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GUDEL FlexxPump4 D Operating Manual

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OPERATING MANUAL
Lubrication system
FlexxPump4 D
Project / Order:
Bill of materials:
Serial number:
Year of manufacture:
B1X.xxxxxxxxx-xxxx
10xxxxxx
2021
90072026741260
BETRIEBSANLE

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Summary of Contents for GUDEL FlexxPump4 D

  • Page 1 OPERATING MANUAL BETRIEBSANLE 90072026741260 Lubrication system FlexxPump4 D Project / Order: B1X.xxxxxxxxx-xxxx Bill of materials: 10xxxxxx Serial number: Year of manufacture: 2021...
  • Page 2 © GÜDEL Translation of the original instructions This manual contains standard illustrations that may deviate from the original. In the case of special models, options, or technical changes, the scope of deliv- ery may differ from the descriptions here. Reprinting the instructions, in whole or in part, requires our permission.

  • Page 3: Tab. -1 Revision History

    OPERATING MANUAL Lubrication system FlexxPump4 D Revision history Revision history Version Date Description 04.03.2021 Added: • Transport Ü 2 36 • Input signals external control Ü Chapter 5.5.2, 2 46 • Output signals external control Ü Chapter 5.5.3, 2 53 • Maintenance intervals Ü 2 76 Structure modified: • Actuate Ü Chapter 5.5, 2 44 • Maintenance tasks Ü 2 76 26.11.2020 Basic version Tab. -1...
  • Page 4 Revision history OPERATING MANUAL Lubrication system FlexxPump4 D...
  • Page 5 OPERATING MANUAL Lubrication system FlexxPump4 D Table of contents Table of contents General  11 Further applicable documentation  ....... . .  11 Purpose of the document ...
  • Page 6 Table of contents OPERATING MANUAL Lubrication system FlexxPump4 D Product description  25 Use  .............. 25 3.1.1 Lifetime ...
  • Page 7 5.4.3.1 FlexxPump4 D 3-fold  ........... .
  • Page 8 Table of contents OPERATING MANUAL Lubrication system FlexxPump4 D Initial commissioning  .......... 64 5.6.1 Checking the lubrication...

  • Page 9: Table Of Contents

    OPERATING MANUAL Lubrication system FlexxPump4 D Table of contents Connect hydraulics  .......... 91 Connecting electrical equipment ...
  • Page 10 Table of contents OPERATING MANUAL Lubrication system FlexxPump4 D 10.3 Waste management compliant assemblies  ..... . . 114 10.3.1 Disassembly  ............ 114 10.3.2 Material...
  • Page 11 OPERATING MANUAL Lubrication system FlexxPump4 D General General Read the entire manual before working with the product. The manual con- tains important information for your personal safety. The manual must be read and understood by all persons who work on the product in any of the product life phases.

  • Page 12: Tab. 1-1 Other Applicable Documentation

    General OPERATING MANUAL Lubrication system FlexxPump4 D Document Explanation Target readership Lubrication quantity • Only available in • Sales / project man- calculator English agement • Only available as Mi- • Software engineer crosoft Excel Software modules for Only available as ZIP Software engineer standard control sys- file...

  • Page 13: Tab. 1-2 Explanation Of Symbols/Abbreviations

    OPERATING MANUAL Lubrication system FlexxPump4 D General Explanation of symbols/abbreviations The following symbols and abbreviations are used in this manual: Symbol/Abbrevia- Explanation tion Ü For cross-reference Possibly for cross-ref- Page erence Fig. Designation of graphics Figure Table Designation of tables Table In the tip Information or tip Tab. 1-2...
  • Page 14 General OPERATING MANUAL Lubrication system FlexxPump4 D...
  • Page 15 OPERATING MANUAL Lubrication system FlexxPump4 D Safety Safety Hazard symbols in the manual 2.1.1 Hazard warnings The hazard warnings are defined for the following four types of danger levels: DANGER DANGER DANGER identifies a hazard with high risk that could lead to serious injury or death.

  • Page 16: Tab. 2-1 Explanation Of Warning Symbol

    Safety OPERATING MANUAL Lubrication system FlexxPump4 D 2.1.2 Explanation of warning symbol Hazard warnings for personal injuries contain the symbol of the correspond- ing hazard. Symbol Explanation of symbols Hazards due to general causes Hazards due to environmental pollution Hazards due to dangerous electrical voltage Tab. 2-1 Explanation of warning symbol Product safety...
  • Page 17 OPERATING MANUAL Lubrication system FlexxPump4 D Safety Danger areas The danger area is the area at a product and/or in its surroundings where there is a potential of danger to the life or health of persons, or to the envi- ronment, or damage to property. The operator must secure the danger area (protective fence/sensors).
  • Page 18 Safety OPERATING MANUAL Lubrication system FlexxPump4 D Personnel The generally accepted occupational safety rules must be observed and imple- mented. 2.4.1 Personal safety equipment The operator is responsible for providing specialists with personal safety equipment.

  • Page 19: Fig. 2 -1 Psa (Personal Safety Equipment)

    OPERATING MANUAL Lubrication system FlexxPump4 D Safety Fig. 2-1 PSA (personal safety equipment) Always wear safety helmet Wear fall protection system when work- ing from 2 m height. Always wear protective goggles Always wear safety shoes Wear welding goggles during welding work Wear hearing protection during opera- Always wear protective clothing tion and when working with compressed...
  • Page 20 Safety OPERATING MANUAL Lubrication system FlexxPump4 D 2.4.2 Personnel qualifications DANGER Lack of safety training Incorrect behavior of untrained or insufficiently trained technicians can result in severe or fatal injuries! Before technicians work on safety-related aspects of the product: • Ensure that the technicians are trained with regard to safety •...
  • Page 21 OPERATING MANUAL Lubrication system FlexxPump4 D Safety • the technicians are kept up-to-date regarding best practice • the technicians are informed about technical progress, modifications, and the like. • the contracted cleaning staff only work under the supervision of a mainte- nance technician 2.4.2.2 Fitters...
  • Page 22 Safety OPERATING MANUAL Lubrication system FlexxPump4 D 2.4.2.5 Manufacturer's technicians The manufacturer's technician: • is employed on site at the premises of the manufacturer or representative • has very good mechanical and/or electrical knowledge • has good software knowledge • has maintenance, service and repair experience •...
  • Page 23 OPERATING MANUAL Lubrication system FlexxPump4 D Safety 2.4.2.7 Service technicians The service technician: • was trained by the operating company or the manufacturer • has very good mechanical and/or electrical knowledge • has software knowledge • has service and repair experience •...
  • Page 24 Read the safety data sheets carefully. Follow all the instructions. We recom- mend that you store the safety data sheets for future reference. The safety data sheet for Güdel H1 can be found in the download area of our company Web site http://www.gudel.com...
  • Page 25 OPERATING MANUAL Lubrication system FlexxPump4 D Product description Product description 3.1.1 Lifetime The lifetime of the product is 20,000 operating hours. 3.1.2 Intended use The system is designed exclusively for lubricating Güdel linear guideway and Güdel gear teeth. Be sure the hydraulic system is installed correctly Ü 2 39 Any other or additional use is not considered to be use in the intended man- ner.

