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Summary of Contents for Lincoln ZPU 08
- Page 1 Operating Instructions Pump ZPU 08 ATEX ZPU 08 810-53711-1 Page 1 / 57 Rev.: 003 31/07/2017...
- Page 2 Operating Instructions Pump ZPU 08 ATEX EU Declaration of conformity (following ATEX directive 2014/34/EU, annex X) The manufacturer SKF Lubrication Systems Germany GmbH, Heinrich-Hertz-Str. 2-8, D - 69190 Walldorf hereby declares at its sole responsibility that machinery Designation: Pump to supply lubricant within a centralized lubrication system...
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Page 3: Table Of Contents
Operating Instructions Pump ZPU 08 ATEX Declaration of conformity Table of contents Guidelines ......................6 Warnings ....................... 6 Illustrations ....................6 Abbreviations ....................7 Manufacturer and Service addresses ............7 Warranty ......................7 Disclaimer ...................... 7 Copyright ....................... 7 Safety information ..................... 8 2.1. - Page 4 Operating Instructions Pump ZPU 08 ATEX 2.28. Operator obligations ................. 22 2.29. Determination of hazards ................. 22 2.30. Explosion protection measures following ATEX ........23 2.31. Provision of necessary information ............23 2.32. Instructions / qualification obligations ............24 2.33.
- Page 5 Operating Instructions Pump ZPU 08 ATEX Technical data of the capacitive sensor ............36 Technical data of the motor ................37 Brief description of the pump ................ 38 Installation and commissioning ..............40 8.1. Filling of the reservoir .................. 40 8.2.
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Page 6: Guidelines
Operating Instructions Pump ZPU 08 ATEX Guidelines As you read these instructions, you will notice a number of depictions and symbols which are to facilitate the navigation and understanding of these instructions. For reasons of better legibility, in these instructions we mainly use the male form for general references. -
Page 7: Abbreviations
Operating Instructions Pump ZPU 08 ATEX Abbreviations The following abbreviations may be used within these instructions. max. maximum Newtonmeter min. minimum incl. including minutes i.e. this means seconds relative humidity etc. and so on approx. approximately poss. possibly Ø diameter e.g. -
Page 8: Safety Information
Operating Instructions Pump ZPU 08 ATEX Safety information Safety information is to be read and observed by any persons entrusted with works on the machine or by those persons who supervise or instruct the before- mentioned group of persons. It is prohibited to commission or operate the machine prior to reading the Instructions. -
Page 9: Foreseeable Misuse
Operating Instructions Pump ZPU 08 ATEX 2.6. Foreseeable misuse Any other use and purpose of the pump than the ones described before are strictly prohibited. It is expressly forbidden to be used: In a different, more critical potentially explosive atmosphere than stated in these Instructions. -
Page 10: Labels On The Pump
Operating Instructions Pump ZPU 08 ATEX 2.10. Labels on the pump Hand injury warning During operation of the pump, never remove the lid and reach into the reservoir. Risk of trapping or shearing off hands and fingers! Behind the protective fitting marked with this symbol there is the lubricant filter. -
Page 11: Other Applicable Documents
Operating Instructions Pump ZPU 08 ATEX 2.11. Other applicable documents In addition to these instructions, the following documents must be observed by the respective target group: Operator's explosion protection document. Operational instructions and release provisions by the operator. -
Page 12: Sources Of Hazard
Operating Instructions Pump ZPU 08 ATEX 2.12. Sources of hazard The pump has been designed, built and tested using state-of-the-art technology. It will have left our company only after having passed stringent safety and reliability tests. Like for all complex machines, also for this pump there may still be involved potential sources of hazard, For example: 2.13. -
Page 13: Existing Residual Risks
Operating Instructions Pump ZPU 08 ATEX 2.17. Existing residual risks Residual risks Remedy Operation in potentially explosive areas Deviating installation position. Maintain installation position (± 5°). Correct Loss of correct low-level signal function. installation position, if necessary. The operator must check thoroughly whether an... - Page 14 Operating Instructions Pump ZPU 08 ATEX Residual risks Remedy Transport lifecycle Tilting or falling of parts during Secure parts against tilting or falling during transport transport, e.g. over inclines. (e.g. using tapes, belts, ropes, etc.). Installation life cycle No people may remain under suspended loads. Keep unauthorized persons away.
