GUDEL 404DLS Operating Manual
404 DLS
OPERATING MANUAL
BETRIEBSANLEITUNG AUTOMATIC LUBRICATION SYSTEM FLEXXPUMP 404DLS72057594178931083_V7.0_EN-US
B1X.xxxxxxxxx-xxxx
09xxxxx
2018
Automatic lubrication system
FlexxPump 404DLS
Project / Order:
Bill of materials:
Serial number:
Year of manufacture:
© 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 delivery may differ from the descriptions here. Reprinting the instructions, in whole
or in part, requires our permission. Subject to change due to technical improvements.
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Revision history
Version Date Description
7.0 01.06.2018 Valid as of FlexxPump serial number
Revision history
1601929
Updated:
• Actuate ÜChapter6.4,243
• Lubrication recommendation Ü255
New:
• Splitter Ü229
ÜChapter5.2.3.1,233
6.0 12.04.2018 Updated:
5.0 12.12.2017 Updated:
4.0 08.08.2017 Added:
3.0 27.02.2017 Corrected:
2.0 29.11.2016 Updated:
1.0 29.07.2016 Basic version
Table-1 Revision history
• Lubrication check Ü261
• Lubrication check Ü261
• Lubrication check Ü261
• Standards and guidelines of the Declaration of conformity ÜChapter1,211
• New signatures on Declaration of conformity ÜChapter1,211
• Entire manual updated
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Revision history
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Table of contents
Table of contents
1 EC declaration of conformity 11
2 General 13
2.1 Further applicable documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.2 Purpose of the document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
2.3 Explanation of symbols/abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3 Safety 15
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3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
3.1.1 Product safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.1.2 Personnel qualifications . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . 16
3.1.2.1 Operating companies. . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.1.2.2 Transport specialists. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.1.2.3 Fitters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.1.2.4 Commissioning technicians . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.1.2.5 Operators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.1.2.6 Manufacturer's technicians. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.1.2.7 Maintenance technicians . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
3.1.2.8 Service technicians . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.1.2.9 Disposal specialists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.1.3 Disregarding safety regulations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.1.4 Installation instructions . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . 20
3.2 Hazard symbols in the manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3.2.1 Hazard warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3.2.2 Explanation of warning symbol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3.3 Fundamentals of safety. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . 23
3.3.1 Product-specific hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
3.3.2 Material safety data sheets (MSDS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
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4 Product description 25
4.1 Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4.1.1 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4.1.2 Non-intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
4.2 Product designation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
4.3 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4.3.1 FlexxPump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4.3.1.1 Dimensions and connections 404DLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4.3.1.2 Temperature ranges. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4.3.1.3 IP protection class . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4.3.1.4 Operating pressure. . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4.3.2 Splitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
4.3.2.1 Temperature ranges. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4.3.2.2 Accuracy of the lubricant distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4.3.2.3 Minimum lubrication quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4.3.2.4 Maximum pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4.3.3 Lubricant amount . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . .29
4.3.4 Shelf life of Güdel H1 lubricant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
5 Design, function 31
5.1 Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
5.1.1 Detailed design of FlexxPump 404DLS . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . .32
5.2 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
5.2.1 Functional description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
5.2.2 FlexxPump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
5.2.2.1 404DLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
5.2.3 Splitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
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5.2.3.1 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
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6 Commissioning 35
6.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
6.1.1 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
6.1.1.1 Personnel qualifications. . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . 35
6.2 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
6.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
6.3.1 Prerequisites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
6.3.2 Installing the FlexxPump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
6.3.3 Connect hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . 38
6.3.3.1 404DLS 3-fold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
6.3.3.2 404DLS 6-fold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
6.3.3.3 404DLS 10-fold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
6.3.4 Connecting electrical equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
6.3.4.1 Connecting the 404DLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
6.4 Actuate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
6.4.1 Recommended solution, software programming . . . . . . . . . . . . . . . . . . . . . . . . . 44
6.4.2 Switching the FlexxPump on and off. . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . 45
6.4.3 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
6.4.4 Filling hydraulic lines / venting the FlexxPump. . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
6.4.5 Error message: Empty . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . .51
