Perma PRO 250 Operator's Manual
Multi-point lubrication system
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- Translation of the original operating instructions (76 pages) ,
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perma-tec GmbH & Co. KG
perma-tec GmbH & Co. KG
Operating Instructions
PRO 250 / 500
The World of Automatic Lubrication
perma Produktname
perma
perma PRO
perma-tec GmbH & Co. KG
This operating manual is valid for the lubricator perma PRO with PRO LC-units 250 cc and 500 cc.
©
2002 perma-tec GmbH & Co. KG
Without the specific approval of perma-tec GmbH & Co. KG no part of this documentation
can be copied or made available to third parties.
We have taken great care when compiling all the details contained in this documentation.
However, we cannot rule out discrepancies and we reserve the right to make technical
changes to the product without giving advance notice.
We do not assume any judicial responsibility or liability for damages which may ensue as
a result.
We will include any necessary changes in the next edition.
Compiled and printed:
The World of Automatic Lubrication
01 / 01 / 2008
perma PRO
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Table of Contents
Related Manuals for Perma PRO 250
Summary of Contents for Perma PRO 250
- Page 1 PRO perma-tec GmbH & Co. KG perma PRO This operating manual is valid for the lubricator perma PRO with PRO LC-units 250 cc and 500 cc. © 2002 perma-tec GmbH & Co. KG Without the specific approval of perma-tec GmbH & Co. KG no part of this documentation can be copied or made available to third parties.
- Page 2 Quick Reference Guide for the Lubrication System perma PRO Lubrication System perma PRO On this page you will find some important information for quick and easy operation and setting of the perma PRO. Before Protection cover With bayonet catch for quick the first installation of the perma PRO, and whenever you need detailed instructions, you should read the complete opening/closing.
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Page 3: Table Of Contents
PRO Table of Contents The lubrication system perma PRO Quick reference guide Content Various 1.1 Delivery / Content 1.2 Storage 1.3 Markings 1.4 Intended Usage 1.5 Legal Requirements Safety Instructions 2 .1 Persons Responsible for Safety 2.2 General Safety Instructions 2.3 Safety Information for perma PRO Technical Data 3.1 Design of the perma PRO Lubricator Mounting and Assembly of the Lubrication System 4.1... -
Page 4: Various
GmbH & Co. KG Various About this Operating Manual ♦ This operating manual is intended for the safe operation of the perma PRO automatic lubricator. It contains safety instructions which must be adhered to. ♦ Everyone who works on or with the lubricator must have access to this operating manual during their shift. They must also pay attention to all relevant instructions and notices. ♦ The operating manual must always be kept complete and in easy to read condition. Terms Used ♦ Lubricator perma PRO In the following text, the “lubricator” will either be called “lubricator” or by its name “perma PRO”. ♦ Lubrication Canister In the following text, the “Lubrication Canister” will be called PRO LC-unit. The user can order the PRO LC-unit with different lubricants and in size 250 cc and 500 cc. Usage of Safety Instructions All safety instructions in this operating manual are standardized. Danger Signs This sign warns you of any danger to people’s health or to subjects. Tips This sign alerts you to application tips which will help you in doing certain tasks quicker and safer. Delivery / Content ♦ perma PRO will be delivered according to customer specifications in regards to type of grease and size... -
Page 5: Markings
PRO Markings ♦ The lubricator perma PRO is clearly marked with a label (serial number) on the drive system and a label on the PRO LC-unit. ♦ CE mark on the drive unit. ♦ UL mark on the drive unit: “This equipment is suitable for use in Class I, Div. 2, Groups A, B, C and D; or Non-Hazardous Locations only. Warning - Explosions Hazard - Substitution of components may impair suitability for Class I, Division 2.” ♦ Manufacturer: perma-tec GmbH & Co. KG Hammelburger Straße 21 D – 97717 Euerdorf Internet: www.perma-tec.com E–mail: info@perma-tec.com Intended Usage The lubricator perma PRO ♦ immediately supplies all lubrication points with lubricant, at a pressure build-up of max. 25 bar (360 psi.), permanently, precisely and independent of temperature. ♦ has passed the environmental audit according to standard EN 60068-2-6 (vibration test) without any component damage or malfunctions. In test: PRO drive unit with MP-6, PRO LC-unit 500 cc, and mounting device in various mounting positions. -
Page 6: Safety Instructions