- Page 15 Operating Instructions Pump ZPU 08 ATEX Residual risks Remedy Lifecycle Commissioning/ operation/ maintenance Lubricant spraying out due to incorrect Tighten all parts with appropriate tightening torques. screw connection of components or Use suitable hydraulic screw connections and lines lines. for the stated pressures. Check these prior to commissioning for correct connection and damage.
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Page 16: Persons Authorized To Operate The Pump
Operating Instructions Pump ZPU 08 ATEX 2.18. Persons authorized to operate the pump 2.19. Operator A person who is qualified by training and experience to carry out the functions and activities related to normal operation. This includes avoiding possible hazards that may arise during machine operation. -
Page 17: Safety Recommendations To Be Complied With
Operating Instructions Pump ZPU 08 ATEX 2.22. Safety recommendations to be complied with 2.23. General behaviour when handling the pump The pump may be used only in awareness of the potential dangers, in proper technical condition, and according to the information in these instructions. -
Page 18: Explosion Protection
Operating Instructions Pump ZPU 08 ATEX 2.24. Explosion protection Always behave so that fire and explosion hazards are avoided. A written work approval from the operator is required prior to working in potentially explosive areas. There must be no indications that parts of the explosion protection are missing or are not working. - Page 19 Operating Instructions Pump ZPU 08 ATEX All parts of the grounding concept must be correctly available and connected with the superordinate machine. If transport lugs are dismantled after set-up, the threaded bores must be permanently sealed in accordance with the protection class.
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Page 20: Transport / Installation / Maintenance / Repairs / Servicing
Operating Instructions Pump ZPU 08 ATEX 2.25. Transport / installation / maintenance / repairs / servicing All relevant persons (e.g., operating personnel, supervisors) must be informed of the respective activity prior to starting any work. Observe the precautionary operational measures and work instructions. - Page 21 Operating Instructions Pump ZPU 08 ATEX Carry out all works on electrical components using voltage insulated tools only. Fuses must not be bypassed. Always replace fuses by such of the same type. Ensure correct grounding of the electrical system.
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Page 22: Initial Commissioning / Daily Start-Up
Operating Instructions Pump ZPU 08 ATEX 2.26. Initial commissioning / daily start-up Ensure that: All safety devices are completely available and functional. All connections are correctly connected. All parts are correctly installed. All warning labels on the machine are completely available, highly visible and undamaged. -
Page 23: Explosion Protection Measures Following Atex
Operating Instructions Pump ZPU 08 ATEX 2.30. Explosion protection - measures following ATEX Due to a holistic assessment of the workplace, the operator ensures that the working equipment and all installation materials are suitable for operation in potentially explosive areas, and that they are assembled, installed and operated so that they do not give rise to explosions. -
Page 24: Instructions / Qualification Obligations
Operating Instructions Pump ZPU 08 ATEX 2.32. Instruction / qualification obligations The operator clearly determines the responsibility of personnel for operation, installation and repairs. The operator is obliged to instruct all people authorized for use in the correct handling of the machine prior to initial use, in accordance with the respective activity and area of responsibility, based on practical exercises. -
Page 25: Training Courses
Operating Instructions Pump ZPU 08 ATEX 2.36. Training courses In order to provide a maximum of safety and economic viability, SKF carries out detailed training courses. It is recommended that the training courses are attended. Please contact SKF Customer Service for information. -
Page 26: Lubricant