6.4.6 Error message: General. . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . 53
6.4.7 Lubrication recommendation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
6.4.7.1 General information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
6.4.7.2 Basics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
6.4.7.3 Minimum lubrication quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
6.4.7.4 Calculation formulas. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
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6.5 Initial commissioning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
6.5.1 Carrying out a lubrication check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61
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7 Operation 66
7.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66
7.2 Personnel .. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
7.3 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67
8 Maintenance 69
8.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
8.1.1 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
8.1.2 Personnel qualifications . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . 69
8.2 Consumables and auxiliary agents. . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . 70
8.2.1 Cleaning agents . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . .70
8.2.1.1 Table of cleaning agents . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . 70
8.2.2 Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
8.2.2.1 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Automatic lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
8.2.2.2 Lubricant table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
8.3 Maintenance tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
8.3.1 Checking automatic lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
8.3.2 Replacing the cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
8.4 Maintenance table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
9 Repairs 79
9.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
9.1.1 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
9.1.2 Personnel qualifications . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . 79
9.2 Malfunctions / Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80
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9.3 Service departments .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
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10 Decommissioning, storage 81
10.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
10.1.1 Personnel qualifications . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . 81
10.2 Storage conditions . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . .81
10.3 Decommissioning. . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . 82
10.3.1 Shutdown. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
10.3.2 Cleaning, rust-proofing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
10.3.3 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
10.4 Recommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
11 Disposal 85
11.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
11.1.1 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
11.1.2 Personnel qualifications . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . 85
11.2 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
11.3 Waste management compliant assemblies . . . . . . . . . . . . . . . . . . . . . . . . 86
11.3.1 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
11.3.2 Material groups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87
11.4 Disposal facilities, authorities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87
12 Accessories 89
12.1 PLC connecting cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
13 Spare parts supply 91
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13.1 Service departments .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
13.2 Explanations regarding the spare parts list . . . . . . . . . . . . . . . . . . . . . . . . 99
13.2.1 Parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
13.2.2 Position drawings . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . .99
9
OPERATING MANUAL Automatic lubrication system
Table of contents
FlexxPump 404DLS
14 Torque tables 100
14.1 Tightening torques for screws. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
14.1.1 Zinc plated screws . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . 101
14.1.2 Black screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
14.1.3 Stainless steel screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Illustrations 105
List of tables 107
Index 109
Appendix
Layout
Spare parts lists
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OPERATING MANUAL Automatic lubrication system
Automatic lubrication system FlexxPump 404DLS
09xxxxx
2018
xx.xx.20xx
FlexxPump 404DLS
Declaration of conformity, declaration of incorporation
1 EC declaration of conformity
The manufacturer: GÜDEL AG
Industrie Nord
CH-4900 Langenthal
hereby declares that the machine:
Product, type
Serial number
Parts list
Year of manufacture
corresponds to the applicable requirements of the Machinery Directive
(2006/42/EC).
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Authorized representative responsible for compiling the technical documentation:
Michael Marti Tel. +41 (0)62 916 91 37
The machine complies with the following other EC directives:
• Low Voltage Directive2014/35/EU
• EMC Directive2014/30/EU
The following harmonized standards have basically been applied:
EN ISO 12100:2010; EN ISO 13850:2015; EN 60204-1:2006; EN ISO
14119:2013; EN ISO 4413:2010; EN ISO 4414:2010; EN ISO 13849-1:2015
Langenthal,
Markus Ruprecht
CEO
Michael Marti
Director R&D
11
Declaration of conformity, declaration of incorporation
OPERATING MANUAL Automatic lubrication system
FlexxPump 404DLS
12
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OPERATING MANUAL Automatic lubrication system
FlexxPump 404DLS
2 General
Read the entire manual before working with the product. The manual contains 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.
2.1 Further applicable documentation
All documents delivered with this manual are further applicable documentation. They must be observed in addition to this operating manual for the safe
handling of the product.
General
2.2 Purpose of the document
This manual describes all the product life phases of the product:
• Transport
• Commissioning
• Operation
• Maintenance
• Repairs
• Disposal
The manual contains the information required for using the product as intended. It is an essential component of the product.
The manual must be available at the product site throughout the entire service life of the product. If the product is sold, the manual must be transferred
to the new owner.
