Page 1
Operating Instructions
Pump ZPU 08 ATEX
ZPU 08
810-53711-1 Page 1 / 57
Rev.: 003
31/07/2017
Page 2
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
Type:
ZPU 08
Part number:
605-40759-6 | 605-40759-7 | 605-41759-8
Year of construction
See type identification plate
complies with the following basic safety and health requirements of ATEX directive 2014/34/EU and the basic safety
and health requirements of machinery directive 2006/42/EC at the time when first being launched in the market.
1.1.2, 1.1.3, 1.3.2, 1.3.4, 1.5.1, 1.5.2, 1.5.6, 1.5.7, 1.5.8, 1.5.9, 1.6.1, 1.7.1, 1.7.3, 1.7.4
Furthermore, the following directives and harmonized standards were applied in the respective applicable areas:
The special technical documents were prepared following:
- ATEX directive 2014/34/EU annex VIII (3) and stored at the named institute (CE 0123).
- Machinery directive 2006/42/EC, annex VII, part B was prepared. We undertake to send this in electronic
form to the respective authorities upon justifiable request.
Harmonized and other standards:
EN ISO 12100:2011
EN 809:2012
EN 1127-1: 2011
EN 60204-1:2007
EN 13463-1: 2009
EN 13463-5:2011
Authorized representative of the technical documentation is the head of standardization. See manufacturer's address.
The machinery must not be put into service until the final machinery into which it is to be incorporated has been
declared in conformity with the previsions of machinery directive 2006/42/EC and any other applicable directives.
Walldorf
31/07/2017
Jürgen Kreutzkämper
Manager R&D Germany
SKF Lubrication Business Unit
Operating Instructions
Pump ZPU 08 ATEX
810-53711-1 Page 2 / 57
Rev.: 003
31/07/2017
Page 3
Operating Instructions
Pump ZPU 08 ATEX
Declaration of conformity
Table of contents
1. Guidelines .......................................................................................................... 6
1.1 Warnings ....................................................................................................... 6
1.2 Illustrations .................................................................................................... 6
1.3 Abbreviations ................................................................................................. 7
1.4 Manufacturer and Service addresses ............................................................ 7
1.5 Warranty ........................................................................................................ 7
1.6 Disclaimer ...................................................................................................... 7
1.7 Copyright ....................................................................................................... 7
2. Safety information ............................................................................................. 8
2.1. Emergency stopping of the pump .................................................................. 8
2.2. Intended use .................................................................................................. 8
2.3. Explosion protection class / Explosion protection marking ............................ 8
2.4. Expiry of the ATEX certification ..................................................................... 8
2.5. Pump operation ............................................................................................. 8
2.6. Foreseeable misuse ...................................................................................... 9
2.7. Prohibition of certain activities ....................................................................... 9
2.8. Conversions or modifications ........................................................................ 9
2.9. Inspections .................................................................................................... 9
2.10. Labels on the pump .................................................................................. 10
2.11. Other applicable documents ..................................................................... 11
2.12. Sources of hazard .................................................................................... 12
2.13. Moving, rotating parts ............................................................................... 12
2.14. Energies ................................................................ ................................ ... 12
2.15. Lubricants ................................................................................................. 12
2.16. Explosive substances at the location of use ............................................. 12
2.17. Existing residual risks ............................................................................... 13
2.18. Persons authorized to operate the pump ................................................. 16
2.19. Operator ................................................................ ................................ ... 16
2.20. Specialist for maintenance and repairs
in potentially explosive atmospheres ........................................................ 16
2.21. Protection of special groups of persons ................................................... 16
2.22. Safety recommendations to be complied with .......................................... 17
2.23. General behaviour when handling the pump ............................................ 17
2.24. Explosion protection ................................................................................. 18
2.25. Transport / installation / maintenance / repairs / servicing ........................ 20
2.26. Initial commissioning / daily start-up ......................................................... 22
2.27. Cleaning ................................................................ ................................ ... 22
810-53711-1 Page 3 / 57
Rev.: 003
31/07/2017
Page 4
Operating Instructions
Pump ZPU 08 ATEX
2.28. Operator obligations ................................................................................. 22
2.29. Determination of hazards ......................................................................... 22
2.30. Explosion protection measures following ATEX ....................................... 23
2.31. Provision of necessary information .......................................................... 23
2.32. Instructions / qualification obligations ....................................................... 24
2.33. Briefing of external technicians ................................................................ 24
2.34. Inspection for correct use ................................................................ ......... 24
2.35. Provision of personal protective equipment .............................................. 24
2.36. Training courses ....................................................................................... 25
2.37. Inspection of the delivery .......................................................................... 25
2.38. Returns ..................................................................................................... 25
2.39. Disposal ................................................................................................... 25
3. Lubricant .......................................................................................................... 26
3.1. Selection of lubricants ................................................................................. 26
3.2. Ageing of lubricants ..................................................................................... 26
3.3. Specification ................................................................................................ 27
4. Technical data ................................................................................................. 28
4.1. Ambient temperatures ................................................................................. 28
4.2. Explosion protection marking ...................................................................... 28
4.3. Operating pressure ...................................................................................... 28
4.4. Installation position ...................................................................................... 28
4.5. Sound pressure level ................................................................................... 28
4.6. Maximum set-up height ............................................................................... 28
4.7. Maximum dust thickness ............................................................................. 28
4.8. Weight ......................................................................................................... 28
4.9. Gear ratio .................................................................................................... 28
4.10. Reservoir .................................................................................................. 29
4.11. Space requirements ................................................................................. 30
4.12. Electrical connection ................................................................................ 31
4.13. IP Types of protection .............................................................................. 31
4.14. Tightening torques.................................................................................... 32
4.15. Connections / outlets ................................................................................ 33
4.16. Filling possibilities..................................................................................... 33
4.17. Rotational direction of the pump ............................................................... 33
4.18. Admissible speed of the eccentric shaft ................................................... 33
4.19. Output ...................................................................................................... 33
4.20. Lubricant filter ........................................................................................... 33
4.21. Type identification plate ............................................................................ 34
4.22. Storage until the first use .......................................................................... 35
810-53711-1 Page 4 / 57
Rev.: 003
31/07/2017
Page 5
Operating Instructions
Pump ZPU 08 ATEX
5. Technical data of the capacitive sensor ........................................................ 36
6. Technical data of the motor ............................................................................ 37
7. Brief description of the pump ........................................................................ 38
8. Installation and commissioning ..................................................................... 40
8.1. Filling of the reservoir .................................................................................. 40
8.2. Inadvertent filling with incorrect lubricant ..................................................... 41
8.3. Inspections prior to initial start-up ................................................................ 41
8.4. Activation of the pump ................................................................................. 42
9. Standard operation .......................................................................................... 43
9.1. Daily start-up ............................................................................................... 43
9.2. Inspections .................................................................................................. 43
9.3. Filling of the reservoir during operation ....................................................... 43
9.4. Cleaning ...................................................................................................... 43
10. Maintenance ..................................................................................................... 44
10.1. Maintenance of pump ............................................................................... 44
10.2. Maintenance of lubricant filter .................................................................. 45
10.3. Maintenance of gear unit .......................................................................... 45
10.4. SEW motor maintenance ......................................................................... 46
10.5. Measurement of the insulation resistance ................................................ 46
10.6. Maintenance of gear unit .......................................................................... 46
11. Troubleshooting .............................................................................................. 47
12. Declarations of conformity of the purchase parts ........................................ 51
810-53711-1 Page 5 / 57
Rev.: 003
31/07/2017
Page 6
Text representations
Meaning
Bold print
Highlighting of particularly important
words or passages
List 1
Marks lists
o List 2
Marks lists
(parenthesis)
Item numbers
Instructions
Instructions to personnel. These
always appear in chronological order.