Operating Instructions Pump ZPU 08 ATEX Lubricant Lubricants are used specifically for certain application purposes. In order to fulfil their tasks, lubricants must fulfil various requirements to varying extents. The most important requirements for lubricants are: Reduction of abrasion and wear ... -
Page 27: Specification
Operating Instructions Pump ZPU 08 ATEX 3.3. Specification Lubricants of the following consistencies can in principle be conveyed using SKF centralized lubrication systems. Lubricating greases up to NLGI 2 solids content up to 5 % maximum mineral oils with a viscosity of minimum 40 mm²/s at +40 °C Lubricants must be compatible with the following materials: ... -
Page 28: Technical Data
Operating Instructions Pump ZPU 08 ATEX Technical data 4.1. Ambient temperatures min. max. Part no.: 605-40759-6 -20 °C +50 °C Part no.: 605-40759-7 -20 °C +40 °C Part no.: 605-41759-8 -20 °C +40 °C 4.2. Explosion protection marking Part no.: 605-40759-6 II 2G c IIB T3 Gb Part no.: 605-40759-7... -
Page 29: Reservoir
Operating Instructions Pump ZPU 08 ATEX 4.10. Reservoir 40 XB 40 XL Used with pump Used with pump 605-41759-8 605-46554-7 605-40759-6 810-53711-1 Page 29 / 57 Rev.: 003 31/07/2017... -
Page 30: Space Requirements
Operating Instructions Pump ZPU 08 ATEX 4.11. Space requirements Width Depth Height approx. 530 mm approx. 580 mm approx. 820 mm It is recommended that an additional free space of 100 mm is provided in each direction for maintenance and inspections works. -
Page 31: Electrical Connection
Operating Instructions Pump ZPU 08 ATEX 4.12. Electrical connection Connection must be done in such way that a permanent, safe electrical connection can be maintained (use safe protective conductor connection and dedicated cable ends; avoid protruding wire ends). Make sure that there are no foreign particles, dirt or humidity in the terminal box. -
Page 32: Tightening Torques
Operating Instructions Pump ZPU 08 ATEX 4.14. Tightening torques Component Tightening torques T1 Pressure control valve AF 24 80 ± 8 Nm T2 Lubricant filter: Protective fitting AF 19 80 ± 8 Nm Filter element AF 11 20 ± 2 Nm... -
Page 33: Connections / Outlets
Operating Instructions Pump ZPU 08 ATEX 4.15. Connections / outlets G ¾“ Pressure line G ¾“ Relief line G ¾“ Filling adapter 4.16. Filling possibilities via filling adapter via reservoir lid 4.17. Rotational direction of the pump The rotational direction is always clockwise (CW). -
Page 34: Type Identification Plate
Operating Instructions Pump ZPU 08 ATEX 4.21. Type identification plate The following information is stated on the type identification plate: Product and manufacturer identification MADE IN Model: Type designation of the pump Country of origin GERMANY Part no.: Order number / Part number... -
Page 35: Storage Until The First Use
Operating Instructions Pump ZPU 08 ATEX 4.22. Storage until the first use in the original packaging in dry rooms with little dust without direct sun or UV radiation without aggressive, corrosive substances at the place of storage ... -
Page 36: Technical Data Of The Capacitive Sensor
Operating Instructions Pump ZPU 08 ATEX Technical data of the capacitive sensor Type designation Capacitive sensor (Namur) Part number 664-34621-3 Rated operating distance 5 mm in case of flush installation 7.5 mm in case of non-flush installation Secured switching distance ≤ (0.72 x Sn) mm 1….. -
Page 37: Technical Data Of The Motor
Operating Instructions Pump ZPU 08 ATEX Technical data of the motor Part no. Type of motor ATEX no. Manufacturer 245-13984-6 EDRS80S4 PTB 10 ATEX 3026/01 Rated power 0.55 Code --------- Operating mode Flange Ø 120 Rated frequency Rated speed 1715... -
Page 38: Brief Description Of The Pump
Carry out work on electrical parts only if the atmosphere is not potentially explosive. Electric shock Disconnect the pump from the mains prior to all work on electrical parts. The ZPU 08 pump consists of the following main components: (1) Reservoir with stirring paddle,... - Page 39 Operating Instructions Pump ZPU 08 ATEX Operating principle: Upper end position The gear reduces the motor speed to Start of the piston movement the necessary speed of the pump. downwards The eccentric shaft drives the high- pressure pump elements and the stirring paddle.
