Lincoln ZPU 08 Operating Instructions Manual
Operating Instructions
Pump ZPU 08 ATEX
ZPU 08
810-53711-1 Page 1 / 57
Rev.: 003
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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
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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
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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
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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
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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.
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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
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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.
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.
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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
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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
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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.
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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
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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
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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
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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
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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.
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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.
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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
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