Grease injection lubrication
system
GVP-S-026-1
Installation and operation manual
Version 01
Date of issue March 2016
Publication number 951-130-453-S026-1
Languages EN
Country/Countries ...
2
Imprint
This manual – containing installation, operation and maintenance instructions complies with EC-Machinery Directive 2006/42/
EC and is an integral part of the described
lubrication system. It must be kept for future
use.
This manual – containing installation, operation and maintenance instructions was
created in accordance with the valid standards and regulations on documentation.
© SKF
This documentation is protected by copyright. All rights reserved. The photomechanical reproduction, copying, and distribution
of this documentation or parts thereof by
means of processes such as data processing,
data carriers, and data networks is strictly
prohibited without the express permission of
SKF.
Subject to editorial or technical
modifications.
English translation of the original manual
in French.
Service
For all technical questions, please contact:
SKF France
Lubrication Business Unit
204, bld Charles de Gaulle
B.P. 239
37540 St-Cyr-sur-Loire
FRANCE
Tel. +33 (0) 247 405 300
Fax +33 (0) 247 405 353
Or an SKF Service Centre, the addresses of
which are given on our website:
www.skf.com/lubrication
Contents
Information concerning the EC Declaration of Incorporation ..................2
General ............................................................3
1 Safety instructions .................................................4
1.1 Intended use ...................................................4
1.2 Authorized personnel .............................................4
1.3 Danger relating to electric current ...................................4
1.4 Danger relating to system pressure ..................................4
1.5 Warranty ......................................................5
2. Lubricants ........................................................5
2.1 General .......................................................5
2.2 Selection of lubricants ............................................5
2.4 Lubricants and the environment .....................................6
2.5 Danger relating to lubricants .......................................6
2.3 Approved lubricants ..............................................6
3 Construction and operation ..........................................7
3.1 Construction ....................................................7
3.2 Function .......................................................9
4 Installation instructions ............................................12
4.1 Positioning and installation ........................................12
4.2 Mechanical adjustments ..........................................13
4.2 Pneumatic connection ...........................................15
4.3 Hydraulic connection ............................................15
4.4 Electric connection ..............................................16
4.5 Proximity switch ................................................16
5 Transport, delivery and storage ......................................18
5.1 Transport .....................................................18
5.2 Delivery ......................................................18
5.3 Storage ......................................................18
6 Commissioning ...................................................19
6.1 General ......................................................19
6.2 Commissioning .................................................19
6.3 Modification of the injector metered volume ...........................20
6.4.2 Lubrication system bleeding .....................................22
7 Shutdown ........................................................23
7.1 Temporary shutdown ............................................23
7.2 Permanent shutdown ............................................23
8. Maintenance .....................................................24
9. Failures .........................................................25
10 Spare parts .....................................................26
11 Technical data ...................................................28
1
Information concerning the EC Declaration of Incorporation
Guillaume Amilien
R&D Manager
SKF France
Lubrication Business Unit
EC Declaration of Incorporation
in accordance with EC-Machinery Directive 2006/42/EC, Appendix II Part B
The manufacturer SKF France, 204, Bld Charles de Gaulle, B.P. 239 – 37540 St-Cyr-sur-Loire – FRANCE, declares herewith the conformity
of the partly completed machine
Designation: Grease injection lubrication system for chains
Type: GVP
No.: GVP-S-026-1G, GVP-S-026-1D
Year of construction: see ID plate
with the following essential health and safety requirements of the EC Machinery Directive 2006/42/EC when released on the market.
1.1.2 · 1.13 · 1.3.2 · 1.3.4 · 1.5.1 · 1.5.6· 1.5.8 · 1.5.9 · 1.6.1 · 1.7.1 · 1.7.3 · 1.7.4
The relevant technical documentation is compiled in accordance with part B of Annex VII of this Directive. We undertake to transmit in electronic format the relevant technical documentation in response to a reasoned request by the competent national authorities. The person
empowered to draw up the declaration is the technical standards manager. See the manufacturer's address.