  • Page 26: Fig. 3 -1 Type Plate

    The product has a type plate. FlexxPump4 XXXXX Bill of materials: XXXXXXX Serial number: 20XXXXXX Güdel AG Industrie Nord CH-4900 Langenthal www.gudel.com Fig. 3-1 Type plate Serial number Pump type Item number Build year (the first two digits of the se-...

  • Page 27: Fig. 3 -2 Position Of The Type Plate

    OPERATING MANUAL Lubrication system FlexxPump4 D Product description 3.2.2 Position of the type plate The type plate is attached to the right side of the casing. The hydraulic out- puts are indicated by engraved numbers. Fig. 3-2 Position of the type plate Type plate Number of the hydraulic output Technical data...

  • Page 28: Fig. 3 -3 Dimensions And Connections Flexxpump4 D

    Product description OPERATING MANUAL Lubrication system FlexxPump4 D 3.3.1 FlexxPump 3.3.1.1 Dimensions and connections FlexxPump4 D 108.5 110.8 Fig. 3-3 Dimensions and connections FlexxPump4 D Hydraulic output Connection plug M12x1 Connections Hydraulic: • Four connections for lubrication lines with a diameter of 6/3 mm Electric: The four-pole connection size M12x1 transmits the following signals: •...

  • Page 29: Tab. 3-1 Operating Voltage

    OPERATING MANUAL Lubrication system FlexxPump4 D Product description Interfaces The FlexxPump4 D features an integrated microprocessor. It is controlled via a programmable logic controller (PLC). Operating voltage Operating voltage Peak power I Standby current I tandby 24 VDC 300 mA <25 mA Tab. 3-1 Operating voltage 3.3.1.2 Temperature ranges The following temperature ranges and humidity apply:...

  • Page 30: Tab. 3-3 Temperature Ranges: Splitter

    Product description OPERATING MANUAL Lubrication system FlexxPump4 D 3.3.2 Splitter 3.3.2.1 Temperature ranges The following temperature ranges and humidity apply: Product life phase Temperature range Air humidity Transport -10 to +60 °C Operation +10 to +80°C Up to and at 85 %, condensation forma- tion is not permissible Storage...

  • Page 31: Fig. 4 -1 Design Of Flexxpump Lubrication System

    OPERATING MANUAL Lubrication system FlexxPump4 D Design, function Design, function Design The product consists of the following components: (Further information Ü 2 39) Fig. 4-1 Design of FlexxPump lubrication system FlexxPump Y-segment (combines lubricants) Connecting cable Splitter (separates lubricants) Lubrication line...

  • Page 32: Fig. 4 -2 Detailed Design Of Flexxpump4 D

    Design, function OPERATING MANUAL Lubrication system FlexxPump4 D 4.1.1 Detailed design of FlexxPump4 D The product consists of the following components: Fig. 4-2 Detailed design of FlexxPump4 D Covering Casing Lubricant cartridge Connection plug for supply and control system Union ring Hydraulic output...

  • Page 33: Fig. 4 -3 Function: Splitter, 2-Fold

    OPERATING MANUAL Lubrication system FlexxPump4 D Design, function Function 4.2.1 Functional description The lubrication system serves to automatically lubricate Güdel components. The FlexxPump4 feeds the lubricant from the lubricant cartridge into the lu- brication lines. Depending on the design, the lubricant is distributed through splitters, combined through Y-segments, or distributed directly to the lubrica- tion areas.

  • Page 34: Fig. 4 -4 Function: Splitter, 3-Fold

    Design, function OPERATING MANUAL Lubrication system FlexxPump4 D ⅓ lubricant quantity Lubricant quantity ⅓ lubricant quantity ⅓ lubricant quantity Fig. 4-4 Function: Splitter, 3-fold 4.2.4 Y-segment The quantity of the lubricant at the inputs is combined at the output. The Y- segment only works in the direction of the arrow. Lubricant quantity 2x: lubrication quantity Lubricant quantity...
  • Page 35 OPERATING MANUAL Lubrication system FlexxPump4 D Commissioning Commissioning Introduction 5.1.1 Safety Only perform the tasks described in this chapter after you have read and un- derstood the chapter "Safety". Ü 2 15 It concerns your personal safety! DANGER Missing safety and monitoring equipment Missing or changed safety and monitoring equipment could lead to serious or fatal injuries! •...
  • Page 36 Commissioning OPERATING MANUAL Lubrication system FlexxPump4 D DANGER Leaking fluids Oils, greases and other operating consumables may leak during the entire service life of the product. These leaking liquids are harmful to the environ- ment! • Observe the specified maintenance intervals and service intervals •...
  • Page 37 OPERATING MANUAL Lubrication system FlexxPump4 D Commissioning Installing 5.4.1 Prerequisites Dispose of the packaging in accordance with the local waste regulations. Ü 2 113 Checking the deliv- Check the content of the delivery by comparing it with the accompanying documents. Check the product for damage. Report transport damage promptly.

  • Page 38: Fig. 5 -1 Installing The Lubricant Pump

    Commissioning OPERATING MANUAL Lubrication system FlexxPump4 D 5.4.2 Installing the lubricant pump The installation position of the lubrication system is not important. Fig. 5-1 Installing the lubricant pump Installation site Lubricant pump Screw Install the lubricant pump as follows: Mount lubricant pump with two screws M6 L = 35 mm The lubricant pump has been assembled.