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13
Ü
2
OPERATING MANUAL Automatic lubrication system
General
2.3 Explanation of symbols/abbreviations
The following symbols and abbreviations are used in this manual:
FlexxPump 404DLS
Symbol/Abbreviation
Fig. Designation of graphics Figure
Table Designation of tables Table
Table2-1 Explanation of symbols/abbreviations
Use Explanation
For cross-reference See
Possibly for cross-ref-
Page
erence
In the tip Information or tip
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OPERATING MANUAL Automatic lubrication system
FlexxPump 404DLS
3 Safety
3.1 General
Read the entire manual before working with the product. The manual contains 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.
3.1.1 Product safety
Safety
Residual danger
Operation
The product is built using state-of-the-art technology. It was designed and
constructed in accordance with the accepted safety regulations. However,
some residual danger remains during its operation.
There is danger to the personal safety of the operator as well as for the product and other property.
When operating the product, always observe this manual and ensure that the
system is always in perfect working order.
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15
Safety
3.1.2 Personnel qualifications
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
• Train and instruct the technicians specifically for their area of responsibility
Only appropriately trained and authorized technicians are allowed to work on
the product.
Persons are authorized if:
• they are familiar with the relevant safety regulations for their area of responsibility
• they have read and understood this manual
• they meet the requirements for an area of responsibility
• they were assigned an area of responsibility by the operator
OPERATING MANUAL Automatic lubrication system
FlexxPump 404DLS
WARNING
The technician is responsible to third parties in his area of responsibility.
During a training session or instruction, the technician may only work on the
product under the supervision of an experienced manufacturer's technician.
3.1.2.1 Operating companies
The operating company is responsible for ensuring that:
• the product is used as intended
• the product is sufficiently lubricated at all times
• all safety aspects are complied with
• the product is put out of operation if the functioning of the safety equipment is not fully guaranteed
• the technician working on the product is appropriately trained
• the technician is provided with personal protective equipment
• the operating manual is available to the technician at the operation site of
the product at all times
• 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 maintenance technician
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OPERATING MANUAL Automatic lubrication system
FlexxPump 404DLS
3.1.2.2 Transport specialists
The transport specialist:
• is able to transport loads safely
• is able to use slings safely and properly
• is able to secure the load properly
• has experience in transportation
3.1.2.3 Fitters
The fitter:
• has very good mechanical and/or electrical knowledge
• is flexible
• has assembly experience
3.1.2.4 Commissioning technicians
Safety
72057594178931083_v7.0_EN-US
The commissioning technician:
• has good programming knowledge
• has mechanical and/or electrical knowledge
• is flexible
The commissioning technician is responsible for the following tasks:
• commissioning the product
• testing the functions of the product
3.1.2.5 Operators
The operator:
• was trained and instructed by the operating company or the manufacturer
• has very good knowledge of the user interface and the operating elements
• has process knowledge which is specifically geared to the product
The operator is responsible for the following tasks:
• switching the control system of the product on and off
• creating production readiness
• monitoring the production process
• localizing minor malfunctions
17
Safety
3.1.2.6 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
• has experience with Güdel products
The manufacturer's technician is responsible for the following tasks:
• performing mechanical and electrical maintenance work in accordance with
the manual
• performing mechanical and electrical service work in accordance with the
manual
• cleaning the product
• replacing spare parts
• localizing and fixing malfunctions
OPERATING MANUAL Automatic lubrication system
FlexxPump 404DLS
3.1.2.7 Maintenance technicians
The maintenance technician:
• was trained by the operating company or the manufacturer
• has very good mechanical and/or electrical knowledge
• has software knowledge
• has maintenance experience
• bears responsibility for the safety of the cleaning staff
The maintenance technician is responsible for the following tasks:
• performing mechanical and electrical maintenance work in accordance with
the manual
• cleaning the product
• replacing spare parts
• monitoring and instructing the cleaning staff in the safety zone during the
cleaning process
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OPERATING MANUAL Automatic lubrication system
FlexxPump 404DLS
3.1.2.8 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
• is flexible
The service technician is responsible for the following tasks:
• performing mechanical and electrical service work in accordance with the
manual
• replacing spare parts
3.1.2.9 Disposal specialists
The disposal specialist:
• is able to separate waste
• is familiar with the country-specific disposal regulations
• has experience in environmentally-friendly disposal
• works carefully and safely
Safety
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19
OPERATING MANUAL Automatic lubrication system
Safety
3.1.3 Disregarding safety regulations
DANGER
Disregarding safety regulations
Disregarding safety regulations can result in damage to property, severe or
fatal injuries.