Furthermore the followings directives and (harmonized) standards have been applied.
2011/65/CE RoHS II
2014/30/EU Electromagnetic compatibility | Industry
Standard Issue Standard Issue Standard Issue Standard Issue
NF EN ISO 12100 12-2010 NF EN 50581 01-2013 NF EN 61000-6-1 03-2007 NF EN 61000-6-4 03-2007
NF EN 809+A1 12-2009 NF EN 60947-5-1 09-2004 NF EN 61000-6-2 01-2006 NF EN 61000-6-3 03-2007
NF EN 60204-1 09-2006
The partly completed machine must not be put into service until the final machinery into which it is to be incorporated has been declared in
conformity with the provisions of the EC Machinery Directive 2006/42/EC and other relevant Directives.
St Cyr-sur-Loire, April 3rd, 2015
Gérard Gaudin
Production unit manager
SKF France
Lubrication Business Unit
2
General
Meaning of symbols and corresponding
information
In this manual, the symbols and safety wordings shown on this page
are intended to communicate a particular risk to persons, material
assets, or the environment.
All safety instructions must be respected by person exposed to
these risks. The safety instructions must be communicated to all
other persons.
Instructions attached directly to the equipment, such as
• rotational direction arrows
• fluid connection labels, etc.
must be respected and remain perfectly legible.
It is essential to read these instructions thoroughly and to respect
the safety instructions given.
Table 1
Hazard symbols
Symbol Standard Meaning
DIN 4844-2 W000 General hazard
DIN 4844-2 W008 Voltage
DIN 4844-2 W026 Hot surface
DIN 4844-2 W028 Slippery floor
DIN 4844-2 W027 Risk of hand injury
DIN 4844-2 W55 Risk of pollution
3
!
These instructions must be read and understood by all
persons who are involved with the installation, operation,
maintenance, and repair of the product. These instructions must
be kept close to the equipment for future reference.
Note that these installation instructions is an integral part of
the product. It must be handed over to the new operator of the
product if the product is sold.
!
In addition to the information provided in the installation
instructions, all generally applicable regulations on acci-
dent prevention and the environment must be observed.
!
All products from SKF may be used only for their intended
purpose as described in this brochure and in any
instructions.
DANGER!
Working on products that have not been disconnected
from the power supply can cause serious injury or death to persons. Installation, maintenance, and repair work may only be
carried out by qualified experts on products that have been disconnected from the power supply. The supply voltage must be
turned off before any product components are opened.
DANGER!
Centralized lubrication systems are under pressure when
they are being operated. Such systems must therefore be depressurized before starting installation, maintenance, or repair
work and before making any changes to the system.
The described product was manufactured in accordance with all
generally acknowledged regulations pertaining to technology, occupational safety, and accident prevention. However, dangers that can
cause physical injury to persons or damage to other material assets
might still occur during the use of the product.
1 Safety instructions
1.1 Intended use
1.4 Danger relating to system pressure
The product is designed for the lubrication of moving conveyor
chains. Other use or use beyond this purpose is considered
unintended.
Products of SKF must not be used in conjunction with fluids,
group I (hazardous fluids), according to the definition of article 2
paragraph 2 of the Directive 67/548/EC dtd. 27th June, 1967; and
are not approved for application with such fluids.
None of the products manufactured by SKF can be used in conjunction with gases, liquefied gases, pressurized gases in solution
and fluids with a vapor pressure exceeding normal atmospheric
pressure (1013 mbar) by more than 0,5 bar at their maximum permissible temperature.
Unless otherwise noted, products of SKF must not be used in
conjunction with explosive atmospheres according to the ATEX-Directive 2014/34/UE.
1.2 Authorized personnel
The products described in the installation instructions may only be
installed, operated, maintained, and repaired by qualified experts.
Qualified experts are persons who have been trained, instructed,
and familiarized with the end product into which the described product is installed.