  • Page 39: Fig. 5 -2 Design Flexxpump4 D 3-Fold

    • Do not close any hydraulic outputs 5.4.3.1 FlexxPump4 D 3-fold Lubrication system with 3 lubrication points Fig. 5-2 Design FlexxPump4 D 3-fold Lubricating pinion (not included in the Y-segment scope of delivery) Lubricating element (not included in the Lubrication line hose diameter of scope of delivery) 6/3 mm...

  • Page 40: Fig. 5 -3 Design Flexxpump4 D 6-Fold

    OPERATING MANUAL Lubrication system FlexxPump4 D 5.4.3.2 FlexxPump4 D 6-fold Lubrication system with 6 lubrication points Fig. 5-3 Design FlexxPump4 D 6-fold Lubricating pinion (not included in the 2. Axis (not included in the scope of de- scope of delivery) livery) Lubricating element (not included in the...

  • Page 41: Fig. 5 -4 Design Flexxpump4 D 9-Fold

    Commissioning 5.4.3.3 FlexxPump4 D 9-fold Lubrication system with 9 lubrication points Fig. 5-4 Design FlexxPump4 D 9-fold Lubricating pinion (not included in the 3. Axis (not included in the scope of de- scope of delivery) livery) Lubricating element (not included in the 2.

  • Page 42: Fig. 5 -5 Design Flexxpump4 D 10-Fold

    OPERATING MANUAL Lubrication system FlexxPump4 D 5.4.3.4 FlexxPump4 D 10-fold Lubrication system with 10 lubrication points Fig. 5-5 Design FlexxPump4 D 10-fold Lubricating pinion (not included in the 2. Axis (not included in the scope of de- scope of delivery) livery) Lubricating element (not included in the 2.

  • Page 43: Connecting Electrical

    OPERATING MANUAL Lubrication system FlexxPump4 D Commissioning 5.4.4 Connecting electrical equipment DANGER Faulty cabling The available mains voltage (supply voltage) has to match the specifications on the rating plate. A faultily connected product can cause material damage, or serious or even fatal injuries. •...

  • Page 44: Tab. 5-1 Connector Pin Assignment

    D424A / 404DLS" provides detailed, non-binding recommendations from Güdel for integration into the overall system. The document can be found in the download area of our company website http://www.gudel.com. Güdel provides software modules for the standard control systems without obligation. The software modules can be found in the download area of our company website http://www.gudel.com...

  • Page 45: Fig. 5 -7 Flow Diagram Programming Software

    OPERATING MANUAL Lubrication system FlexxPump4 D Commissioning 5.5.1 Suggested solution: Programming software Start Pump fault? / Set warning message** Cartridge empty? Indicator reached? / Manual start? Indicator (distance; cycle number; Pump ready?* time) started? Start lubrication cycle Set flag for machine stop Successful? (no Set warning message** timeout)

  • Page 46: Tab. 5-2 Input Signals And External Control System

    Commissioning OPERATING MANUAL Lubrication system FlexxPump4 D 5.5.2 Input signals and external control system Signal length Designation Function [s] (PIN 2) 8 high Signal 8 seconds Lubricating 12 high Signal 12 seconds Filling lubrication lines / Venting FlexxPump 14 high Signal 14 seconds Reset the error Tab. 5-2 Input signals and external control system...

  • Page 47: Fig. 5 -8 Switching Time Diagram: Lubrication (Normal Case)

    OPERATING MANUAL Lubrication system FlexxPump4 D Commissioning 5.5.2.1 Lubrication The following signal on PIN 2 causes the output of 0.16 cm lubricant at each of the four hydraulic outputs: Accuracy of the impulses (High) on PIN 2: +/- 0.1 s! Input signal PIN 2 +24 V (High) min.
  • Page 48 Commissioning OPERATING MANUAL Lubrication system FlexxPump4 D...

  • Page 49: Fig. 5 -9 Switching Time Diagram: Filling Lubrication Lines / Venting Flexxpump4 D

    OPERATING MANUAL Lubrication system FlexxPump4 D Commissioning 5.5.2.2 Filling lubrication lines / Venting FlexxPump4 D The following signal on PIN 2 causes the output of 40 x 0.16 cm lubricant at each of the four hydraulic outputs: Accuracy of the impulses (High) on PIN 2: +/- 0.1 s! Input signal PIN 2 12 s +24 V...
  • Page 50 Commissioning OPERATING MANUAL Lubrication system FlexxPump4 D...

  • Page 51: Fig. 5 -10 Switching Time Diagram: Reset The Error

    OPERATING MANUAL Lubrication system FlexxPump4 D Commissioning 5.5.2.3 Reset the error The following signal on PIN 2 causes the reset of general errors: Input signal PIN 1 14 s +24 V (High) + 0 V (Low) Output signal PIN 4 +24 V (High) + 0 V >3 s...
  • Page 52 Commissioning OPERATING MANUAL Lubrication system FlexxPump4 D...

  • Page 53: Tab. 5-3 Output Signals And External Control System

    OPERATING MANUAL Lubrication system FlexxPump4 D Commissioning 5.5.3 Output signals and external control system Function Output signal (PIN 4) switched off low, permanent switched on high, permanent Input signal receiving high, permanent Dispensing process low, 10…18 s Empty status, lubricant cartridge 0.5 Hz rectangular signal, permanent General error low, permanent Tab. 5-3...
  • Page 54 Commissioning OPERATING MANUAL Lubrication system FlexxPump4 D...

  • Page 55: Fig. 5 -11 Switching Time Diagram: Switching On And Off

    OPERATING MANUAL Lubrication system FlexxPump4 D Commissioning 5.5.3.1 Switching on and off Input signal PIN 1 +24 V (High) + 0 V (Low) Output signal PIN 4 +24 V (High) + 0 V (Low) Hydraulic output Fig. 5-11 Switching time diagram: Switching on and off The lubrication system is switched on as long as a constant voltage of +24 V DC is applied at PIN 1.
  • Page 56 Commissioning OPERATING MANUAL Lubrication system FlexxPump4 D...