• Always comply with the safety regulations
FlexxPump 404DLS
Liability
Güdel shall not be held liable under any of the following circumstances:
• The installation regulations were disregarded
• Included protective equipment was not installed
• Included protective equipment was modified
• Included monitoring equipment was not installed
• Included monitoring equipment was modified
• The product was not used as intended
• The maintenance work was not performed in the specified intervals, or
was carried out incorrectly.
3.1.4 Installation instructions
Protective mea-
sures
The operating company is responsible for ensuring safe conditions in the vicinity of the product. In particular, he must ensure compliance with the general
safety regulations, guidelines and standards. Before commissioning the system
the operating company must check whether all the protective measures have
been implemented. These must cover all hazards. This is the only way to ensure that application of the product conforms to CE regulations.
Modifications
General rules for
occupational
20
As stipulated by the Machinery Directive, the protective measures must:
• Correspond to best practices
• Comply with the required safety category
The product must never be modified or used in a manner contrary to its intended use. Ü225
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The generally accepted occupational safety rules must be observed and implemented.
safety
OPERATING MANUAL Automatic lubrication system
FlexxPump 404DLS
3.2 Hazard symbols in the manual
3.2.1 Hazard warnings
The hazard warnings are defined for the following four types of danger levels:
DANGER
DANGER
DANGER refers to hazards with a high risk of severe physical injury or immediate fatality.
WARNING
WARNING
Safety
WARNING refers to hazards with a moderate risk of severe physical injury
or potential fatality.
CAUTION
CAUTION
CAUTION refers to hazards with a slight risk of moderate physical injury.
NOTE
NOTE
NOTE refers to hazards that can lead to property damage.
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OPERATING MANUAL Automatic lubrication system
Safety
3.2.2 Explanation of warning symbol
Hazard warnings for personal injuries contain the symbol of the corresponding hazard.
Symbol Explanation of symbols
Hazards due to general causes
Hazards resulting from automatic startup
Hazards due to falling axles
FlexxPump 404DLS
Hazards due to environmental pollution
Hazards due to dangerous electrical voltage
Hazards from leaking batteries
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OPERATING MANUAL Automatic lubrication system
FlexxPump 404DLS
3.3 Fundamentals of safety
3.3.1 Product-specific hazards
Leaking batteries
Battery fluids and their fumes are hazardous to the environment, corrosive
and poisonous! They cause injury to persons and damage to property!
Observe the following points:
• Make sure there is good ventilation in closed rooms before repairing leaks
• Wear safety goggles and gloves
• Prevent battery fluids from getting into the drinking water supply
• Use only dry cleaning cloths without detergents
Safety
CAUTION
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• Dispose of batteries in an environmentally friendly manner
CAUTION
Oil, greases
Oils and greases are harmful to the environment!
• The oils and greases must not get into the drinking water supply. Take appropriate measures
• Observe the country-specific safety data sheets
• Oils and greases must be disposed of as hazardous waste, even if the total
quantity is small
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OPERATING MANUAL Automatic lubrication system
Safety
3.3.2 Material safety data sheets (MSDS)
Safety data sheets contain safety information about the materials. They are
country-specific. Safety data sheets are issued, for example, for materials such
as oils, greases, cleaning agents, etc. The operating company is responsible for
obtaining safety data sheets for all materials used.
Safety data sheets can be obtained as follows:
• Suppliers of chemicals usually supply their substances together with safety
data sheets
• Safety data sheets are available on the Internet.
(Enter "msds" and the name of the material in a search engine. Safety information about the material will be displayed.)
Read the safety data sheets carefully. Follow all the instructions. We recommend that you store the safety data sheets for future reference.
FlexxPump 404DLS
The safety data sheet for Güdel H1 can be found in the download area of our
company Web site http://www.gudel.com
24
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OPERATING MANUAL Automatic lubrication system
FlexxPump 404DLS
4 Product description
4.1 Use
4.1.1 Intended use
The automatic lubrication system is designed exclusively for lubricating Güdel
guideways and Güdel gear teeth. Be sure the hydraulic system is installed correctly ÜChapter6.3.3,238
Any other or additional use is not considered to be use in the intended manner. The manufacturer assumes no liability for any resulting damage. All risks
are borne solely by the user.