These persons are considered capable of such tasks due to their
education, training, and experience with valid standards, conditions,
accident prevention regulations in effect, and installation conditions.
They should be able to carry out the required tasks and to recognize
– and thus avoid – any dangers that might otherwise occur.
A definition of what constitutes a qualified person and who are
unqualified persons are stipulated in DIN VDE 0105 and IEC 364.
1.3 Danger relating to electric current
The electrical connection for the described product may only be established by qualified, instructed persons who have been authorized
by the operator or owner to carry out this task. If the product is improperly connected, substantial material or personal damage my be
the consequence.
4
!
All SKF products must only be used for their intended
purpose and in accordance with the specifications of the
installation instructions for the product in question.
!
You must observe the machinery manufacturer's information on the lubricants to be used in the machinery.
DANGER!
The manufacturer of the bearing or machinery to be lubricated will specify the lubricant requirements for each point to
be lubricated. You must make sure that the required quantity of
lubricant is provided to the relevant lubricating point. If a lubricating point is insufficiently lubricated, the bearing may become
damaged or jammed.
2. Lubricants
2.1 General
The intended use of this product is for the centralized lubrication/lubrication of bearings and wear points with lubricants. All physical
limitations of use stipulated in the documentation of the product
such as the owner’s manual, technical drawings and catalogs must
be observed.
Hazardous materials of any kind, especially the materials classified as hazardous by European Community Directive EC 67/548/
EEC, Article 2, Par. 2, may only be used to fill SKF centralized lubrication systems and components and delivered and/or distributed
with the same after consulting with and receiving written approval
from SKF.
All products manufactured by SKF are not approved for use in
conjunction with gases, liquefied gases, pressurized gases in solution and fluids with a vapor pressure exceeding normal atmospheric
pressure (1013 mbar) by more than 0,5 bar at their maximum permissible temperature.
Should there be a need to use the product to convey media other
than lubricants or hazardous substances, this must be discussed
with SKF first and the company must give express written
permission.
In the opinion of SKF, lubricants constitute a design element that
must be considered when selecting components and designing centralized lubrication systems. The lubrication properties of the lubricants in question must be considered.
2.2 Selection of lubricants
1.5 Warranty
The instructions do not contain any information on the warranty.
This can be found in the General Conditions of Sales, which are
available at: www.skf.com/lubrication.
5
DANGER!
Only lubricants that have been approved by SKF for use
with the product may be used. Unsuitable lubricants can cause
product malfunctions and damage to property.
DANGER!
Different lubricants must not be mixed together. Doing so
can cause damage and require extensive cleaning of the products/centralized lubrication system. To prevent confusion, we
recommend that you attach information indicating the lubricant
to be used on the lubricant reservoir.
The described product can be operated with lubricants that comply
with the specifications in the technical data.
Note that some lubricants may have properties that lie within the
permitted limit values and yet not be suitable for use in centralized
lubrication systems for other reasons. For example, some synthetic
lubricants are not compatible with elastomers.
DANGER!
Lubricants can contaminate the ground and watercourses. Lubricants must be used and disposed of in compliance with
the rules. Instructions and local regulations must be observed
when handling lubricants.
DANGER!
Centralized lubrication systems must be absolutely leakfree. Leaking centralized lubrication systems can cause a slip
hazard. When performing installation, maintenance, and repairs
test the centralized lubrication system for leaks. Leaky parts of
the centralized lubrication system or components of the lubrication equipment have to be sealed immediately.
Leaking centralized lubrication systems or components of the lubrication equipment are a source of danger in relation to slip hazard
and the risk of injury. These dangers can cause physical injury to
persons or damage to other material assets.
Refer to safety precautions in the lubricant manufacturer's mate-
rial safety data sheet.
Lubricants are hazardous substance. It is essential to respect any
safety instructions given in the lubricant safety data sheet. You can
ask the manufacturer of the lubricant for the material safety data
sheet.