  • Page 57: Fig. 5 -12 Switching Time Diagram: Empty

    OPERATING MANUAL Lubrication system FlexxPump4 D Commissioning 5.5.3.2 Empty If the lubricant cartridge is empty, the lubrication system issues the following signal on PIN 4: Input signal PIN 2 +24 V (High) + 0 V (Low) Output signal PIN 4 0.5 Hz ( 1 s High / 1 s Low) +24 V (High) + 0 V...

  • Page 58: Tab. 5-4 Malfunctions / Troubleshooting

    Commissioning OPERATING MANUAL Lubrication system FlexxPump4 D Malfunction Cause Measure Lubrication system does not lubricate • Lubricant cartridge missing • Insert new lubricant cartridge (Pump function has been stopped.) • Vent the lubrication system • Lubricant cartridge empty • Air in the lubrication system The lubrication system continues running without change Tab. 5-4 Malfunctions / Troubleshooting...

  • Page 59: Fig. 5 -13 Switching Time Diagram: General Error

    OPERATING MANUAL Lubrication system FlexxPump4 D Commissioning 5.5.3.3 General error The following causes may lead to a general error (the list is not exhaustive): • Overpressure in the lubrication line • the voltage supply does nit lie within the specified parameters (undervoltage/overvoltage) •...

  • Page 60: Tab. 5-5 Malfunctions / Troubleshooting

    Commissioning OPERATING MANUAL Lubrication system FlexxPump4 D Malfunction Cause Measure Lubrication system does not lubricate Overpressure • Check lubrication lines (Pump function has been stopped.) • Rectify causes (defective lubrication line, hardened lubricant, etc.) • Reset the error Ü Chapter 5.5.2.3, 2 51 Lubrication system does not lubricate Undervoltage or overvoltage •...
  • Page 61 OPERATING MANUAL Lubrication system FlexxPump4 D Commissioning 5.5.4 Lubrication recommendation 5.5.4.1 General information NOTE Lubricating film missing A missing lubricating film on rails and racks leads to damage to the product. This results in operational failure. • Ensure that there is always a lubricating film on rails and racks during oper- ation •...

  • Page 62: System

    Commissioning OPERATING MANUAL Lubrication system FlexxPump4 D 5.5.4.2 Basics Average lubricant The following lubricant quantities should be dispensed at least per lubrication requirement at a point. These are empirical values from Güdel. These values can be met only lubrication point approximatively due to the number of outputs of the lubricant pump and the installed splitters.

  • Page 63: Tab. 5-8 Calculation Formulas: Emptying Time Of The Lubricant Cartridge (P1)

    Calculation formulas: Emptying time of the lubricant cartridge (P1) The lubrication quantity calculator will help you determine the corresponding settings and lubrication quantities for your application. The lubrication quan- tity calculator can be found in the download area of our company website http://www.gudel.com...
  • Page 64 Commissioning OPERATING MANUAL Lubrication system FlexxPump4 D Initial commissioning...
  • Page 65 OPERATING MANUAL Lubrication system FlexxPump4 D Commissioning 5.6.1 Checking the lubrication system Mount all lubrication lines on the hydraulic outputs of Start the lubricant pump Start the lubricant pump's lubrication cycle Clean the rails and racks Start lubrication point check Lubricate rails and racks with lubricating spray (material number 10406825) Fill lubrication line with Is the lubrication line...
  • Page 66 Commissioning OPERATING MANUAL Lubrication system FlexxPump4 D ü û VIII 404 DLS 402 B ü ü û û...

  • Page 67: Tab. 5-9 Lubricant, Cleaning Agents: Pre-Lubricating Rails And Racks

    OPERATING MANUAL Lubrication system FlexxPump4 D Commissioning 404 DLS 402 B ü ü û û Lubrication ex works Specifications Lubricant quantity Elkalub FLC 8 H1 Cannot be determined Running surfaces of the roller and pinion need to be covered completely by a lubricating film Cleaning agents mild universal cleaner free from aromatic compounds (e.g.
  • Page 68 Commissioning OPERATING MANUAL Lubrication system FlexxPump4 D...
  • Page 69 OPERATING MANUAL Lubrication system FlexxPump4 D Commissioning Check the connections of the hydraulic system before starting up the prod- uct.
  • Page 70 Operation OPERATING MANUAL Lubrication system FlexxPump4 D Operation General Only operate the product after observing the installation instructions. For information on operating the product, refer to the appropriate chapter of the documentation for the complete system. Personnel qualifications Only appropriately trained and authorized technicians are allowed to work on the product.

  • Page 71: Maintenance

    OPERATING MANUAL Lubrication system FlexxPump4 D Maintenance Maintenance Introduction Maintenance The listed tasks have to be carried out at the prescribed time intervals. If they tasks are not carried out at the specified intervals or improperly, all warranty is voided. Observing these obligations is a significant condition so that the prod- uct performing without malfunction as well as its long service life.
  • Page 72 Maintenance OPERATING MANUAL Lubrication system FlexxPump4 D 7.1.1 Safety Only perform the tasks described in this chapter after you have read and un- derstood the chapter "Safety". Ü 2 15 It concerns your personal safety! DANGER Hazardous voltage The product contains components that are energized with hazardous volt- ages.

  • Page 73: Tab. 7-1 Table Of Cleaning Agents

    OPERATING MANUAL Lubrication system FlexxPump4 D Maintenance Consumables and auxiliary agents 7.2.1 Cleaning agents Use a soft rag or cloth for cleaning tasks. Only use permissible cleaning agents. 7.2.1.1 Table of cleaning agents Cleaning agents Location of application Lubrication system: Lubrication pump, lu- mild universal cleaner free brication lines, other components from aromatic compounds...

  • Page 74: Fig. 7 -1 Lubrication System Flexxpump

    Maintenance OPERATING MANUAL Lubrication system FlexxPump4 D 7.2.2.1 Lubrication Standard The following lubricants are intended for use in the lubrication system: Fig. 7-1 Lubrication system FlexxPump Lubrication ex Specifica- Lubri- Location of Cate- works tions cant application gory quantity Güdel H1 NSF Cannot be de- Lubrication sys- no.