Warning level
Consequence
Probability
DANGER
Death/ serious injury
imminent
WARNING
Death/ serious injury
possible
CAUTION
Minor injury
possible
NOTICE
Property damage
possible
Operating Instructions
Pump ZPU 08 ATEX
1. 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. Of course, the female form is also always intended.
1.1 Warnings
Activities which generate actual hazards (to life and limb or possible damage to the
material) are marked by warnings. Definitely observe the instructions given in the
warnings. The following warnings are possible.
1.2 Illustrations
The illustrations used refer to a specific product. In the case of other products or
product versions they may have a schematic character only. The basic functions,
however, do not change.
810-53711-1 Page 6 / 57
Rev.: 003
31/07/2017
Page 7
max. maximum
min. minimum
min minutes
s seconds
etc. and so on
poss. possibly
e.g. for example
ml millilitre
ccm cubic cm
mm millimetre
°C degrees Celsius
°F degrees Fahrenheit
K Kelvin
inch inch
etc. et cetera
kg kilogram
l litre
mbar millibar
no. number
rpm revolutions per min
Nm Newtonmeter
incl. including
i.e. this means
rh relative humidity
approx. approximately
Ø diameter
® registered trademark
© Copyright
TM Trademark
% per cent
dB (A) sound pressure level
> greater than
< less than
± plus minus
SW width across flats
ESD electrostatic
discharge
N/A not applicable
MTTF mean time to failure
Manufacturer
Customer Service
SKF Lubrication Systems Germany GmbH
Heinrich-Hertz-Str. 2-8
DE - 69190 Walldorf
Central Customer Service Dept.
P.O. Box 1263
DE - 69183 Walldorf
Operating Instructions
Pump ZPU 08 ATEX
1.3 Abbreviations
The following abbreviations may be used within these instructions.
1.4 Manufacturer and Service addresses
1.5 Warranty
The instructions do not contain any information on the warranty. This can be found
1.6 Disclaimer
1.7 Copyright
810-53711-1 Page 7 / 57
Rev.: 003
31/07/2017
in our general terms and conditions.
Observation of these instructions is the prerequisite for safe operation and the
achievement of product characteristics and performance levels. The manufacturer
shall bear no liability for damages - of any kind - resulting from the non-observance
of these instructions.
© SKF. All rights reserved.
Page 8
Operating Instructions
Pump ZPU 08 ATEX
2. 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 beforementioned group of persons. It is prohibited to commission or operate the machine
prior to reading the Instructions. These Instructions must be kept at an accessible
location for further use.
2.1. Emergency stopping of the pump
In case of an emergency stop the pump by:
Switching off the machine or system in which the pump has been
integrated.
2.2. Intended use
Supply of lubricants within a centralized lubrication system following the
specifications made in these Instructions and the stated explosion protection class:
The pump may be used within commercial machines or systems exclusively.
2.3. Explosion protection class / Explosion protection marking
See declaration of conformity or type identification plate of the pump.
2.4. Expiry of the ATEX certification
The ATEX certificate for this product expires through:
Use not in accordance with the intended purpose
Unauthorized modifications.
Use of non-original spare parts.
Non-observance of these instructions and other applicable documents.
Use of non-specified lubricants.
Non-observance of the specified maintenance and repair intervals.
Wrong, lacking or damaged ATEX painting.
2.5. Pump operation
Operation is permitted only, if in compliance with:
All information given in these instructions or stated in the referenced
documents.
All laws and regulations to be complied with by the user.
Information on explosion protection according to directive 1999/92/EC
(ATEX 137).
ATEX approval.
810-53711-1 Page 8 / 57
Rev.: 003
31/07/2017
Page 9
Operating Instructions
Pump ZPU 08 ATEX
2.6. Foreseeable misuse
Any other use and purpose of the pump than the ones described before are strictly
prohibited. It is expressly forbidden to be used:
In a different, more critical potentially explosive atmosphere than stated in
these Instructions.
Outside the indicated temperature range.
In areas with aggressive or corrosive materials (e.g. high ozone pollution).
These may affect seals and painting.
In areas with harmful radiation (e.g. ionising radiation).
to use the CLS to feed, forward, or store hazardous substances and
mixtures in accordance with annex I part 2-5 of the CLP regulation (EC
1272/2008).
to supply, transport, or store hazardous substances and mixtures in
accordance with annex I part 2-5 of the CLP regulation (EC 1272/2008)
and marked with GHS01 - GHS06 and GHS08 hazard pictograms.
For the supply, transport, stockpiling of gases, liquefied gases, dissolved
gases, vapours, and fluids whose vapour pressure exceeds normal
atmospheric pressure (1013 mbar) by more than 0.5 bar at the maximum
admissible operating temperature.
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:
Repairs/ changes to the motor/ gear
2.8. Conversions or modifications
Unauthorized conversions or modifications may result in unforeseeable impacts on
safety. Therefore, any unauthorized reconstructions or changes are expressly
prohibited.
2.9. Inspections
The following inspections were carried out prior to delivery:
Inspections following ATEX.
Electrical inspections following DIN EN 60204-1:2007 /
VDE 0113-1:2007.
Safety and functional tests
810-53711-1 Page 9 / 57
Rev.: 003
31/07/2017
Page 10
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.
Behind the protective fitting marked with this
symbol there is the check valve.
Marks the equipotential bonding connection of
the pump.
Provides instructions on how to clean the
lubricant filter.
Operating Instructions
Pump ZPU 08 ATEX
2.10. Labels on the pump
810-53711-1 Page 10 / 57
Rev.: 003
31/07/2017
Page 11
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.
Safety data sheet (MSDS) of the lubricant used.
Gear
Rehfuss
Instructions for the SM type series
Motor
SEW
Explosion-protected three-phase motors EDR.71-225 documentation no.:
19402007
Where appropriate:
Any documents of other components required to set up the centralized
lubrication system.
Project planning documents.
Other relevant documents for the integration of the pump into the machine
or system.
The owner must supplement these documents by the respective valid national
or regional regulations laid down by the country in which the product is to be
used. If the product is sold or transferred, any associated documents must be
passed on to the subsequent operator as well.
810-53711-1 Page 11 / 57
Rev.: 003
31/07/2017
Page 12
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. Moving, rotating parts
Drive, stirring paddles
2.14. Energies
Electricity
Temperature (hot/ cold surfaces)
Position energy (raised components)
Parts subject to (operating) pressure
Parts subject to spring tension
2.15. Lubricants
Greases
2.16. Explosive substances at the location of use
Gases, dusts
810-53711-1 Page 12 / 57
Rev.: 003
31/07/2017
Page 13
Residual risks
Remedy
Operation in potentially explosive areas
Deviating installation position.
Loss of correct low-level signal function.
Maintain installation position (± 5°). Correct
installation position, if necessary.
Heat-up of non-lubricated lubrication points
in the area of ignition temperature through
undetected faults within the centralized
lubrication system.