2.4 Lubricants and the environment
Note that lubricants are harmful to the environment and flammable;
their transportation, storage, and processing are subject to special
precautionary measures. For specifications on transportation, storage, processing, and dangers to the use and the environment for the
lubricant, refer to the material safety data sheet provided by or available from the lubricant manufacturer. You can ask the manufacturer
of the lubricant for the material safety data sheet.
2.5 Danger relating to lubricants
2.3 Approved lubricants
!
If required, SKF can help customers to select suitable
components for the conveyance of the selected lubricant
and to plan and design their centralized lubrication system.
While the machinery/bearing manufacturer usually specifies lubricants, it is the owner/operator (or maintenance person) who must
finally select the appropriate lubricant, with the help of the lubricant
supplier. When selecting a lubricant, the type of bearing/wear point,
the stresses and strains to be expected during operation, and anticipated ambient conditions must be taken into account. All financial/
economic aspects must also be considered.
If you have further questions, you can contact SKF.
We can test lubricants in our own laboratory to establish their
suitability for conveyance (e.g. 'oil separation' behavior) in centralized
lubrication systems.
You can request an overview of lubricant tests offered by SKF
from our Service Center.
6
Fig. 1
GVP unit
1
3
10
2
11
7
4
8 9
12
6
Legend fig. 1
1 Air inlet
2 Lubricant inlet
3 Carriage return cylinder
4 Stop cylinder
5 Capstan
6 Injector
7 Analog pressure sensor (for VisioLub*)
8 Injector cylinder
9 Lubricant treatment unit (pressure gauge,
pressure regulator)
10 Injector carriage
11 Pneumatic unit (pressure gauge, pressure reg-
ulator, filter)
12 Limit switch (safety)
*
According to the model and the control unit of the GVP system
3 Construction and
operation
3.1 Construction
A GVP grease injection lubrication system
includes all the mechanical, hydraulic, pneumatic and electrical components required to
lubricate moving conveyor chains.
!
Different components can be
used on the GVP system. Their
position can also differ. The main functions are the same. They might be also
some slight dimension differences.
For further information, please refer to
the technical documentation delivered
with the GVP system or contact the SKF
Service Center.
5
7
B
35
12
40
6
3
60
655
6
8
5
1
0
71
0
1
0
7
3
0
1
0
580
502
155
5
175
117
115 30
10
15
30
74
334
8
310
50
100
Ø8 (×6)
M8 (x4)
M8 (x4)
Fig. 2
GVP-S-026-1G dimensions
chain movement direction
chain movement direction
8
Fig. 3
Example of the lubrication installation for sterilizer
1 Pneumatic control unit
2 Pneumatic drum pump
3 Lubricant drum
4 Control and monitoring unit
5 Proximity switch
6 GVP grease injection lubrication system
1
3
3
6
6
7
7 Sterilizer conveyor
Blue line: pneumatic line
Black line: grease line
Brown line: electric cable
5
2
3.2 Function
3.2.1 Lubrication unit
A chain lubrication system comprises the different pneumatic, hydraulic, mechanical and electronic components necessary to an optimal lubrication. The figure beneath shows an example of a lubrication installation. It comprises the following main elements:
• Tw o GVP lubrication systems. They are mounted close to the
chain and they inject the lubricant directly in the chain nipples. A
control unit controls and monitors them and a drum pump type
PT supplies lubricant.
• A control and monitoring unit (customer). It triggers the lubri-
cant injection according to the signals it receives from the proximity switch. It monitors the function of the GVP system by means of
the different sensors on the system. It controls also the pneumatic
control unit.
• A pneumatic drum pump, type PT to supply lubricant to the GVP
system. It is actuated by a pneumatic control unit.
• A pneumatic control unit to actuate the pneumatic drum pump.
It is controlled by the control unit.
• A proximity switch on the chain to detect the lubrication points. It
sends a corresponding signal to the control unit.
9
3.2.2 GVP system
The function principle of the grease injection system for the lubrication of conveyor chains is more or less the same for all systems.