  • Page 75: Fig. 7 -3 Lubrication System Flexxpump

    OPERATING MANUAL Lubrication system FlexxPump4 D Maintenance Temperature range 0°C to +5°C The following lubricants are intended for use in the lubrication system at a temperature range 0°C to +5°C: Fig. 7-3 Lubrication system FlexxPump Lubrication ex Specifica- Lubricant Location of Cate- works tions quantity...

  • Page 76: Tab. 7-6 Lubricant Table

    Maintenance OPERATING MANUAL Lubrication system FlexxPump4 D 7.2.2.2 Lubricant table Lubrication Specifica- Lubricant Location of ap- Cate- ex works tions quantity plication gory Lubrication system Elkalub FLC 8 Cannot be FlexxPump: Pre-lu- determined bricating rails and racks Güdel H1 NSF Cannot be Lubrication system no.

  • Page 77: Tab. 7-7 Conversion Table: Operating Hours At The Respective Duty Cycle

    OPERATING MANUAL Lubrication system FlexxPump4 D Maintenance Duty cycle The maintenance intervals refer to the effective operating hours of the prod- uct at a duty cycle (ED) of 100%. The duty cycle always refers to the entire process. This means that the duty cycle of specific axes cannot be considered individually.

  • Page 78: Tab. 7-8 Maintenance Intervals In Shift Operation (5 Days A Week)

    Maintenance OPERATING MANUAL Lubrication system FlexxPump4 D Exclusion of gaskets and bearings The maintenance interval specifications apply without gaskets and bearing. Gaskets are subject to special wear and are not considered. In the case of gearboxes, the bearings are also excluded. The definition is based on 5/7 working days per week.
  • Page 79 OPERATING MANUAL Lubrication system FlexxPump4 D Maintenance 7.3.2 Maintenance tasks after 2,200 hours 7.3.2.1 Replacing lubricant cartridge Replace the lubricant cartridge if the malfunction message E1 (Empty) appears. DANGER Residual amounts in empty lubricant cartridges Empty lubricant cartridges contain lubricant residues. Oils and greases are harmful to the environment! •...

  • Page 80: Fig. 7 -5 Replace Lubricant Cartridge

    Maintenance OPERATING MANUAL Lubrication system FlexxPump4 D Fig. 7-5 Replace lubricant cartridge Covering Union ring Lubricant cartridge Casing Cover Lubrication ex works Specifications Lubricant quantity Ü Chapter 7.2.2.1, 2 74 Ü Chapter 7.2.2.1, 400 ml 2 74 Tab. 7-10 Lubricant: Lubrication system FlexxPump...
  • Page 81 OPERATING MANUAL Lubrication system FlexxPump4 D Maintenance Replace the lubricant cartridge as follows: Prerequisite: The lubrication system is switched off Turn the cover by the union ring in the direction of the arrow and re- move it Turn the empty lubricant cartridge in the direction of the arrow and re- move it Turn the cover lid of the new lubricant cartridge in the direction of the arrow and remove it...
  • Page 82 Maintenance OPERATING MANUAL Lubrication system FlexxPump4 D...
  • Page 83 OPERATING MANUAL Lubrication system FlexxPump4 D Maintenance 7.3.2.2 Checking the lubrication system Mount all lubrication lines on the hydraulic outputs of Start the lubricant pump Start the lubricant pump's lubrication cycle Clean the rails and racks Start lubrication point check Lubricate rails and racks with lubricating spray (material number 10406825) Fill lubrication line with Is the lubrication line...
  • Page 84 Maintenance OPERATING MANUAL Lubrication system FlexxPump4 D ü û VIII 404 DLS 402 B ü ü û û...

  • Page 85: Tab. 7-11 Lubricant, Cleaning Agents: Pre-Lubricating Rails And Racks

    OPERATING MANUAL Lubrication system FlexxPump4 D Maintenance 404 DLS 402 B ü ü û û Lubrication ex works Specifications Lubricant quantity Elkalub FLC 8 H1 Cannot be determined Running surfaces of the roller and pinion need to be covered completely by a lubricating film Cleaning agents mild universal cleaner free from aromatic compounds (e.g.
  • Page 86 Maintenance OPERATING MANUAL Lubrication system FlexxPump4 D...

  • Page 87: Fig. 7 -6 Cleaning And Checking Lubrication System

    OPERATING MANUAL Lubrication system FlexxPump4 D Maintenance 7.3.3 Maintenance tasks after 10,000 hours 7.3.3.1 Cleaning and checking lubrication system Fig. 7-6 Cleaning and checking lubrication system Cleaning agents mild universal cleaner free from aromatic compounds (e.g. Motorex OPAL 5000) Tab. 7-12 Cleaning agents: Lubrication system: Lubrication pump, lubrication lines, other components Check the lubrication system according to the following table.

  • Page 88: Tab. 7-13 Inspection Table

    Maintenance OPERATING MANUAL Lubrication system FlexxPump4 D Inspection Description Measures point Lubrication lines Check lubrication lines Remove kinks and air pock- for kinks and air pock- ets immediately ü û Function Check function Replace defective compo- nents immediately Tab. 7-13 Inspection table NOTE Lubricating film missing A missing lubricating film on rails and racks leads to damage to the product.
  • Page 89 OPERATING MANUAL Lubrication system FlexxPump4 D Maintenance 7.3.4 Maintenance tasks after 20,000 hours 7.3.4.1 Replacing the lubricant pump Removing the lubricant pump Remove the lubricant pump as follows: Switch off the system and secure it with a padlock against being switched on again Remove connecting cable Disconnect the lubrication lines from the hydraulic outputs...

  • Page 90: Fig. 7 -7 Installing The Lubricant Pump

    Maintenance OPERATING MANUAL Lubrication system FlexxPump4 D Installing the lubricant pump The installation position of the lubrication system is not important. Fig. 7-7 Installing the lubricant pump Installation site Lubricant pump Screw Install the lubricant pump as follows: Mount lubricant pump with two screws M6 L = 35 mm The lubricant pump has been assembled.

  • Page 91: Connect Hydraulics

    • Do not close any hydraulic outputs FlexxPump4 D 3- Lubrication system with 3 lubrication points fold Fig. 7-8 Design FlexxPump4 D 3-fold Lubricating pinion (not included in the Y-segment scope of delivery) Lubricating element (not included in the Lubrication line hose diameter of scope of delivery) 6/3 mm...