Product description
4.1.2 Non-intended use
The product is not intended for:
• Lubrication of runners, bearings, or other elements
• Operation in potentially explosive areas
• Lubrication of elements in or on automobiles
• Operation outside of specified performance data
• Operation outside of permissible temperature range
• Using lubricants with properties other than the ones specified
Any use other than the specified intended use will be considered improper
use and is prohibited!
Do not make any modifications to the product.
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D003061
www.gudel.com Made in Germany
Artikelnummer 0193906
GÜDEL
A
B
C
D003063
A
B
Product description
4.2 Product designation
The product has a type plate. It contains the following information:
Fig.4-1 Type plate
OPERATING MANUAL Automatic lubrication system
FlexxPump 404DLS
A Product name
B Pump type
C Item number
The type plate is attached to the bottom of the casing. The hydraulic outputs
are indicated by engraved numbers.
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Fig.4-2 Product designations
A Numbers of the hydraulic outputs
B Type plate
26
D003135
94
110
96
107
112
35,3
196
A
B
OPERATING MANUAL Automatic lubrication system
FlexxPump 404DLS
4.3 Technical data
For specific information on the product, refer to the respective drawings as
well as the documentation on the complete plant.
Product description
Emission sound
pressure level
The emission sound pressure level depends on the machine properties and
the operating conditions. Generally the emissions sound pressure level LpA is
≤ 80dB(A), measured at a distance of 1 m from the safety fence and 1.6 m
above ground level. The measurement is performed according to the ISO
11202 standard. The measured value is time-averaged over a machine specific
cycle and offset with correction factors for room and environment noise correction. The measured value contains measuring uncertainty of +/- 4dB(A)
(accuracy grade 3) and applies for a single machine, measured separately.
4.3.1 FlexxPump
4.3.1.1 Dimensions and connections 404DLS
The FlexxPump 404DLS weighs approx. 1500 g and has the following dimensions:
72057594178931083_v7.0_EN-US
Fig.4-3 Dimensions and connections 404DLS
A Hydraulic outputs
B Connection plug M12x1
27
Product description
OPERATING MANUAL Automatic lubrication system
FlexxPump 404DLS
Connections
Hydraulic:
• Four connections for hydraulic hoses with diameter of 6/3 mm
Electrical: The four-pole connection size M12x1 transmits the following signals:
• Control signals
• Operating voltage
Interfaces
The FlexxPump 404DLS features an integrated microprocessor. It is controlled via a programmable logic controller (PLC).
Operating voltage
Operating
voltage
24 V DC 200 mA 350 mA <20 mA 300 mA
Table4-1 Operating voltage
4.3.1.2 Temperature ranges
The following temperature ranges and humidity apply:
Operating
power
Peak
power I
max
Standby
current
Peak output power
Product life phase Temperature range Air humidity
Transport -10 to +60 °C
Operation -20 to +70 °C Up to and at 85 %,
Storage -10 to +40 °C Up to 75 %
Table4-2 Temperature ranges: FlexxPump
4.3.1.3 IP protection class
The product conforms to the protection class IP65.
4.3.1.4 Operating pressure
The operating pressure is 70bar and is monitored electronically by counterpressure measuring. The maximum pressure is 150bar.
condensation formation is not permissible
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OPERATING MANUAL Automatic lubrication system
FlexxPump 404DLS
4.3.2 Splitter
4.3.2.1 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 %,
Storage -10 to +40°C Up to 75 %
Table4-3 Temperature ranges: Splitter
Product description
condensation formation is not permissible
72057594178931083_v7.0_EN-US
4.3.2.2 Accuracy of the lubricant distribution
The accuracy of the lubricant distribution is ±10%. The accuracy is valid up to
a pressure difference of less than 6 bar.
4.3.2.3 Minimum lubrication quantity
Splitters only function correctly if > 0.5 cm3 of lubricant is produced at their
input per lubrication cycle.
4.3.2.4 Maximum pressure
The maximum pressure at the input of splitters is 110 bar.
4.3.3 Lubricant amount
The cartridge contains 400cm3 of lubricant. The empty level is monitored by
an integrated reed contact.
4.3.4 Shelf life of Güdel H1 lubricant
The date of filling of the lubricant is shown on the lubricant cartridge. The
Güdel H1 lubricant has a shelf life of two years from date of filling. This applies to sealed original containers stored under the required storage conditions.
29
Product description
OPERATING MANUAL Automatic lubrication system
FlexxPump 404DLS
30
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