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Summary of Contents for SKF ZPU 08
- Page 1 Operating Instructions Pump ZPU 08 ATEX ZPU 08 810-53711-1 Page 1 / 56 Rev.: 007 24/01/2022...
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Page 2: Eu Declaration Of Conformity
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... -
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 Returns ..................... 24 2.30. Disposal ....................24 2.31. Lubricant ......................25 3.1. Selection of lubricants ................. 25 3.2. Ageing of lubricants ..................25 3.3. Specification ....................26 Technical data ....................27 4.1. Ambient temperatures ................. 27 4.2.
- Page 5 Operating Instructions Pump ZPU 08 ATEX Technical data of the capacitive sensor ............35 Technical data of the motor ................36 Brief description of the pump ................ 37 Installation and commissioning ..............39 8.1. Filling of the reservoir .................. 39 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 etc. and so on relative humidity poss. possibly approx. approximately e.g. for example Ø... -
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: • outside the indicated temperature range • with non-specified means of operation •... -
Page 10: Prohibition Of Certain Activities
Operating Instructions Pump ZPU 08 ATEX 2.7. Prohibition of certain activities The following activities may be carried out by manufacturer specialists or authorized persons only due to potential sources of faults that may not be visible for the user, or due to legal regulations: •... -
Page 11: 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 12: 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 13: 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 14: Existing Residual Risks
Operating Instructions Pump ZPU 08 ATEX 2.17. Existing residual risks Residual risks Remedy Operation in potentially explosive area 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 15 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 16 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 17: 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 18: 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 19: 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 20 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 21: 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 22 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 23: 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 24: Training Courses
Pump ZPU 08 ATEX 2.28. 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 25: Lubricant
Should you have little or no experience with the selection of lubricants for centralized lubrication systems, please contact SKF. You will avoid possible costly downtimes through damage to your machine/ system or damage to the centralized lubrication system. -
Page 26: 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 27: 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 Part no.: 605-46211-3 -20 °C +40 °C Part no.: 6050-00000008... -
Page 28: Reservoir
Operating Instructions Pump ZPU 08 ATEX 4.10. reservoir 40 XB 40 XL (Part no.: 605-46554-6) (Part no.: 605-46554-7) Used with pump 6050-00000008 Used with pump 605-41759-8 Part no.: 605-40759-7 605-40759-6 40 XBF (Part no.: 605-77177-1) Used with pump 605-46211-3 810-53711-1 Page 28 / 56 Rev.: 007... -
Page 29: 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 30: 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 31: 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 32: Connections / Outlets
Operating Instructions Pump ZPU 08 ATEX 4.15. Connections / outlets • Pressure line G ¾“ • Relief line G ¾“ • Filling adapter G ¾“ 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 33: Type Identification Plate
Operating Instructions Pump ZPU 08 ATEX 4.21. Type identification plate The following information is stated on the type identification plate: 810-53711-1 Page 33 / 56 Rev.: 007 24/01/2022... -
Page 34: 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 35: 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 664-34621-2 Rated operating distance 5 mm for flush installation 7.5 mm for non-flush installation Secured switching distance ≤ (0.72 x Sn) mm Hysteresis 1….. -
Page 36: 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 for pumps with part number 605-40759-6 Rated power 0.55 Code --------- Operating mode Flange Ø 120... -
Page 37: 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 38 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 39: 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 40: 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 41: 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 42: 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 43: 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 44: 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 45: 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 46: 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 47 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. Constant unusual Consult the manufacturer. running noise Consult the manufacturer. Irregular toothing (knocking noise)
- Page 48 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 49 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 50: Declarations Of Conformity Of The Purchase Parts
Operating Instructions Pump ZPU 08 ATEX Declarations of conformity of the purchase parts 810-53711-1 Page 50 / 56 Rev.: 007 24/01/2022... - Page 51 Operating Instructions Pump ZPU 08 ATEX 810-53711-1 Page 51 / 56 Rev.: 007 24/01/2022...
- Page 52 Operating Instructions Pump ZPU 08 ATEX 810-53711-1 Page 52 / 56 Rev.: 007 24/01/2022...
- Page 53 Operating Instructions Pump ZPU 08 ATEX 810-53711-1 Page 53 / 56 Rev.: 007 24/01/2022...
- Page 54 Operating Instructions Pump ZPU 08 ATEX 810-53711-1 Page 54 / 56 Rev.: 007 24/01/2022...
- Page 55 Operating Instructions Pump ZPU 08 ATEX 810-53711-1 Page 55 / 56 Rev.: 007 24/01/2022...
- Page 56 Operating Instructions Pump ZPU 08 ATEX 810-53711-1 Page 56 / 56 Rev.: 007 24/01/2022...
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