The operator must check thoroughly whether an
operation without low-level signal leads to a new
hazard potential (e.g. through heat-up of bearing
points on the machine in the area of ignition
temperature). If uncertain, provide low-level signal.
Heat-up of components in the area of
ignition temperature or formation of a
potentially explosive atmosphere through
whirling up of dust.
Avoid dust accumulation and remove dust
regularly. Select a location of installation with as
little dust as possible.
Strong heating up of the motor in case of
high load or failure of the motor circuit
breaker.
Switch the pump off. Let parts cool down, eliminate
cause. Replace the motor circuit breaker or adjust
it correctly.
Loosening of plug-in connections under
voltage.
Secure plug-in connections against inadvertent
loosening by means of safety clips. Prior to
loosening the plug-in connections: de-energise the
pump.
Generation of electrostatic charges or
sparks through unsuitable clothing or tools.
Within potentially explosive areas use ESD clothing
and tools only.
Generation of sparks through dropping
parts.
Secure parts against falling. Where appropriate,
cover parts in order to avoid the formation of
sparks.
Missing or insufficient grounding
Check the grounding on the pump.
Bringing catalytic, unstable or pyrophoric
substances into a potentially explosive
area.
Ensure that none of these substances gets into the
potentially explosive area. Have all substances
approved by the operator.
Use of isolating amplifiers to operate the
capacitive sensor in potentially explosive
areas.
Mount isolating amplifiers outside potentially
explosive areas only.
Operation with damaged or lacking ATEX
painting or ATEX painting done wrongly
later on and not complying with the
standards applicable for ATEX
Before the first start-up and later at regular
intervals check the painting and let it be renewed
by authorized personnel, where appropriate.
Operating Instructions
Pump ZPU 08 ATEX
2.17. Existing residual risks
810-53711-1 Page 13 / 57
Rev.: 003
31/07/2017
Page 14
Residual risks
Remedy
Transport lifecycle
Tilting or falling of parts during
transport, e.g. over inclines.
Secure parts against tilting or falling during transport
(e.g. using tapes, belts, ropes, etc.).
Installation life cycle
Dropping of lifted parts or tools.
No people may remain under suspended loads. Keep
unauthorized persons away. Secure suspended loads
using suitable hoisting equipment (e.g. tapes, belts,
ropes, etc.).
Falling of parts due to insufficient
fixing to the machine.
Fix parts only to machine parts with sufficient load
capacity. Observe the weight. Observe the stated
tightening torques. If no tightening torques are stated,
the tightening torques are to be applied according to the
screw size for 8.8 screws.
Electric shock when connecting the
pump.
Prior to connection of the pump, de-energize all
affected electrical components. If necessary, please
observe discharge times. The electrical connection may
be carried out by commissioned and qualified
electricians only and in accordance with the connection
diagram.
People falling due to
contamination of floors with spilled
lubricant.
Take care when filling. Bind and remove leaked or
spilled lubricant immediately with a suitable agent.
Observe the legal or company regulations on dealing
with oils and greases and contaminated parts.
Ripping out or damage to lines when
assembling movable machine parts
(e.g. pivot arm).
If possible, do not mount onto movable parts. Should
this not be possible, use flexible hose lines of sufficient
length.
Deviating installation position.
Foreign objects falling into the motor
air intake.
Borehole for drainage of condensation
water is no longer at the lowest point
of the motor.
Installation of a suitable protective roof over the air
intake.
Deviating installation position only, if the formation of
condensation water has been completed.
Operating Instructions
Pump ZPU 08 ATEX
810-53711-1 Page 14 / 57
Rev.: 003
31/07/2017
Page 15
Residual risks
Remedy
Lifecycle Commissioning/ operation/ maintenance
Lubricant spraying out due to incorrect
screw connection of components or
lines.
Tighten all parts with appropriate tightening torques.
Use suitable hydraulic screw connections and lines
for the stated pressures. Check these prior to
commissioning for correct connection and damage.
Contact with the stirring paddle when
filling from the top during operation of
the pump.
Fill preferably via the filling connection. Fill only from
the top when the pump is not moving. When filling,
do not reach into the reservoir.
Electric shock through reduced
insulation resistance.
Check the formation of condensation water in the
motor regularly. If applicable, drain off condensation
water at the drain plug.
Check the insulation resistance regularly.
Electric shock when connecting the
pump.
Prior to connection of the pump, de-energize all
affected electrical components. If necessary, please
observe discharge times. The electrical connection
may be carried out by commissioned and qualified
electricians only and in accordance with the
connection diagram.
Residual risks
Remedy
Fault lifecycle
Severe heat-up or defect of motor
through blockage.
Switch the pump off. Let parts cool down, eliminate
cause.
Residual risks
Remedy
Disposal lifecycle
Contamination of the environment with
lubricant and wetted
parts.
Dispose of the parts following the valid legal and
company regulations.
Operating Instructions
Pump ZPU 08 ATEX
810-53711-1 Page 15 / 57
Rev.: 003
31/07/2017
Page 16
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.
2.20. Specialist for maintenance and repairs in potentially explosive
atmospheres
A person who is qualified by training and experience to identify and assess
possible risks and hazards during work on the machine or partial components in
potentially explosive areas and to initiate suitable measures to prevent such risks.
The specialist has knowledge of the different ignition protection types, installation
procedures and zone divisions. He is familiar with the rules and regulations
relevant for his activities and explosion protection, in particular with ATEX directive
94/9 EG.
2.21. Protection of special groups of persons
The respective legal employment restrictions do apply.
Persons with cardiac pacemakers and/or
metal implants
Magnetic fields existing in the environment of live conductors and motors may
present a hazard to above-mentioned persons. Should it be necessary for them to
access such areas, a doctor should be consulted beforehand, as health
impairments cannot be excluded generally.
810-53711-1 Page 16 / 57
Rev.: 003
31/07/2017
Page 17
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.
Familiarize yourself with the functions and operation of the product. The
specified assembly and operating steps and their sequences must be
observed.
Any unclear points regarding proper condition or correct assembly/
operation must be clarified. Operation is prohibited until issues have been
clarified.
Keep unauthorized persons away from the machine.
Precautionary operational measures and instructions for the respective
work must be observed.
Responsibilities for different activities must be clearly defined and
observed. Uncertainty seriously endangers safety.
Safety-related protective and emergency devices must not be removed,
modified or affected otherwise in their function and are to be checked at
regular intervals for completeness and function.
Remedy occurring faults in the frame of responsibilities. Immediately
inform your superior in the case of faults beyond your competence.
Do not open the reservoir lid during operation. Do not reach into the
reservoir.
Wear personal protective equipment always.
When handling lubricants, adhere to the respective safety data sheets.
Never use parts of the centralized lubrication system or of the machine as
standing or climbing aids.
810-53711-1 Page 17 / 57
Rev.: 003
31/07/2017
Page 18
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. Should such indications become apparent,
switch off the machine and inform a superior without delay. Keep
unauthorized persons away.
Measures for explosion protection must never be deactivated, modified or
bypassed.
It is forbidden to bring in ignition sources such as sparks, open flames and
hot surfaces in potentially explosive areas.
Check the machine at regular intervals for damage which may represent
an ignition risk.
The ignition temperature of the lubricant must lie at least 50 K over the
maximum admissible surface temperature of the components.