GmbH & Co. KG Safety Instructions Persons Responsible for Safety ♦ The operator or his safety officer must warrant, ▪ that all the relevant regulations, instructions and laws are adhered to; ▪ that only qualified personnel will work with and on the lubricator; ▪ that unauthorized personnel are not allowed to work with and on the lubricator; ▪ that the safety regulations are adhered to when mounting the lubricator or during maintenance. General Safety Instructions ♦ We are not laying claim to completeness in regards to these safety instructions. Please contact perma-tec Customer Service if you have any questions or problems. ♦ At the time of delivery the lubricator is in line with state-of-the-art technology and in principle is considered to be safe to operate. ♦ Dangers emanate from the lubricator for persons, the lubricator itself and for other material assets of the operator if: ▪ unqualified personnel operates the lubricator; ▪ the lubricator is used inappropriately and for operations that it was not intended to be used for; ▪ the lubricator setting / variation is incorrect; ▪ the lubricator is opened by force while in operation;... -
Page 7: Technical Data
Low temp. grease The dashed standard grease- and dotted low temperature-lines show the maximum values allowed. If your application is out of the specification range shown in this diagram, please contact your local distributor. perma-tec cannot be held liable for these applications. Example: 1. The application temperature is + 5 °C / + 41 °F. What is the maximum tube length allowed for standard grease? Correct Answer: 3 m max. tube length for standard grease, 5 m max. tube length for low temp. grease (arrow 1 meets the dashed line of the standard grease range at 3 m). 2. You want to use a 4 m tube. Up to which temperature can the system be used? Correct Answer: + 10 °C / 50 °F with standard grease - 5 °C / 23 °F with low temp. grease (arrow 3 meets the... -
Page 8: Design Of The Perma Pro Lubricator
GmbH & Co. KG Design of the perma PRO Lubricator Lubricators are available as 250 cc and 500 cc versions and they can be supplied with the lubricant requested by the customer. They consist of (refer to figure 2): Protection cover for the drive unit, re-usable. PRO LC-unit (Lubrication Canister), can be supplied as 250 cc and 500 cc versions with the lubricant requested by the customer. Usage of perma pro PRO LC-units only! Battery set, consisting of two batteries. The batteries are not rechargeable and must be changed every time the PRO LC-unit is replaced. Batteries can only be used once! Usage of perma-tec battery sets only! Drive unit, consisting of a gear motor, a pump system and an electronic unit for the control system, re-usable. -
Page 9: Mounting And Assembly Of The Lubrication System
PRO Mounting and Assembly of the Lubrication System 4.1 Mounting the Drive Unit onto a Fixing Device for Wall-Mounting ♦ Attach the supplied mounting device to the drive unit using the two enclosed hex head bolts (M6 x 16) and the two washers. ♦ Screw the mounting device with the drive unit onto a support of your system. The boring template of the three mounting screws (141.5 x 45) can be seen below in picture 3 or on the template that is included. You have to use at least three hexagon screws M6 x 25 (e.g. on metal ground). ♦ Before you connect the outlet of the drive unit to the lubricant tube, you have to make sure that the lubrication points and the complete lubricant tube is pre-lubricated with the same lubricant that is contained in the PRO LC-unit. For that, perma-tec offers a 400 g lubrication cartridge for manually-operated grease presses with the requested lubricant. ♦ Connect the lubricant tube (connection G 3/8 outside or G 1/8 inside) to the outlet of the drive unit and install the tube correctly between the outlet and the lubrication point. The lubricant tube must not be longer than five meters. Make sure that you assemble the connections and lubricant tubes correctly and tightly to avoid possible leakage. -
Page 10: Assembly Of The Lubricator
GmbH & Co. KG Assembly of the Lubricator ♦ Insert the battery set into the drive unit (according to the direction of the arrow on the label). No function! Setting of PRO LC-unit size is done via menu on display Battery set figure 4 Catch Interlocking teeth ♦ Place the PRO LC-unit inside the protection cover and remove the plug of the PRO LC-unit (refer to figure 5). Protection cover PRO LC-unit Plug figure 5 The World of Automatic Lubrication - 10 -... - Page 11 PRO ♦ Push the PRO LC-unit into the protection cover until lubricant comes out of the opening (refer to figure 6). figure 6 ♦ Place the PRO LC-unit with its protection cover on the drive-unit. Make sure that the catch locks and that the teeth of the PRO LC-unit and the drive unit interlock (refer to figure 4 and figure 7). ♦ Turn the cover clockwise until the bayonet catch locks. figure 7 - 11 -...