However some models differ from others by the type of lubrication
points, the number of injection heads, etc.
!
In the following description of the GVP system function
the chain runs upwards.
But a sterilizer chain can also run horizontally, downwards or
with a slope. The used GVP system is always design for a given
application.
Start position
• The chain is running
• The GVP system waits
• The carriage with the injector is in its initial position
• The capstan turns freely with the chain
• No signal from the proximity switch
Detection of the lubrication point by the
proximity switch
• The proximity switch sends a signal to the
control unit of the GVP system
• The control unit triggers a lubrication
• The stop cylinder is actuated and blocks
the capstan
10
Injection phase
• The capstan is blocked by the stop
• The chain moves the carriage with the
injector
• When the carriage starts, the injector cylinder is actuated
• The injector comes in contact with the
roller greaser
Lubricant injection
• The capstan is blocked by the stop
• The carriage with the injector moves in
parallel with the chain
• The injector injects lubricant in the greaser of the roller
End of the lubrication phase
• The injection time is over
• The return of the injector cylinder is driven. The injector disengages from the
greaser and comes back to its initial
position
• The return of the stop cylinder is driven.
The stop comes back to its initial position.
• The capstan is not blocked anymore by
the stop and turns again freely with the
chain
• The return of the carriage cylinder is driven. The carriage with the injector comes
back to its initial position.
• When all components are back to their
initial position, the GVP is waiting for the
next injection
!
The contact time between the in-
jector and greaser is given by the
control unit that controls the GVP system. The injected volume of lubricant
does not depends on the time but on the
metering piston stroke of the injector
(see Modification of the injector metered
volume).
11
4 Installation instructions
The lubrication system described in the mounting instructions may
only be installed, operated, maintained, and repaired by qualified
experts. Qualified personnel are persons who have been trained, instructed, and familiarized by the user of the end product into which
the system is installed. These persons are considered capable of
such tasks due to their education, training, and experience with valid
standards, conditions, accident prevention regulations in effect, and
installation conditions. They should be able to carry out the required
tasks and to recognize – and thus avoid – any dangers that might
otherwise occur.
A definition of what constitutes a qualified person and who are
unqualified persons are stipulated in DIN VDE 0105 and IEC 364.
Before installing/positioning the lubrication system, remove the
packaging material and any transportation safety devices such as
sealing plugs. Keep the packaging material until any and all problems have been clarified.
Country-specific accident prevention regulations and the operating and maintenance instructions for the operator must be observed
when carrying out all installation work on machines.
!
For the product-specific technical data on a specific lubri-
cation system, see the relevant documentation. If you do
not have access to this documentation, you can request it directly from SKF.
DANGER!
All installation, setting, maintenance and repair works on
the lubrication system must be carried out only when the conveyor is off duty. Working closed to a running conveyor chain
may cause operator's injuries and/or important material
damages.
4.1 Positioning and installation
The lubrication system must be protected from vibrations but on the
other hand mounted so that it is easily accessible to ensure that all
further installation work can be carried out without difficulty. Ensure
that there is sufficient circulating air to prevent the system from
overheating. For information on the maximum admissible ambient
temperature, see the technical data section.
Fig. 4
20 mm
!
Mounting dimensions
Please refer to the lubrication system general drawing for
the mounting dimensions. This drawing is delivered with the lubrication system. If you do not have this drawing, please contact
the SKF Service Centre to get it.
!
Moving direction
You have to take in account the moving direction of the
chain when installing the lubrication system. A wrong installation
of the system will lead to the destruction of the system and important damages on the chain. The moving direction is indicated
with an arrow on the GVP system.
• The lubrication system is mounted along on the side of the chain
and fixed on brackets previously fitted by the user.
• The GVP system must be mounted according to the motion direction of the chain.
• The GVP system has four fixing points.