Only use tools and clothing which are permitted for use in potentially
explosive areas (ESD).
Transport, installation, repairs and work on electrical components may only
be carried out, if it has been ensured that the atmosphere is not potentially
explosive.
Repairs or modifications to machines which are protected against
explosions may be carried out only by the manufacturer or by a workshop
recognized by a named institution and confirmed in writing. If the work is
not carried out by the manufacturer, the repairs must be approved by a
named expert and confirmed in writing. The repairs are to be marked by a
repair sign on the machine, stating the following:
o Date
o Company responsible for the work
o Type of repair
o If applicable, expert's code
Transport damages can result in the loss of the explosion protection. If
transport damages can be seen, do not assemble the machine or put it into
operation
810-53711-1 Page 18 / 57
Rev.: 003
31/07/2017
Page 19
Operating Instructions
Pump ZPU 08 ATEX
All parts of the grounding concept must be correctly available and
connected with the superordinate machine.
If transport lugs are dismantled after set-up, the threaded bores must be
permanently sealed in accordance with the protection class.
Handle the materials so that no sparks generated by tilting, falling, sliding,
rubbing, impacting, etc. If needed, cover materials with suitable means.
Never disconnect plug-in connections when energized. Secure plug-in
connections against inadvertent manual disconnection with the safety clips
included in the delivery.
The operator must check thoroughly whether an operation without low-
level signal leads to a new hazard potential (e.g. through heat-up of
bearing points on the machine in the area of ignition temperature). If this
cannot be ascertained, provide a low-level signal or suitable organisational
measures for monitoring of the bearing point temperature.
Avoid dust accumulation and remove dust immediately. Dust
accumulations have a thermally insulating effect and, if whirled up,
generate the formation of a potentially explosive atmosphere.
The pump should be integrated into the operator's lightning protection
concept.
All parts are to be checked regularly for corrosion. Replace the affected
parts.
Terminal boxes must be firmly closed and the cable breakthroughs
correctly sealed.
Additional electrical monitoring devices must be firmly connected and
correctly adjusted.
Protect the motor with a motor circuit breaker against inadmissible heating
up.
When reaching their nominal life, the motor bearings have to be replaced
or inspected to ensure their suitability for further utilisation.
810-53711-1 Page 19 / 57
Rev.: 003
31/07/2017
Page 20
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.
If protective and safety equipment has to be dismantled, it must be
reassembled immediately after finishing the work, and then checked for
correct function.
Ensure through suitable measures that movable or detached parts are
immobilized during the work and that no limbs can be caught in between
by inadvertent movements.
Carry out transport using only suitable hoisting equipment.
All the parts to be mounted onto the shaft end of the motor have to be
dynamically balanced according to the balancing system of the motor. With
a direct coupling, ensure that the parts align precisely (observe the
manufacturer's guidelines).
Assemble the product only outside of the operating range of moving parts,
at an adequate distance from sources of heat or cold.
Dry wet, slippery surfaces.
Cover hot or cold surfaces accordingly.
Prior to performing work, de-energize and depressurize the pump and
secure it against unauthorized switch-on. Work on electrical components
must be carried out by electrical specialists only. Observe any waiting
periods for discharging, if necessary.
Carry out electrical connections only according to the information in the
valid wiring diagram and taking the relevant regulations and the local
connection conditions into account.
Do not touch cables or electrical components with wet or damp hands.
Maintenance and repair work can be subject to restrictions in low or high
temperatures (e.g. changed flow properties of the lubricant). Therefore,
where possible, try to carry out maintenance and repair work at room
temperature.
810-53711-1 Page 20 / 57
Rev.: 003
31/07/2017
Page 21
Operating Instructions
Pump ZPU 08 ATEX
Carry out all works on electrical components using voltage insulated tools
only.
Fuses must not be bypassed. Always replace fuses by such of the same
type.
Ensure correct grounding of the electrical system.
Undertake drilling at non-critical, non-load bearing parts only. Use any
available boreholes. Do not damage lines and cables when drilling.
Observe possible abrasion points. Protect the parts accordingly.
Other units of the machine or vehicle must not be damaged or impaired in
their function by the installation of the centralized lubrication system.
All components used must be designed for:
o maximum operating pressure
o maximum/ minimum ambient temperature
o lubricant to be supplied
o required ATEX zone
o operating/ ambient conditions at the location of use
Parts of the centralized lubrication system must never be subjected to
torsion, shearing or bending.
Check all parts prior to use for contamination and clean, if necessary.
Lubricant lines should be primed with lubricant prior to installation. This
makes the subsequent ventilation of the system easier.
Observe the specified tightening torques. When tightening, use a
calibrated torque wrench.
When working with heavy parts use suitable lifting tools.
Avoid mixing up or wrong assembly of dismantled parts. Mark these parts
accordingly.
810-53711-1 Page 21 / 57
Rev.: 003
31/07/2017
Page 22
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.
Illegible or missing warning labels are to be replaced without delay.
The machine is correctly earthed.
2.27. Cleaning
Risk of fire and explosion when using inflammable cleaning agents. Only
use non-flammable cleaning agents suitable for the purpose.
Do not use any aggressive cleaning agents.
Do not use sharp-edged or spark-generating tools for cleaning (e.g. cooling
fins of the motor).
Do not use steam jet or high pressure cleaners. Electrical components may
be damaged. Observe the IP protection class.
Cleaning work on energized components may be carried out by electrical
specialists only.
Do not touch cables or electrical components with wet or damp hands.
Mark damp areas accordingly.
Remove dust accumulations regularly. Do not whirl up dust whilst doing so.
2.28. Operator obligations
2.29. Determination of hazards
The operator must determine all hazards resulting from the integration of the pump
into the superordinate machine and the hazards at the location of operation of the
machine, and carry out the measures necessary to ensure safety and health
protection.
810-53711-1 Page 22 / 57
Rev.: 003
31/07/2017
Page 23
Operating Instructions
Pump ZPU 08 ATEX
2.30. Explosion protection - measures following ATEX
Due to a holistic assessment of the workplace, the operator ensures that the
working equipment and all installation materials are suitable for operation in
potentially explosive areas, and that they are assembled, installed and operated so
that they do not give rise to explosions.
If changes, extension and/or redesigns are undertaken in potentially explosive
areas, the operator must carry out the required measures so that these changes,
extensions or redesigns fulfil the minimum regulations for explosion protection.
The operator
documents the measures for explosion protection.
marks the potentially explosive areas.
prepares written operating instructions.
selects suitable employees.
Provides these employees with sufficient and appropriate instructions
with reference to explosion protection.
applies an approval system for hazardous activities and for those which
may become hazardous in interaction with other work.
carries out the necessary inspections and monitoring.
ensures that only original spare parts are used.
2.31. Provision of necessary information
The operator must make the instructions required for the respective activity
accessible to all people commissioned with operation, maintenance and repairs.
He must ensure that these people have read the necessary instructions and have
understood them.
The same applies for all relevant safety data sheets, company instructions,
accident prevention regulations, instructions from suppliers of purchase parts and
utilities.
Depending on the business organization, the relevant instructions may have to be
made accessible to other people and departments.