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Page 12: Display And Control Elements Of The Lubrication System
GmbH & Co. KG Display and Control Elements of the Lubrication System Display Elements The operating status of the lubricator can be determined via the green or the red LED and via the display at the control unit (refer to figure 8) of the perma PRO. The perma PRO offers a menu-guided setting. Changes of the settings are shown on the display. Error messages, e.g. in case the pressure in the lubricant tube gets too high, are also indicated on the display. push-button MODE SAVE Red LED Green LED push-button ON/OFF SELECT Connector for distributor MP-6 figure 8 5.2 Function Indication on the Display The display is located on the control unit of the perma PRO (refer to figure 8, chapter 5.1). The display shows settings, operating conditions and error messages of the lubricator. In case of an error free operation of the lubrication system, the display shows the remaining volume of the mounted PRO LC-unit in percent volume (% Vol.). Figure 9 shows an example of the displayed information if the PRO LC 500-unit is new and full. LC2500 %Vol. figure 9 The display cannot be switched off by the operator. -
Page 13: Control Buttons
PRO Control Buttons There are two push-buttons on the control unit (refer to figure 8) which can be used for a menu-guided change of the settings. ♦ With the MODE/SAVE button (refer to figure 11), you can reach the configuration menu, change the mode and save the modified settings for further operation. ♦ With the ON/OFF SELECT button (refer to figure 12) you can do the following: turn lubricator On/Off, increase discharge period (Days, Weeks, Months - each time you press the button increases the discharge period by one calendar unit), change PRO LC-unit size, activate MP-6 outlets and set PIN. Long >4 sec. until Long >4 sec. until PRESS Short Short the display content the display content changes completely changes completely MODE ON/OFF BUTTON MODE ON/OFF SAVE... -
Page 14: Setting Into Operation
GmbH & Co. KG Setting into Operation ♦ If necessary, mount the drive unit onto a fixing device for wall-mounting (refer to chapter 4.1). ♦ Insert the battery set into the drive unit and the PRO LC-unit into the protection cover and close the complete system (refer to chapters 4.2 b - d). ♦ Determine the discharge period (refer to chapter 6.7). ♦ Set volume of PRO LC-unit, discharge period, outlets of MP-6, and the PIN via buttons on display (refer to chapter 6.8). ♦ Switch-on the lubrication system (refer to chapter 6.5). ♦ Carry out an additional discharge (refer to chapter 6.8). If the drive motor has started and the green LED is lit, the lubricator has started to discharge. The display indicates the remaining volume (% Vol.) of the PRO LC-unit. The operator must always check the customer-specific settings and if necessary change them before the lubricator is set into operation! During Operation ♦ Carry out regular inspections during the operation. You should pay special attention with regard to leakage and to the condition of the lubricator! ♦ Check the condition of the lubricant tube and the connections regularly! ♦ Check the filling level of the transparent PRO LC-unit regularly! ♦ After one or several additional discharges, you have to calculate the reduced discharge period and note this on your lubrication and maintenance schedule. -
Page 15: Determining The Discharge Period
40.1 80.1 38.6 77.2 37.2 74.4 35.9 71.8 34.7 69.4 chart 4 Please take into account that in case of one or several additional discharges, the remaining discharge period of the lubrication system must be recalculated (refer to chapter 6.7). This also applies in case of a cut-off of the lubrication system due to a long machine standstill (e.g. weekends or annual holidays). You should also note the result of your calculation of the remaining discharge period in your lubrication and maintenance schedule. The perma SELECT software helps you to determine the discharge period. Visit our website www.perma-tec.com for a free download of this software. - 15 -... -
Page 16: Settings And Display