• The injection head must be at a distance of ca. 20 mm from the
grease nipple († fig. 4)
• The capstan finger († pos. 5 fig. 8) must come between the two
inner plate of the chain and must be aligned with the stop head
(† pos. 6 fig. 8).
12
Fig. 6
1
2
4.2 Mechanical adjustments
!
The position setting must be carried out at the same time
on both sides of the lubrication system. The adjustment of
only one side of the system may cause material damages on the
lubrication system (misalignment).
DANGER!
Adjustments to the pick-up system must only be made
when the pneumatic feed is shut off and the chain stopped.
The position of the lubrication system must be mechanically adjust
to optimize the lubrication process. Several mechanical adjustment
can be carried out:
4.2.1 Position of the injector
The injector must be correctly centered with regard to the lubrication
point and be at a distance of 20 mm for the greaser. The position of
the injector is set according to three axis († fig. 5).
4.2.1.1 A axis
The A axis corresponds to the 20 mm maximal distance between the
injector and the greaser. Do this adjustment when installing the
frame of the GVP system. It is hard to modify it later. Take all necessary measures to reach the distance.
!
The intermediate supports between the GVP system and
the client's machine are the client's responsibility, except if
specified differently.
A
B
C
Fig. 5
4.2.1.2 B axis
• Loosen the 4 locking screws († pos. 1 fig. 6), 2 locking screws
on each side of the GVP system.
• Tighten or loosen the nuts († pos. 2 fig. 6) to position the injec-
tor with regard to the greaser.
• When the injector is aligned with the greaser, tighten the 4 locking
screws († pos. 1 fig. 6).
13
4.2.2 Position of the capstan
It is possible to adjust the position of the capstan fingers with regard
to the chain inner plates, but above all with regard to the stop head
(† fig. 8).
• Loosen the nut (1)
• Loosen the threaded nut (2)
• Screw on or unscrew the nut (3) with regard to the threaded nut
(2) to adjust the position of the capstan.
• Bring the threaded nut (2) in contact the the steel sheet (4)
• Tighten nut (1)
Fig. 7
1
4.2.1.3 C axis
It is possible to adjust a little the position of the injector with regard
to the C axis. Therefore screw on or unscrew the stop head
(† pos. 1 fig. 6) to slightly modify the axis of the capstan finger.
Fig. 8
4
1
2
3
5
6
14
4.2 Pneumatic connection
The lubrication system must be connected to the client's compressed air network.
The compressed air quality must comply with purity class 5 de-
fined by DIN ISO 8573-1:
– Maximum particle size: 40 µm
– Maximum particle density: 10 mg/m
3
– Dew point: 7 °C
– Maximum water content : 7 800 mg/m
3
– Maximum residual oil content: 25 mg/m
3
The air line is directly connected to the air treatment unit
(† pos. 1 fig. 9) with a quick connector for tube OD 8 mm.
The air treatment unit comprises:
• An isolation valve († pos. 2 fig. 9) to shut down the air supply
• A pressure gauge († pos. 4 fig. 9) to monitor the pressure and
an turning button († pos. 3 fig. 9) to adjust the pressure if
necessary.
• A filter († pos. 5 fig. 9)
!
DANGER!
The maximum primary air pressure indicated for lubrica-
tion system operation must not be exceeded.
Fig. 9
1
2
3
5
4
Fig. 10
1
2
3
4
5
4.3 Hydraulic connection
The lubrication system is supplied with lubricant by an external
pump. Connection to the lubricant inlet with a G 3/8 connector,
depth 8 († pos. 1 fig. 10).
The lubricant treatment unit comprises:
• A pressure switch († pos. 5 fig. 10)
• A safety valve († pos. 2 fig. 10)
• A pressure gauge to monitor the pressure († pos. 3 fig. 10)
• A pressure regulator (set and sealed at the factory)
(† pos. 4 fig. 10)
DANGER!
The maximum lubricant pressure indicated for system
operation must not be exceeded.
4.3.1 Supply pump
The lubricant supply pump must be located as close as possible to
the GVP system.