810-53711-1 Page 23 / 57
Rev.: 003
31/07/2017
Page 24
Operating Instructions
Pump ZPU 08 ATEX
2.32. Instruction / qualification obligations
The operator clearly determines the responsibility of personnel for operation,
installation and repairs. The operator is obliged to instruct all people authorized for
use in the correct handling of the machine prior to initial use, in accordance with
the respective activity and area of responsibility, based on practical exercises.
The instructions must contain at least:
zone divisions
scope and limits of the activity and area of responsibility of the respective
group of people.
safe behaviour and behaviour in case of emergency.
avoidance of hazards when dealing with the machine.
meaning of warning guidelines and warning labels
dealing with lubricants and cleaning agents.
use and inspection of personal protective equipment, where appropriate.
These instructions are to be documented and repeated at regular intervals. New
personnel may operate the machine under supervision and instruction by
experienced personnel only. Maintenance and repair work may be carried out by
qualified personnel only.
2.33. Briefing of external technicians
Prior to commencing the activities, external technicians must be informed by the
operator of the company safety provisions, the applicable accident prevention
regulations to be maintained, and the functions of the superordinate machine and
its protective devices.
2.34. Inspection for correct use
The operator must check at regular intervals through suitable measures that the
machine is being used according to its intended purpose, that no conversions or
manipulations have been made to the machine and that all parts are fully
functional.
2.35. Provision of personal protective equipment
The operator must provide suitable personal protective equipment for the
respective location of operation and the purpose of operation. This includes ESD
clothing and ESD tools for work in potentially explosive atmospheres.
810-53711-1 Page 24 / 57
Rev.: 003
31/07/2017
Page 25
Do not burden / this side up!
Protect against moisture
Handle with care!
Fragile, do not throw!
Operating Instructions
Pump ZPU 08 ATEX
2.36. Training courses
In order to provide a maximum of safety and economic viability, SKF carries out
detailed training courses. It is recommended that the training courses are attended.
Please contact SKF Customer Service for information.
2.37. Inspection of the delivery
The delivery must be inspected for completeness based on the delivery papers.
Transport damages must be reported to the forwarder immediately. Keep the
packaging material until any discrepancies are resolved.
2.38. Returns
Clean all parts and pack them properly before returning them. Mark returns on the
packaging as follows.
2.39. Disposal
At the end of its service life, the pump must be dismantled correctly and disposed
of according to the respective valid provisions.
It is forbidden to use parts of a pump that is to be disposed of or to assemble these
parts to make a new pump.
Electrical components:
Dispose of or recycle electrical components following WEEE directive 2012/19/EU.
Plastic or metal parts
can be disposed of with commercial waste.
810-53711-1 Page 25 / 57
Rev.: 003
31/07/2017
Page 26
Operating Instructions
Pump ZPU 08 ATEX
3. Lubricant
Lubricants are used specifically for certain application purposes. In order to fulfil
their tasks, lubricants must fulfil various requirements to varying extents. The most
important requirements for lubricants are:
Reduction of abrasion and wear
Corrosion protection
Noise minimisation
protection against contamination or penetration of foreign objects
Cooling (primarily with oils)
longevity (physical/ chemical stability)
Compatibility with as large a number of materials as possible
economic and ecological aspects.
3.1. Selection of lubricants
A suitable lubricant is selected already when designing the machine and forms the
basis for the planning of a centralized lubrication system.
The selection is made by the manufacturer/ operator of the machine, preferably
together with the lubricant supplier based on the requirement profile defined by the
specific application.
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.
3.2. Ageing of lubricants
After a prolonged downtime, the lubricant must be inspected prior to
recommissioning as to whether it is still suitable for use due to chemical or physical
ageing. We recommend that you undertake this inspection already after a machine
downtime of 1 week. If doubts arise as to the suitability of the lubricant, please
replace it prior to re-commissioning and, if necessary, undertake initial lubrication
manually.
810-53711-1 Page 26 / 57
Rev.: 003
31/07/2017
Page 27
NOTICE
Risk of damage to the machine or system
Do not mix lubricants. This may have unforeseeable effects on the usability and
therefore on the function of the centralized lubrication system.
Due to the multitude of possible additives, it is possible that individual lubricants,
which - according to the manufacturer's data sheets - fulfil the necessary
specification, are not in fact suitable for use in centralized lubrication systems (e.g.
incompatibility between synthetic lubricants and materials). In order to avoid this,
always use lubricants tested by SKF.
Please contact the SKF Service Department for an overview of lubricants tested
by SKF.
DANGER
Risk of explosion
The ignition temperature of the lubricant must lie at least 50 K over
the maximum admissible surface temperature of the components.
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:
steel / grey iron / brass / copper / aluminium
NBR / FPM / ABS / PA / PU
810-53711-1 Page 27 / 57
Rev.: 003
31/07/2017
Page 28
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.: 605-40759-6
II 2G c IIB T3 Gb
Part no.: 605-40759-7
II 2G c IIC T4 Gb
II 2D c IIIC T120 °C Db
Part no.: 605-41759-8
II 2G c IIC T4 Gb
II 2D c IIIC T120 °C Db
Operating pressure is limited to max. 410 bar ± 10 % by a pressure control
valve.
All system parts must be designed for the maximum operating pressure.
Operating Instructions
Pump ZPU 08 ATEX
4. Technical data
4.1. Ambient temperatures
4.2. Explosion protection marking
4.3. Operating pressure
4.4. Installation position
Vertical, i.e. reservoir at top. Maximum deviation ± 5°
4.5. Sound pressure level
< 70 dB (A)
4.6. Maximum set-up height
1000 m above sea level.
4.7. Maximum dust thickness
< 5 mm
4.8. Weight
The weight of the empty pump is approx. 62 kg.
4.9. Gear ratio
i = 20:1
810-53711-1 Page 28 / 57
Rev.: 003
31/07/2017
Page 29
40 XB
40 XL
Used with pump
605-41759-8
605-40759-6
Used with pump
605-46554-7
Operating Instructions
Pump ZPU 08 ATEX
4.10. Reservoir
810-53711-1 Page 29 / 57
Rev.: 003
31/07/2017
Page 30
Width
A
Depth
B
Height
C*
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.
The distance between the motor air intake and any obstacle must total to at least
40 mm. Ensure that the air can flow into the motor without hindrance. Outflowing
air must not be sucked in again directly.
* When planning consider an additional free space of 350 mm above the reservoir
to remove the reservoir lid.
C*
A
B
Operating Instructions
Pump ZPU 08 ATEX
4.11. Space requirements
810-53711-1 Page 30 / 57
Rev.: 003
31/07/2017
Page 31
Nominal voltage
Distance to motors
Ex category 2
For motors up to 500 V
5 mm
gear
Motor
Capacitive sensor
Terminal box
IP 65
IP 55
IP 67
IP 65
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. Close the terminal box dust- and watertight.
In addition to the general valid installation prescriptions for electrical systems, the
electrical connection is carried out in accordance with the applicable national ATEX
regulations, for example:
ElexV
DIN EN 60079-14:2014, VDE 0165-1:2014
Electrical systems in explosive areas
DIN EN 60079-17:2014
Electrical equipment for use in areas with combustible dust
DIN VDE 0100
Tolerance voltage ± 5 %
Tolerance frequency ± 2 %
The waveform and mains symmetry must be maintained so that the motor heat-up
remains within the permitted limits.
The distance to any voltage-carrying or conductive parts has to correspond to the
minimum values following DIN EN 60079-7:2007 / VDE 0170-6:2007.