  • Page 92: Fig. 7 -9 Design Flexxpump4 D 6-Fold

    OPERATING MANUAL Lubrication system FlexxPump4 D FlexxPump4 D 6- Lubrication system with 6 lubrication points fold Fig. 7-9 Design FlexxPump4 D 6-fold Lubricating pinion (not included in the 2. Axis (not included in the scope of de- scope of delivery) livery) Lubricating element (not included in the...

  • Page 93: Fig. 7 -10 Design Flexxpump4 D 9-Fold

    Maintenance FlexxPump4 D 9- Lubrication system with 9 lubrication points fold Fig. 7-10 Design FlexxPump4 D 9-fold Lubricating pinion (not included in the 3. Axis (not included in the scope of de- scope of delivery) livery) Lubricating element (not included in the 2.

  • Page 94: Fig. 7 -11 Design Flexxpump4 D 10-Fold

    OPERATING MANUAL Lubrication system FlexxPump4 D FlexxPump4 D 10- Lubrication system with 10 lubrication points fold Fig. 7-11 Design FlexxPump4 D 10-fold Lubricating pinion (not included in the 2. Axis (not included in the scope of de- scope of delivery) livery) Lubricating element (not included in the 2.

  • Page 95: Fig. 7 -12 Connecting

    OPERATING MANUAL Lubrication system FlexxPump4 D Maintenance Connecting electrical equipment DANGER Faulty cabling The available mains voltage (supply voltage) has to match the specifications on the rating plate. A faultily connected product can cause material damage, or serious or even fatal injuries. •...

  • Page 96: Tab. 7-14 Connector Pin Assignment

    Maintenance OPERATING MANUAL Lubrication system FlexxPump4 D Assignment Color Input voltage 24VDC brown Input signal of the CLS white Ground (GND), 0V blue Output signal to the CLS black Tab. 7-14 Connector pin assignment Connect the product as follows: Prerequisite: The hydraulics is connected Connect the PLC connecting cable to the connection plug The product is connected...
  • Page 97 OPERATING MANUAL Lubrication system FlexxPump4 D Maintenance Checking the lubrication system Mount all lubrication lines on the hydraulic outputs of Start the lubricant pump Start the lubricant pump's lubrication cycle Clean the rails and racks Start lubrication point check Lubricate rails and racks with lubricating spray (material number 10406825) Is the lubrication line Fill lubrication line with...
  • Page 98 Maintenance OPERATING MANUAL Lubrication system FlexxPump4 D ü û VIII 404 DLS 402 B ü ü û û...

  • Page 99: Tab. 7-15 Lubricant, Cleaning Agents: Pre-Lubricating Rails And Racks

    OPERATING MANUAL Lubrication system FlexxPump4 D Maintenance 404 DLS 402 B ü ü û û Lubrication ex works Specifications Lubricant quantity Elkalub FLC 8 H1 Cannot be determined Running surfaces of the roller and pinion need to be covered completely by a lubricating film Cleaning agents mild universal cleaner free from aromatic compounds (e.g.
  • Page 100 Maintenance OPERATING MANUAL Lubrication system FlexxPump4 D...

  • Page 101: Tab. 7-16 Maintenance Table

    OPERATING MANUAL Lubrication system FlexxPump4 D Maintenance Maintenance table Maintenance work Maintenance cycle [h] Duration [min] Target group Lubricant Further information Cleaning agents Maintenance technicians Replacing lubricant car- The manufacturer's technicians Güdel H1 NSF no. 146621Rivolta  Ü Chapter 7.3.2.1, 2 79 tridge F.L.500Rivolta F.L.125 Service technicians 2000 Elkalub FLC 8 H1;...
  • Page 102 Maintenance OPERATING MANUAL Lubrication system FlexxPump4 D...

  • Page 103: Fig. 7 -13 Identification Number Of The Instructions

    FlexxPump4 D Maintenance Feedback on the instructions Your feedback helps us to keep improving these instructions. Thank you! mailto: docufeedback@ch.gudel.com Please provide the following information with your feedback: • Identification number of the instructions • Product, type • Project number, order number Fig. 9-7...

  • Page 104: Introduction

    Repairs OPERATING MANUAL Lubrication system FlexxPump4 D Repairs Introduction Work sequences Perform the work sequences in the order described. Perform the described tasks at the specified times. This ensures a long service life for your product. Original spare Only use original spare parts. Ü 2 119 parts Tightening torques Unless otherwise indicated, adhere to the tightening torques of Güdel.

  • Page 105: Personnel Qualifications

    OPERATING MANUAL Lubrication system FlexxPump4 D Repairs DANGER Leaking fluids Oils, greases and other operating consumables may leak during the entire service life of the product. These leaking liquids are harmful to the environ- ment! • Observe the specified maintenance intervals and service intervals •...

  • Page 106: Troubleshooting

    Repairs OPERATING MANUAL Lubrication system FlexxPump4 D Malfunctions / Troubleshooting Malfunction Cause Measure Lubrication system Overpressure • Check lubrication lines does not lubricate • Rectify causes (defective (Pump function has lubrication line, hardened been stopped.) lubricant, etc.) • Reset the error Ü Chapter 5.5.2.3, 2 51 Lubrication system Undervoltage or...

  • Page 107: Decommissioning, Storage

    OPERATING MANUAL Lubrication system FlexxPump4 D Decommissioning, storage Decommissioning, storage Introduction Only perform the tasks described in this chapter after you have read and un- derstood the chapter "Safety". Ü 2 15 It concerns your personal safety! 9.1.1 Personnel qualifications Only appropriately trained and authorized technicians are allowed to work on the product.

  • Page 108: Decommissioning

    Decommissioning, storage OPERATING MANUAL Lubrication system FlexxPump4 D Temperature The ambient temperature must remain between -10 and +40 °C. Make sure that the product is not subjected to great temperature fluctuations. Air humidity The air humidity must be below 75%. Decommissioning 9.3.1 Shutdown Do not empty the lubrication lines and the gearbox when shutting down the...