In the case the pump supplies simultaneously several GVP systems, it must be located in the middle of the system to get an equal
length of tubing.
15
4.5 Proximity switch
The proximity switch detects the rollers of the moving chain.
When a roller is detected the proximity switch sends a signal to
the control unit of the GVP lubrication system. According to the running lubrication program, the control unit triggers or not a
lubrication.
The position of the proximity switch is very important. It makes
possble to trigger a lubrication at the right time so that the injection
head comes in contact with the greaser of the roller.
!
For the product-specific technical data the proximity
switch, see the relevant documentation. If you do not have
access to this documentation, you can request it directly from
SKF.
DANGER!
Only qualified, instructed specialists who are authorized
by the operator may install the electrical connections for the lubrication unit. The connection conditions and the local regulations (e.g. DIN, VDE) must be scrupulously respected. If systems
are improperly connected, substantial material or personal
damage my be the consequence.
4.4 Electric connection
Refer to the electrical documentation supplied with the lubrication
system for information about the electrical connection
(† pos. 1 fig. 11) of the system.
!
For the product-specific electric data see the relevant
documentation. If you do not have access to this documentation, you can request it directly from SKF.
DANGER!
The proximity switches may be connected only by properly qualified and instructed personnel.
Working on proximity switches under electrical voltage could
lead to personal injury.
4.4.1 Position of the proximity switch
The proximity switch must be above the chain to detect the rollers.
It must be at a certain distance before or after the lubrication system. This distance is measured from the axis of the capstan of the
GVP system.
d = n × P
d = distance
n = random whole number
P = chain pitch (distance distance between two lubrication points)
It might be necessary to adjust the position of the proximity switch
according to the chain speed and the system response time. This
manual adjustment is done empirically.
Therefore SKF recommends to use a switch support with an oblong hole parallel to the chain to make the adjustment easier.
Fig. 11
External electric connection
1
16
It is important to correctly position the proximity switches in relation
with the lubrication point to guarantee an optimal function. The
proximity switches must be perfectly positioned in the axis of the
point to be detected († fig. 12).
Metal support
The mounting of the sensor differs if it suits or not for flush
mounting in metal († fig. 13).
If the detector is suitable for flush mounting is metal, then no side
clearance is required. But if it is not suitable for flush mounting in
metal, then a side clearance is required.
Sensing distance of the proximity switch
(† fig. 14)
Nominal sensing distance (Sn)
The rated operating distance for which the sensor is designed. It
does not take into account any variations (manufacturing tolerances,
temperature, voltage).
Real sensing distance (Sr)
The real sensing distance is measured at the rated voltage (Un) and
the rated ambient temperature (Tn).
It must be between 90% and 110% of the nominal sensing distance
(Sn): 0,9 Sn ≤ Sr ≤ 1,1 Sn.
Usable sensing distance (Su)
The usable sensing distance is measured at the limits of the permissible variations in the ambient temperature (Ta) and the supply voltage (Ub). It must be between 90% and 110% of the real sensing distance (Sn): 0,9 Sn ≤ Su ≤ 1,1 Sr.
Assured sensing distance (Sa).
This is the operating zone of the sensor. The assured operating distance is between 0 and 81% of the nominal sensing distance (Sn): 0
≤ Sa ≤ 0,9 x 0,9 x Sn
Fig. 12
Sa : 0 < Sa < 0,81 Sn
Sa
Sa
Sensor, flush mounting in metal
metal
metal
metal
metal
Sensor, no flush mounting in metal
objet à
détecter
object to be
detected
Fig. 13
Sensing face
H = differential travel
Sa =
assured detection
Standard metal target
Output ON Output OFF
Fig. 14
17
There are no restrictions relating to land, air, or sea transportation.
5.2 Delivery
Following receipt of the shipment, the product or products must be
checked for damage and the shipping documents should be used to
make sure that the delivery is complete. Keep the packaging material until any and all problems have been clarified.