4.13. IP Types of protection
810-53711-1 Page 31 / 57
Rev.: 003
31/07/2017
Page 32
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
T3
Check valve
Protective fitting
AF 19
80 ± 8 Nm
Check valve (flat-bladed screwdriver)
20 ± 2 Nm
T4
Pressure gauge
AF 22
45 ± 4.5 Nm
T6
Grounding connection lid / reservoir
AF 6
8 ± 1 Nm
T7
Pump to foundation
18 ± 2 Nm
If no tightening torques are stated, the tightening torques are to be applied to the
screw size for 8.8 screws.
T1
T2
T4
T3
T5
T6
Operating Instructions
Pump ZPU 08 ATEX
4.14. Tightening torques
810-53711-1 Page 32 / 57
Rev.: 003
31/07/2017
The rotational direction is always clockwise (CW). Observe the
arrow on the reservoir. The rotational direction of the motor is as
needed.
Page 33
Minimum speed
Maximum speed
10 rpm
85 rpm
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
4.18. Admissible speed of the eccentric shaft
When supplying the pump without motor and gear, speeds must be maintained by
selecting a suitable motor and gear.
4.19. Output
approx. 11.2 dm3/h
This information applies for grease of NLGI class 2 at +20 °C and 100 bar
counterpressure. Deviating conditions such as different NLGI class, temperature or
counterpressure may lead to a deviation in the flow rate. This should be taken into
account when designing the lubrication points.
4.20. Lubricant filter
Filter area: 5.1 cm2
Grade of filtration: 280 μm
810-53711-1 Page 33 / 57
Rev.: 003
31/07/2017
Page 34
The following information is stated on the type identification plate:
Product and manufacturer identification
Model:
Type designation of the pump
MADE IN
GERMANY
Country of origin
Part no.:
Order number / Part number
Manufacturer
CE / EX marking
Electrical information
≤ Ta ≤
Min. / max. ambient temperature
Voltage
Voltage
V AC
Series:
Year of construction/ Order no./ batch
4 figures/ 6 figures/ 3 figures
Frequency
Hz
Observe associated instructions
Control
voltage
Control
Voltage
V DC
WW/YY
Calendar week/ year of construction
Power
Output
watt
Operating Instructions
Pump ZPU 08 ATEX
4.21. Type identification plate
810-53711-1 Page 34 / 57
Rev.: 003
31/07/2017
Page 35
NOTICE
Risk of damage to the machine or system
Prior to initial use or after the storage time ends, prefilled components must
be inspected and replaced, if necessary, in case the lubricant quality has
changed, or filled with lubricant suitable for the application purpose.
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
without vibrations
protected against pests (insects, rodents, etc.)
Temperature range: - 20 °C minimum
+ 40 °C maximum
Air humidity (relative): 90 % maximum
Storage time: 24 months max.
Special storage conditions of the motor
Do not store the motor on the fan cover.
After a longer period of storage, make sure to check the insulation
resistance.
In case of storage > 1 year:
Make sure to observe the grease service life of the ball bearings which is reduced
by 10 % per year.
810-53711-1 Page 35 / 57
Rev.: 003
31/07/2017
Page 36
Type designation
Capacitive sensor (Namur)
Part number
664-34621-3
Rated operating distance
Sn
5 mm in case of flush installation
7.5 mm in case of non-flush
installation
Secured switching distance
≤ (0.72 x Sn) mm
Hysteresis
1….. 20 %
Temperature drift
≤ ± 20 %
Repeatability
≤ 2 %
Ambient temperature
-25 °C - +70 °C
Voltage
nominal 8.2 VDC
Connection diagram
Current consumption, not
activated
≤ 1.2 mA
Current consumption,
activated
≥ 2.1 mA
Switching frequency
0.1 kHz
Output function
2-wire NAMUR
Internal capacity (Ci)
150 nF
Inductivity (Li)
150 µH
Design
Threaded tube M 18 x 1
Dimensions
74 mm
Housing material
Plastic PA12-GF30
Material of active surface
Plastic PA12-GF30, yellow
Admissible pressure onto
front closing cap
≤ 6 bar
Max. tightening torque
Housing nut
2 Nm
Connection
Cable
Cable quality
Ø 5.2 LiYY, PVC, 10 m
Cable cross section
2 x 0.34 mm2
Vibration resistance
55 Hz (1mm)
Shock resistance
30 g (11ms)
Type of protection
IP 67
MTTF
448 years following SN 29500
40 °C
Switching status display
LED, yellow
Fine adjustment
Potentiometer
Approvals
KEMA 02 ATEX 1090X
Marking
II 2G EX ia IIC T6 Gb
II 1D EX ia IIIC T 115 °C Da
max. Ui = 20 V, Ii = 20mA, Pi = 200 mW
Operating Instructions
Pump ZPU 08 ATEX
5. Technical data of the capacitive sensor
810-53711-1 Page 36 / 57
Rev.: 003
31/07/2017
Page 37
Part no.
Type of motor
ATEX no.
Manufacturer
245-13984-6
EDRS80S4
PTB 10 ATEX 3026/01
SEW
Rated power
0.55
kW
Code
---------
Operating mode
S 1 Flange
Ø 120
Rated frequency
60
Hz
IP
55
Rated speed
1715
rpm
Design
B14
Rated voltage
254 / 440
V DC
Size
80
Circuit
D /
Y
Shaft
19x40
Nominal current
2.15
1.24
A
Performance factor
0.81
cos φ
Insulation class
F
Part no.
Type of motor
ATEX no.
Manufacturer
245-13984-7
EDRS80S4
PTB 10 ATEX 3026/01
SEW
Rated power
0.55
kW
Code
---------
Operating mode
S 1 Flange
Ø 120
Rated frequency
50
Hz
IP
55
Rated speed
1415
rpm
Design
B14
Rated voltage
219 – 241 / 380- 440
V DC
Size
80
Circuit
D
Y
Shaft
19x40
Nominal current
2.35
1.36
A
Performance factor
0.81
cos φ
Insulation class
F
Operating Instructions
Pump ZPU 08 ATEX
6. Technical data of the motor
810-53711-1 Page 37 / 57
Rev.: 003
31/07/2017
Page 38
The ZPU 08 pump consists of the
following main components:
(1) Reservoir with stirring paddle,
capacitive sensors for fillinglevel monitoring and
grounding
(2) Pressure gauge
(3) Motor
(4) Gear
(5) Pressure control valve
(6) Pump housing
(7) Lubricant filter
(8) Check valve
Connections:
(A) Pressure line
(B) Relief line
(C) Filling line
DANGER
Risk of explosion
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.
2
7
1
3
4
5
6
A
B
C
8
Operating Instructions
Pump ZPU 08 ATEX
7. Brief description of the pump
810-53711-1 Page 38 / 57
Rev.: 003
31/07/2017
Page 39
Operating principle:
The gear reduces the motor speed to
the necessary speed of the pump.
The eccentric shaft drives the highpressure pump elements and the
stirring paddle. The stirring paddle
homogenizes and vents the lubricant.
The high-pressure pump element
works as a piston pump with two
counter-actively acting pistons that
alternately take in lubricant and
dispense it via the outlet bore to the
pressure line. The outlet channels of
the high-pressure pistons are
controlled by a floating valve piston.