GmbH & Co. KG Settings and Display (see caption on page 17) MODE ON/OFF Display Meaning / Description SAVE SELECT –– Display at delivery with attached PRO LC-unit Time Shows discharge period Months PIN-reset MODE SAVE Change first digit Enter first digit of current PIN MODE PIN “ ” at delivery SAVE ON/OFF SELECT Change second digit Enter second digit MODE of current PIN SAVE ON/OFF... - Page 17 PRO Caption for Chart on Left Side Instructions should be followed from top to bottom and from left to right (also refer to chart. 3). The instructions correspond to the operating sequence on the turned-off lubrication system perma PRO. Configuration is also possible if perma PRO is On. Function short push long push blinking display Go to Symbol chart 6 Configuration sections (see vertical bar, chart 5) INTRO INTRO informs (INFO) and asks for the current PIN (PIN-entry). Settings can be changed in the configuration menu with its different sections (LC, Time, Outlets, PIN). CONFIGURATION MENUE You can change the PRO LC-unit size from LC250 to LC500 and back by pushing the ON/OFF/SELECT button (refer to chapter 7.1 and 7.2). Time The discharge period can only be set in one type of calendar unit (i.e. either Months, Weeks or Days). When the highest unit size is reached, counting starts again with number “ ”. Outlets If a MP-6 distributor is connected, outlets 1 - 6 can be set individually. The activated outlets 1-6 are displayed with a filled-in square in the display (please refer to the operating instruction of the MP-6 distributor for more details). We strongly suggest to enter a personal PIN in order to protect your settings from unauthorized access. The PIN can only be changed during initial configuration or after a PIN-reset. A PIN-reset (short push of buttons: left-left-right-right-left in the INTRO-Info-menu) changes your personal PIN back to “ ”. The PIN-reset was successful when the displayed time disappears for a second and then comes back on. All other settings remain unchanged. Save or Reject Changed Settings The display settings can be saved with a long push of the MODE/SAVE button. If you do not want to save your...
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Page 18: Calculation Of The Remaining Discharge Period
GmbH & Co. KG Low-Temperature Cut-Off of the Lubrication System The temperature range from 0 °C to - 19 °C (32 °F to –2.2 °F) is indicated by a blinking ice crystal symbol (refer to figure 16). In this temperature range the lubrication system perma PRO continues to operate without interruption. Please note, that in this temperature range an additional discharge is not possible! LC2500 %Vol. figure 16 Display with a blinking ice crystal (in this example with % Vol.) In order to protect the system from damage, the low-temperature cut-off of the lubrication system is automatically carried out by the control system and the built-in temperature sensor. If the temperature reaches or falls below - 20 °C (- 4 °F), the lubricator is switched off by the low-temperature cut-off and the ice crystal symbol is permanently indicated on the display. The remaining volume is still displayed in % Vol. From this time onwards, the lubricant is no longer discharged. You have to take this fact into account if your system continues to operate in order to prevent damages! As soon as the temperature rises and reaches - 19 °C (- 2.2 °F) or higher, the control system switches the... -
Page 19: Replacement Of The Pro Lc-Unit
PRO Replacement of the PRO LC-Unit The Following Must Always Be Taken into Account If the replacement of an empty PRO LC-unit becomes necessary, it will be indicated by a simultaneous blinking of the red and the green LED. Additionally, the display indicates that the PRO LC-unit is empty (refer to figure 17). LC2500 %Vol. figure 17 If you replace the PRO LC-unit, you also have to change the battery set. Otherwise, the correct operation of the lubricator cannot be guaranteed! If you replace the PRO LC-unit by a PRO LC-unit of a different size, a corresponding protection cover (refer to chart 8a, chapter 9) must be used. -
Page 20: How To Replace The Pro Lc-Unit
GmbH & Co. KG How to Replace the PRO LC-Unit Drive system and circuit board must be protected from moisture. Exchanges should only be done in a dry place and it must be ensured that no moisture enters the drive unit. a) Turn the protection cover on the drive unit counter-clockwise and remove it. b) Remove the empty PRO LC-unit. The display indicates “ ” and the red LED is blinking. c) Remove the used battery set from the drive unit. d) Insert the new battery set into the drive unit. Follow the directions of the arrows. e) Remove the plug of the PRO LC-unit (refer to figure 5, chapter 4.2). f) Push the PRO LC-unit into the protection cover until lubricant comes out of the opening (refer to figure 6, chapter 4). g) Place the new PRO LC-unit on the