  • Page 109: Recommissioning

    OPERATING MANUAL Lubrication system FlexxPump4 D Decommissioning, storage Recommissioning For recommissioning, follow the steps described for commissioning. After cleaning work on the product or a downtime of one to four weeks, carry out the following jobs: • Check the lubrication system Ü 2 87 •...

  • Page 110: Cleaning The Rails And Racks

    Decommissioning, storage OPERATING MANUAL Lubrication system FlexxPump4 D 9.4.1.1 Cleaning the rails and racks DANGER Moving the axis The work requires moving the axis. This can lead to severe or fatal injuries! • Ensure that no persons are in the danger area while the axis is moving CAUTION Risk of injury There is a risk of cuts and crushing in the area of the gearbox, pinion, and...

  • Page 111: Pre-Lubricating Rails And Racks

    OPERATING MANUAL Lubrication system FlexxPump4 D Decommissioning, storage 9.4.1.2 Pre-lubricating rails and racks ü û Fig. 9-2 Pre-lubricating rails and racks Lubrication ex works Specifications Lubricant quan- tity Ü Chapter 7.2.2.1, 2 74 Ü Chapter 7.2.2.1, 2 74 Tab. 9-2 Lubricant: Rails, racks, and pinions Pre-lubricate the rails and racks as follows: Prerequisite: The rails and racks have been cleaned.
  • Page 112 Decommissioning, storage OPERATING MANUAL Lubrication system FlexxPump4 D ü û • Check lubrication system according to separate documentation on lubrica- tion system If the machine downtime is longer than one year, carry out the following tasks: • Rinse the lubrication lines with fresh lubricant •...

  • Page 113: Disposal

    OPERATING MANUAL Lubrication system FlexxPump4 D Disposal Disposal 10.1 Introduction Observe the following during disposal: • Adhere to the country-specific regulations • Separate the material groups • Dispose of the materials in an environmentally friendly way • Recycle waste if possible 10.1.1 Safety Only perform the tasks described in this chapter after you have read and un-...

  • Page 114: Waste Management Compliant

    Disposal OPERATING MANUAL Lubrication system FlexxPump4 D 10.2 Disposal Your product consists of the following items: • Packaging • Contaminated materials / auxiliary agents (oil paper) • Wood • Plastic (film) • Consumable • Lubricants (oils / greases) • Batteries • Base unit •...
  • Page 115 OPERATING MANUAL Lubrication system FlexxPump4 D Disposal DANGER Leaking fluids Oils, greases and other operating consumables may leak during the entire service life of the product. These leaking liquids are harmful to the environ- ment! • Observe the specified maintenance intervals and service intervals •...

  • Page 116: Material Groups

    Disposal OPERATING MANUAL Lubrication system FlexxPump4 D 10.3.2 Material groups Dispose of the material groups in accordance with the following table: Material Disposal method Contaminated materials / auxiliary Hazardous waste agents Wood Municipal waste Plastic Collecting point or municipal waste Lubricant Collecting point disposal in accor- dance with the safety data sheets Ü 2 24...

  • Page 117: Accessories

    OPERATING MANUAL Lubrication system FlexxPump4 D Accessories Accessories 11.1 PLC connecting cable The following M12 connecting cables are permitted for the product: Material number Designation Round plug connector M12 4-pin prefitted LED 0200513 Length 1 m 0152900 Length 2 m 0200515 Length 5 m 0200516 Length 10 m 0200517...
  • Page 118 Accessories OPERATING MANUAL Lubrication system FlexxPump4 D...

  • Page 119: Spare Parts Supply

    OPERATING MANUAL Lubrication system FlexxPump4 D Spare parts supply Spare parts supply...
  • Page 120 Spare parts supply OPERATING MANUAL Lubrication system FlexxPump4 D...

  • Page 121: Service Departments

    • Drawing number (if applicable) Regular inquiries If you have questions relating to service, please use the service form at www.gudel.com or contact the responsible service department: For all other countries not included in the following list, please contact the service department in Switzerland.

  • Page 122: Tab. 12-1 Service Departments Americas

    OPERATING MANUAL Lubrication system FlexxPump4 D Americas Country Relevant service department Phone E-mail Brazil Güdel Lineartec Comércio de Automção Ltda. +55 11 99590 8223 info@br.gudel.com Rua Américo Brasiliense n° 2170, cj. 506 Chácara Santo Antonio CEP 04715-005 São Paulo Brazil Argentina Güdel TSC S.A. de C.V. +52 81 8374 2500 107 service@mx.gudel.com Gustavo M.

  • Page 123: Tab. 12-2 Service Departments In Asia

    OPERATING MANUAL Lubrication system FlexxPump4 D Spare parts supply Country Relevant service department Phone E-mail Korea Güdel Lineartec Inc. +82 32 858 05 41 gkr.service@gudel.co.kr 11-22 Songdo-dong Yeonsu-Ku Post no. 406-840 Incheon City South Korea Taiwan, China Güdel Lineartec Co. Ltd. +88 635 97 8808 info@tw.gudel.com No. 99, An-Chai 8th St. Hsin-Chu Industrial...
  • Page 124 Spare parts supply OPERATING MANUAL Lubrication system FlexxPump4 D Country Relevant service department Phone E-mail Bosnia and Herzegovina Güdel GmbH +43 7226 20690 0 service@at.gudel.com Schöneringer Strasse 48 Croatia 4073 Wilhering Austria Austria Romania Serbia Slovenia Hungary Slovakia Güdel a.s. +420 602 309 593 info@cz.gudel.com Holandská 4...

  • Page 125: Tab. 12-3 Service Departments In Europe

    20060 Bussero (Mi) Italy Belgium Güdel Benelux +31 541 66 22 50 info@nl.gudel.com Eertmansweg 30 Luxembourg 7595 PA Weerselo The Netherlands The Netherlands Estonia Gudel Sp. z o.o. +48 33 819 01 25 serwis@pl.gudel.com ul. Legionów 26/28 Latvia 43-300 Bielsko-Biała Poland Lithuania Poland Ukraine Russia Gudel Russia +7 848 273 5544 info@ru.gudel.com...

