximately 6 cm³ of grease, which helps to clear air from the lines and ensure proper lubricant flow. The purge cycle can be stopped at any time by pressing the SET button once. This is a critical maintenance feature for ensuring the system is primed and ready for operation, especially after cartridge replacement or initial setup.

Perma STAR CONTROL Specifications

General

Protection Class	IP 65
Application	Single-point lubrication
Lubricant Capacity	60 cm³, 120 cm³, 250 cm³, 500 cm³
Drive	Electromechanical
Power Supply	Battery or external power supply