drive unit, turn it until the catch locks and the teeth of the PRO LC-unit and the drive unit interlock. The control system automatically recognizes the new PRO LC-unit. The display indicates “ ” if the perma PRO was switched off prior to the replacement of the PRO LC-unit. Or it indicates “ % Vol.” if the perma PRO was switched on before the replacement. You should only use completely full perma-tec PRO LC-units, in order to guarantee a trouble-free operation. h) The lubrication system continues to operate with the previous setting of the discharge period. i) If required, change lubricator settings (see chapter 6.8). If the lubricator was ON before changing the LC-unit, it will automatically resume operation with existing settings. If the lubricator was OFF, it must be turned ON (refer to figure 13, chapter 6.5). -
Page 21: Trouble Shooting
System does not detect No PRO LC-unit installed Install an PRO LC-unit the PRO LC-unit No power supplied to the system No battery inserted or battery set Insert a new battery set and from the battery empty use a full PRO LC-unit In addition to the above, the following malfunctions can occur when a perma MP-6 distributor is connected to the lubrication system: Lubrication system has been Excess motor current of the perma Replace perma MP-6 switched off MP-6 distributor Clear the blockage and Excess motor current of the acknowledge the fault by... -
Page 22: Accessories And Spare Parts
GmbH & Co. KG Accessories and Spare Parts Due to the high pressure of up to 25 bar (360 psi), you should only use genuine spare parts and accessories from perma-tec in order to ensure a reliable operation of the distributor and the complete lubrication system. This especially applies to connections and lubricant tubes. Spare parts and accessories must meet the technical requirements! This is always guaranteed with genuine spare parts and accessories from perma-tec. Spare parts Part. No. Illustration PRO LC-unit 250 cc filled 2220 XXX*... - Page 23 PRO Spare parts Part. No. Illustration perma PRO mounting device 27 008 007 Grease cartridge 400 g filled with on request to be used for pre-filling grease lines with a grease gun Straight connecting piece G 1/8 27 008 010 for lubricant tubes Angle G 1/8 for connecting a 27 008 011 lubricant tube Special lubricant tube (Ø 8 x 1.5, 27 008 009 inner-Ø 5 mm) with different lengths Reducer G 3/8 – G 1/4 27 008 017 CD ROM with SELECT software on request (calculation of the lubricant amount), lubrication and maintenance schedule and operating instructions as PDF file chart 8b - 2 -...
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Page 24: Disposal
GmbH & Co. KG Disposal Help us in protecting the environment and saving resources by recycling valuable raw material. Please follow your local waste disposal regulations. Service ♦ Please contact your local supplier for availability and cost of the following: ▪ Returning of the empty lubricator for environmentally safe recycling or disposal. ▪ exchange of battery set. ▪ exchange of PRO LC-unit. ▪ to pre-set lubricator (LC/lubrication period/outlets) The World of Automatic Lubrication - 24 -... -
Page 25: Conformity Declaration For Perma Pro
PRO Conformity Declaration for perma PRO EC – Conformity Declaration According to the Machinery Directive 98/37/EC and according to EMV (Electromagnetic Compatibility) – Directive 89/336/EWG. The manufacturer perma-tec GmbH & Co. KG Hammelburger Straße 21 D – 97717 Euerdorf hereby declares that the product as described in the given statement conforms to the regulations appertaining to the directives referred to above, including any amendments thereto which are in force at the time of the declaration. Product description: Automatic lubricator Product name: Lubricator perma PRO Type: perma PRO 250 and perma PRO 500 The following harmonised standards were applied: EN ISO 12100-1:2003 Safety of machinery – basic concepts, general terms of reference as regards design and construction – Section 1: Basic Terminology, Methodology EN ISO 12100- 2:2003 Safety of machinery – basic concepts, general terms of reference as regards... - Page 26 GmbH & Co. KG perma PRO perma-tec GmbH & Co. KG Internet: www.perma-tec.com E-mail: info@perma-tec.com The World of Automatic Lubrication 08/01/01...
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Questions and answers
Getting the E5 error on the lubricator. Not sure what "outlets configuration missing" means? It was working before we changed out the refill cartridge and battery