The pump element is driven via a
hollow shaft with eccentric pin and
switch roll, whereby the rotational
movement is transformed into an
oscillating linear movement of the
pump pistons.
This type of drive allows to select or
change the rotational direction of the
pump shaft as needed.
The lubricant supplied by the pump
element is dispensed to the
pressure-line connection via a check
valve and a lubricant filter.
One respectively two sensors
determine the reservoir filling level
(low-level respectively high- and lowlevel indication).
Upper end position
Start of the piston movement
downwards
Downward working stroke
Supply piston 1 displaces the
floating piston upwards together
with the lubricant in front of it.
Lubricant is supplied into the
pressure line via the open outlet
bore. Supply piston 2 generates
a negative pressure that sucks
in lubricant after opening bore II.
Lower end position
Start of the piston movement
upwards
Upward working stroke
By means of the lubricant of the
previous suction stroke, supply
piston 2 displaces the floating
piston downwards.
Lubricant is supplied into the
pressure line.
Supply piston 1 sucks in
lubricant.
Pump ZPU 08 ATEX
810-53711-1 Page 39 / 57
Rev.: 003
31/07/2017
Operating Instructions
Page 40
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.
Manual filling:
Filling procedure must be supervised by a
second person.
Switch the filling pump on.
Fill the reservoir
Switch off the filler pump.
Filling port (C)
Filling via the reservoir lid
Switch the pump off.
Open the reservoir lid (1.1).
Ensure that no dirt enters the reservoir
or the inner side of the reservoir lid. In
case of reservoirs equipped with a
sensor, the sensor must not be
damaged or contaminated.
Fill in lubricant up to a maximum of
1 cm below the reservoir rim.
Reposition and close the reservoir lid
(1.1). Make sure not to crush the
grounding cable.
Switch the pump on.
C
1.1
Operating Instructions
Pump ZPU 08 ATEX
8. Installation and commissioning
8.1. Filling of the reservoir
810-53711-1 Page 40 / 57
Rev.: 003
31/07/2017
Page 41
NOTICE
Risk of damage to the machine
Fill the feed lines with lubricant and fill the lubrication points manually. Otherwise
the bearing points may become damaged due to a lack of lubricant.
Check the entire system for accordance with the intended purpose and the
planning documentation.
Ensure that all parameters, characteristic values and means of operation have
been correctly adjusted or are present.
If deviations are detected, they must be remedied without delay.
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.
Fill in lubricant of correct specification.
Switch the pump on.
Inform your superior to ensure that the error won't occur again.
8.3. Inspections prior to initial start-up
In order to warrant safety and function, a person assigned by the operator must
inspect certain areas of the central lubrication system prior to initial commissioning.
Report any detected deficiencies immediately to your superior and remedy them.
Deficiencies may be remedied by an authorized and qualified specialist only.
Check the following points prior to initial commissioning.
810-53711-1 Page 41 / 57
Rev.: 003
31/07/2017
Page 42
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.
Monitoring devices and additional equipment (e.g. motor circuit breaker)
are correctly connected and adjusted.
Grounding is complete.
All parts such as lines, cables, metering devices, etc. have been correctly
installed and are undamaged.
Mechanics:
No dust accumulations present, in particular on the air intake of the motor.
Loose or missing parts remaining (e.g. pressure relief valves, feed lines).
Damages, deformations, or cracks.
Smoke or smouldering spots.
Discolorations, contaminations and/or corrosion.
Unusual humidity.
Unusual odours, vibrations, or sounds.
Leakages of lubricant at connections and from lines.
8.4. Activation of the pump
The pump is activated on:
Installation into a machine
o By switching on the machine contact.
o By a control provided by the customer.
810-53711-1 Page 42 / 57
Rev.: 003
31/07/2017
Page 43
DANGER
Danger to life
Risk of fire and explosion when using inflammable cleaning
agents. Do not use steam jet or high pressure cleaners.
Electrical components may be damaged.
Do not touch cables or electrical components with wet or damp
hands. Cleaning work on energized components may be carried
out by electrical specialists only.
Wear personal protective equipment always.
Operating Instructions
Pump ZPU 08 ATEX
9. 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.
9.3. Filling of the reservoir during operation
Fill the reservoir as described in the chapter "Installation and commissioning".
9.4. Cleaning
Exterior cleaning
Thorough cleaning of all surfaces with a damp cloth.
Mark and secure wet areas.
Interior cleaning
Normally, interior cleaning is not required.
810-53711-1 Page 43 / 57
Rev.: 003
31/07/2017
Page 44
DANGER
Risk of explosion
When carrying out maintenance, repair or modification works on
explosion-protected machines, observe the legal and operational
prescriptions. If the works are not carried out by the
manufacturer, authorized and qualified personnel only is allowed
to carry out such works. Works then have to be reviewed by a
qualified and officially recognised person.
Carry out work on electrical parts only, if the atmosphere is not
potentially explosive.
Electric shock
Make sure to disconnect the pump from the power supply before
carrying out works on electrical parts.
Operating Instructions
Pump ZPU 08 ATEX
10. 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.
10.1. Maintenance of pump
Any maintenance works may be carried out only while the pump is idle and when
there is no potentially explosive atmosphere.
The pump is mainly maintenance-free.
However, the following parts should be inspected and, if necessary, replaced by
new parts at regular intervals:
Pressure relief valves
Check valves
Lubricant filter
Tolerance frequency of the pressure control valve ± 10 %
If this tolerance is exceeded, the pressure control valve must be replaced.
810-53711-1 Page 44 / 57
Rev.: 003
31/07/2017
Page 45
For further relevant information on maintenance, see original Instructions by the
gear manufacturer.
Activity
Interval
Visual check for:
Leakages
Damages to the surface protection/
corrosion protection
Every 3,000 hours, but at least
once a year
Depending on the type of
application and ambient conditions
Switch the pump off.
Unscrew protective fitting (9.1) from
lubricant filter
(AF 19).
Unscrew lubricant fitting (9)
(SW 11).
Clean lubricant filter with non-
flammable cleaning agents.
Blow lubricant filter with compressed
air from inside two outside - as shown
in the accompanying figure - to avoid
contaminations in the strainer.
Reinstall lubricant filter and protective
fitting.
Tightening torques
Lubricant filter 20 ± 2 Nm
Protective fitting 80 ± 8 Nm
9.1
9
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:
10.3. Maintenance of gear unit
810-53711-1 Page 45 / 57
Rev.: 003
31/07/2017
Page 46
For further relevant information on maintenance, see original Instructions by the
motor manufacturer.
Activity
Interval
Check the airways and
surfaces
Depending on the local degree of contamination, at
the latest, however, every 4 weeks
Initial inspection
After about 500 operating hours, at the latest,
however, after 1/2 a year.
Ball bearing/ radial sealing
ring
Check and, if necessary, replace every 10,000
operating hours
Re-lubrication / oil change
Re-lubrication interval, grease volume and grease
quality see type identification respectively
lubrication plate of the motor
Main inspection
After about 10,000 operating hours, at the latest,
however, after 1 year.
DANGER
Electric shock
Do not touch the terminals when measuring the
insulation resistance. If necessary, wear insulating
gloves. Observe the manual of the insulation
measurement device.
NOTICE
Risk of damage to the motor
The voltage applied for the insulation test must not exceed 500
V.