  • Page 126: Tab. 12-4 Service Departments For All Other Countries

    All other countries Country Relevant service department Phone E-mail All other countries Güdel AG +41 62 916 91 70 service@ch.gudel.com Gaswerkstrasse 26 Industrie Nord 4900 Langenthal Switzerland Tab. 12-4 Service departments for all other countries Inquiries outside of business hours If you have service inquiries outside of business hours, please contact the following service departments: Europe Güdel AG...

  • Page 127: Explanations Regarding The Spare Parts List

    Güdel AG Insustrie Nord CH-4900 Langnethal phone +41 62 916 91 91 +41 62 916 95 29 14.07.2008 / Page 1 of 1 info@ch.gudel.com VS0035 2-Amod ZP-4 M MO mec 3.10 10947-001A t i s y t i V000134...

  • Page 128: Torque Tables

    Torque tables OPERATING MANUAL Lubrication system FlexxPump4 D Torque tables 13.1 Tightening torques for screws NOTE Vibrations Screws without screw lock can come loose. • Secure screw connections on moving parts with Loctite medium strength 243. • Apply the adhesive on the nut thread, not on the screw!

  • Page 129: Zinc Plated Screws

    OPERATING MANUAL Lubrication system FlexxPump4 D Torque tables 13.1.1 Zinc plated screws Unless otherwise specified, the following tightening torques apply for zinc- plated screws lubricated with Molykote (MoS2) grease or secured with Loc- tite 243: Thread size Tightening torque [Nm] 10.9 12.9 1.58 13.2...
  • Page 130 Torque tables OPERATING MANUAL Lubrication system FlexxPump4 D...

  • Page 131: Illustrations

    Type plate ..................26 Fig. 3 -2 Position of the type plate ............. 27 Fig. 3 -3 Dimensions and connections FlexxPump4 D ......28 Fig. 4 -1 Design of FlexxPump lubrication system ........31 Fig. 4 -2 Detailed design of FlexxPump4 D ..........32 Fig.
  • Page 132 Illustrations OPERATING MANUAL Lubrication system FlexxPump4 D Fig. 7 -10 Design FlexxPump4 D 9-fold ............93 Fig. 7 -11 Design FlexxPump4 D 10-fold ............. 94 Fig. 7 -12 Connecting ..................95 Fig. 7 -13 Identification number of the instructions ......... 103 Fig.
  • Page 133 OPERATING MANUAL Lubrication system FlexxPump4 D List of tables List of tables Tab. -1 Revision history................Tab. 1-1 Other applicable documentation ..........11 Tab. 1-2 Explanation of symbols/abbreviations ......... 13 Tab. 2-1 Explanation of warning symbol............. 16 Tab. 3-1 Operating voltage ................29 Tab.
  • Page 134 List of tables OPERATING MANUAL Lubrication system FlexxPump4 D Tab. 7-13 Inspection table ................87 Tab. 7-14 Connector pin assignment............. 96 Tab. 7-15 Lubricant, Cleaning agents: Pre-lubricating rails and racks ..97 Tab. 7-16 Maintenance table................101 Tab. 8-1 Malfunctions / Troubleshooting............ 106 Tab.
  • Page 135 OPERATING MANUAL Lubrication system FlexxPump4 D Index Index Decommissioning ......107 Accuracy Splitter ........30 Dimensions FlexxPump4 D ......28 Air humidity ....29, 30, 108 Disassembling ........ 114 Discharge BOM ..........127 Lubricant ........47 Disposal .......... 113 Disposal facilities ......116 Calculate Downtime ......
  • Page 136 Index OPERATING MANUAL Lubrication system FlexxPump4 D Feedback ........103 Identification ........108 Feedback on the instructions ..103 Initial commissioning ...... 64 Filling Input signal Lubrication lines ......49 External control system ..46 FlexxPump Installing Software modules ....44 Lubricant pump ....
  • Page 137 OPERATING MANUAL Lubrication system FlexxPump4 D Index Maintenance tasks ......71 Lubricant After 11,250 hours ....87 Discharge ........47 After 2,250 hours ...... 79 Shelf life ........30 After 22,500 hours ....89 Lubricant cartridge Malfunctions ........106 Empty .......... 57 Emptying time P1 ......
  • Page 138 Index OPERATING MANUAL Lubrication system FlexxPump4 D Personnel qualifications ....36 Rack Cleaning ........110 Connecting cable ....117 Pre-lubricating ......111 Power Off Rail Lubrication system ....55 Cleaning ........110 Pre-lubricating ......111 Power On Lubrication system ....55 Removing Lubricant pump ......
  • Page 139 OPERATING MANUAL Lubrication system FlexxPump4 D Index Safety data sheet ......24 Technical data ........ 27 Safety equipment ......17 Temperature ........ 108 Screw Temperature range ....29, 30 Tightening torque ....128 Tightening torque ....71, 104 Service departments ....121 Screw ........
  • Page 140 Index OPERATING MANUAL Lubrication system FlexxPump4 D...
  • Page 141 OPERATING MANUAL Lubrication system FlexxPump4 D Appendix Appendix The appendix of this operating manual contains the following documents: • Layout • Spare parts lists • Declaration of conformity for TriboServ...
  • Page 142 Appendix OPERATING MANUAL Lubrication system FlexxPump4 D...
  • Page 143 OPERATING MANUAL Lubrication system FlexxPump4 D Appendix Layout...
  • Page 144 Appendix OPERATING MANUAL Lubrication system FlexxPump4 D...
  • Page 145 OPERATING MANUAL Lubrication system FlexxPump4 D Appendix Spare parts lists...
  • Page 146 Appendix OPERATING MANUAL Lubrication system FlexxPump4 D...
  • Page 147 OPERATING MANUAL Lubrication system FlexxPump4 D Appendix Declaration of conformity for TriboServ See also 2 Declaration of conformity for TriboServ [} 149]...
  • Page 148 Appendix OPERATING MANUAL Lubrication system FlexxPump4 D...
  • Page 150 OPERATING MANUAL Lubrication system FlexxPump4 D Version larwue Author Date 04.03.2021 GÜDEL AG Industrie Nord CH-4900 Langenthal Switzerland +41 62 916 91 50 E-mail info@ch.gudel.com www.gudel.com...
  • Page 151 GÜDEL AG Industrie Nord CH-4900 Langenthal Switzerland info@ch.gudel.com www.gudel.com...

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