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Page 40: Installation And Commissioning
Operating Instructions Pump ZPU 08 ATEX Installation and commissioning 8.1. Filling of the reservoir NOTICE Risk of centralized lubrication system faults When filling ensure that no dirt enters the reservoir. Filling via filling adapter Automatic Filling: The filler pump is started by the low-level indication and stopped by the high-level indication. -
Page 41: Inadvertent Filling With Incorrect Lubricant
Operating Instructions Pump ZPU 08 ATEX 8.2. Inadvertent filling with incorrect lubricant Should incorrect lubricant have been filled, please proceed as follows: Switch off the pump and secure it against being switched on. Remove lubricant. Clean the reservoir, pump housing and, if applicable, the tubing system. -
Page 42: Activation Of The Pump
Operating Instructions Pump ZPU 08 ATEX Electrics Electrical connections carried out correctly. Cable entries sealed correctly. The voltage and frequency of the power network correspond to the information on the type identification plate of the motor. ... -
Page 43: Standard Operation
Operating Instructions Pump ZPU 08 ATEX Standard operation 9.1. Daily start-up Below find the activities to be carried out in case of standard operation. 9.2. Inspections With regard to the actions listed below "Inspections prior to commissioning" the operator has to determine adequate control intervals depending on the respective operating situation of the pump. -
Page 44: Maintenance
Operating Instructions Pump ZPU 08 ATEX Maintenance Regular and appropriate maintenance is a prerequisite to detect and clear faults in time. As individual operating conditions cannot be defined for all applications, the listed terms represent a general advice for undisturbed operation. The terms have to be adapted to the local conditions always. -
Page 45: Maintenance Of Lubricant Filter
Operating Instructions Pump ZPU 08 ATEX 10.2. Maintenance of lubricant filter The lubricant filter should be checked and, if necessary, be cleaned every 100 operating hours. To do so proceed as follows: Switch the pump off. Unscrew protective fitting (9.1) from lubricant filter (AF 19). -
Page 46: Sew Motor Maintenance
Operating Instructions Pump ZPU 08 ATEX 10.4. SEW motor maintenance For further relevant information on maintenance, see original Instructions by the motor manufacturer. Activity Interval Check the airways and Depending on the local degree of contamination, at surfaces the latest, however, every 4 weeks... -
Page 47: Troubleshooting
Operating Instructions Pump ZPU 08 ATEX Troubleshooting Motor of pump does not run Possible cause Visible Remedy Fault in the superior machine/ no pump noise Check power supply lines/ external control unit. external control/ motor circuit Motor circuit breaker has tripped. - Page 48 Operating Instructions Pump ZPU 08 ATEX Rehfuss gear Fault Possible cause Remedy Bearing damage Check oil and oil level, if required, (grinding noise) change bearing. Consult the manufacturer. Constant unusual Consult the manufacturer. running noise Irregular toothing (knocking noise)
- Page 49 Operating Instructions Pump ZPU 08 ATEX SEW motor Fault Possible cause Remedy Feed line interrupted Check and correct connections, if necessary. Blown fuse Replace fuse Motor circuit breaker has Check correct adjustment of motor Motor does not start responded circuit breaker. If necessary, remedy...
- Page 50 Operating Instructions Pump ZPU 08 ATEX SEW motor Fault Possible cause Remedy Overload Measure performance, if necessary, use larger motor or reduce load Insufficient cooling Correct cooling air supply or open cooling air ways, if necessary, retrofit external fan Ambient temperature is too high...
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Page 51: Declarations Of Conformity Of The Purchase Parts
Operating Instructions Pump ZPU 08 ATEX Declarations of conformity of the purchase parts 810-53711-1 Page 51 / 57 Rev.: 003 31/07/2017... - Page 52 Operating Instructions Pump ZPU 08 ATEX 810-53711-1 Page 52 / 57 Rev.: 003 31/07/2017...
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