Operating Instructions
Pump ZPU 08 ATEX
10.4. SEW motor maintenance
10.5. Measurement of the insulation resistance
Before the first start-up and after longer downtimes measure the insulation
resistance following the standards (e. g. VDE 0100 / DIN EN 61557-1:2007) valid in
the country of use.
If the insulation resistance falls below the required minimum value, determine and
eliminate the cause (e.g. appropriate drying of the coil, etc.).
10.6. Maintenance of gear unit
Capacitive sensor:
The capacitive sensor is maintenance-free. Repairs are not possible.
810-53711-1 Page 46 / 57
Rev.: 003
31/07/2017
Page 47
Motor of pump does not run
Possible cause
Visible
Remedy
Fault in the superior machine/
external control unit.
Motor circuit breaker has tripped.
no pump noise
Check power supply lines/
external control/ motor circuit
breaker.
Motor runs, but pump does not supply lubricant
Possible cause
Visible
Remedy
Reservoir empty
by visual check
Refill
Air pockets in the lubricant
Air bubbles in the lubricant
Vent
Contaminated filter
Short deflections on the
pressure gauge (fluttering)
Check and clean filter and
replace, if necessary.
Suction bore of pump element is
clogged.
After disassembling the
pump element
Disassemble and clean the pump
element.
Defective or dirty check valve
After disassembling the
pump element
Replace check valve.
Eccentric shaft or driving parts of
the swivelling lever and the
stirring device defective.
Visual check
Replace the affected parts.
Faults on the change-over device
See instructions of
change-over device.
See instructions of change-over
device.
Blockade in the downstream
lubrication system
Lubricant leaking from the
pressure relief valve
Determine cause and eliminate it.
If the fault cannot be determined/ remedied, contact our Customer Service.
Operating Instructions
Pump ZPU 08 ATEX
11. Troubleshooting
810-53711-1 Page 47 / 57
Rev.: 003
31/07/2017
Page 48
Rehfuss gear
Fault
Possible cause
Remedy
Constant unusual
running noise
Bearing damage
(grinding noise)
Check oil and oil level, if required,
change bearing.
Consult the manufacturer.
Irregular toothing
(knocking noise)
Consult the manufacturer.
Inconstant unusual running noise
Foreign particle in the gear oil
Check oil and oil level (see original
instructions of the gear
manufacturer).
Consult the manufacturer.
Oil / grease leaking from shaft
seal#
Defective seal
Consult the manufacturer.
Oil leaking from vent valve
Too much oil in the gear; vent
valve dirty; frequent cold starts
(foaming oil)
Consult the manufacturer.
Output shaft does not rotate
although motor is on
Defective shaft-hub joint
Sent gear to manufacturer for repair.
For further relevant information on maintenance, see original Instructions by the gear manufacturer. Make
sure to observe these at all times.
#
Oil/ grease leaking from the radial sealing ring (small quantities) during the run-in phase (24 hours
runtime) is deemed normal (DIN 3761).
Operating Instructions
Pump ZPU 08 ATEX
810-53711-1 Page 48 / 57
Rev.: 003
31/07/2017
Page 49
SEW motor
Fault
Possible cause
Remedy
Motor does not start
Feed line interrupted
Check and correct connections, if
necessary.
Blown fuse
Replace fuse
Motor circuit breaker has
responded
Check correct adjustment of motor
circuit breaker. If necessary, remedy
the fault
Motor circuit breaker does not
switch; fault in the control program.
Check control program of motor
circuit breaker and, if necessary,
remedy the fault
Motor is hard to start
Motor has been designed for delta
connection, but has been wired to
star connection
Correct the wiring
Voltage or frequency largely differ
from the target value at least when
starting the motor
Provide better grid conditions; check
cross section of the feed line
Motor does not start
when wired as a star connection,
but only when wired as a delta
connection
In case of star connection torque is
not sufficient
Provided the delta starting current is
not too high, immediately switch the
motor on. Otherwise use larger motor
or special version (after consultation)
Contact fault on star respectively
delta connection
Remedy the fault
Wrong direction of motor rotation
Motor connected wrongly
Reverse two phases
Motor hums and has
a high power consumption
Defective winding
Consult the manufacturer. Motor
must be sent to the workshop for
repair
Rotor touches
Fuse is tripped
or motor circuit breaker trips
immediately
Short circuit in the line
Remedy the short circuit
Short circuit in the motor
Consult the manufacturer. Motor
must be sent to the workshop for
repair
Lines connected wrongly
Correct the wiring
Short circuit on the motor
Consult the manufacturer. Motor
must be sent to the workshop for
repair
Speed decreasing significantly
in case of load
Overload
Measure performance, if necessary,
use larger motor or reduce load
Voltage drops out
Increase cross section of feed line
For further relevant information on maintenance, see original Instructions by the motor manufacturer. Make
sure to observe these at all times.
Operating Instructions
Pump ZPU 08 ATEX
810-53711-1 Page 49 / 57
Rev.: 003
31/07/2017
Page 50
SEW motor
Fault
Possible cause
Remedy
Motor heats up too much
(measure the temperature)
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
Observe admissible temperature
range
Motor is wired to delta connection
instead of planned star connection
Correct the wiring
Feed line has a loose contact
(one phase is missing)
Remedy the loose contact
Blown fuse
Search the cause and remedy (see
above); replace fuse
Mains voltage deviates by more
than 5 % from the rated motor
voltage. Higher voltage is very
unfavourable in case of high-pole
motors, as in case of a normal
voltage their no-load current is
already close to the rated current.
Adapt the motor to the mains voltage
Nominal operating mode (S1 to
S10) exceeded, e.g. because of
too high switching frequency
Adapt the nominal operating mode of
the motor to the required operating
conditions; if necessary, consult an
expert to determine the appropriate
type of drive
Extreme noise emission
Ball bearing strained,
contaminated or damaged
Realign the motor, inspect the ball
bearing and replace it, if necessary
(see original instructions of the motor
manufacturer)
Vibration of the rotating parts
Determine cause, e.g. imbalance,
and eliminate it.
Foreign particle in the cooling
airways
Clean cooling airways
For further relevant information on maintenance, see original Instructions by the motor manufacturer.
Make sure to observe these at all times.
Operating Instructions
Pump ZPU 08 ATEX
810-53711-1 Page 50 / 57
Rev.: 003
31/07/2017
Page 51
Operating Instructions
Pump ZPU 08 ATEX
12. Declarations of conformity of the purchase parts
810-53711-1 Page 51 / 57
Rev.: 003
31/07/2017
Page 52
Operating Instructions
Pump ZPU 08 ATEX
810-53711-1 Page 52 / 57
Rev.: 003
31/07/2017
Page 53
Operating Instructions
Pump ZPU 08 ATEX
810-53711-1 Page 53 / 57
Rev.: 003
31/07/2017
Page 54
Operating Instructions
Pump ZPU 08 ATEX
810-53711-1 Page 54 / 57
Rev.: 003
31/07/2017
Page 55
Operating Instructions
Pump ZPU 08 ATEX
810-53711-1 Page 55 / 57
Rev.: 003
31/07/2017
Page 56
Operating Instructions
Pump ZPU 08 ATEX
810-53711-1 Page 56 / 57
Rev.: 003
31/07/2017
Page 57
Operating Instructions
Pump ZPU 08 ATEX
810-53711-1 Page 57 / 57
Rev.: 003
31/07/2017
Loading...