5.3 Storage
The following conditions apply to the storage of SKF products.
5.3.1 Storage of lubrication units
• Ambient conditions: dry, dust-free environment; storage in wellventilated, dry area
• Storage time: 24 months max.
• Permitted air humidity: < 65%
• Warehouse temperature: 10 – 40 °C
• Light: direct sunlight/UV radiation must be avoided; nearby sources of heat must be screened
5.3.2 Storage of electronic and electrical devices
• Ambient conditions: dry, dust-free environment; storage in wellventilated, dry area
• Storage time: 24 months max.
• Permitted air humidity: < 65%
• Warehouse temperature: 10 – 40 °C
• Light: direct sunlight/UV radiation must be avoided; nearby sources of heat must be screened
5.3.3 Storage – general information
• Ensure that no dust gets into stored products by wrapping them
in plastic film
• Store products on racks or pallets to protect them from damp
floors
• Before placing products into storage, protect uncoated metal surfaces - and drive parts and mount surfaces in particular - from
corrosion using long-term corrosion protection.
!
The product must not be tipped up or dropped.
5 Transport, delivery and storage
5.1 Transport
SKF products are packaged in accordance with the regulations of the
recipient country and in accordance with DIN ISO 9001. Our products must be transported with care. Products must be protected
against mechanical influences such as impacts. Transport packaging
must be labeled with the information 'Do not drop!'.
18
6 Commissioning
6.1 General
Before starting the lubrication unit, check that all outer connections (reservoir, air supply, electric connections, etc.) have been well
mounted and tightened.
• Check that the lubricant feed device is drained.
!
You must observe the machinery manufacturer's information on the lubricants to be used in the machinery.
!
CAUTION!
Only use a clean lubricant. Soiled lubricants can cause
major defects in the system.
!
CAUTION!
Different lubricants must not be mixed together. Doing so
can cause damage and require extensive cleaning of the lubrication unit/centralized lubrication system. To prevent any risk of
error, it is recommended to clearly identify the lubricant used on
the reservoir.
• Switch on the control unit.
• Pass a metallic object in front of the optional DOC origin sensor
(option): the LED should light up
• Check that the following LEDs light up:
– return cylinder sensor SO1
– injection cylinder sensor SO2
• Reset the control unit.
6.2.2 Proximity switch function
• Check the detection system
• Reconnect the EVE solenoid valve
• Pass a metal object in front of the roller sensor D1 : the LED on
the roller sensor D1 and the LED on the connector of the EVE so-
lenoid valve should light up and the roller pick-up system should
be deployed.
• Smoothly push the carriage of the GVP. The LED on the connector
of the EVG solenoid valve should light up and the LED on the con-
nector of the EVE solenoid valve remains lit.
DANGER!
Remove your hands quickly.
• After the lubrication phase the pick-up system retracts and the
carriage returns to their initial position.
• Close the air valve.
The injection time corresponds to the time of contact between the
injection head and the lubrication point. This interval is programmed
using the AEP3 control unit (factory setting: 0,1 s).
6.2.3 Activation - Conveyor running
• Check that no parts touch the chain when it is moving. If this is
the case, take the necessary measures to adjust the system
position.
• Reconnect the EVG solenoid valve
• Reposition the protective cover in place
• Open the air valve.
The system should restart automatically. If the client has not configured the AEP3 control unit to their own specifications, the GVP system operates according to the original factory settings: roller lubrication cycle = 1 000 lubrication pulses.
6.2 Commissioning
When activating the lubrication system, you can use the hydropneumatic diagram delivered with the system to identify the different elements.
6.2.1 Activation - conveyor stopped
• Remove the protective cover.
• Remove the connectors on the control solenoid valves for the EVG
and EVE injectors.
• Check if the end switch is not on position 'OFF' ; otherwise pull to
get on position 'ON' .
• If a machine contact is connected, disconnect it from the control
unit.
• Open the air valve.
DANGER!
Be careful of the carriage return.
19
6.3 Modification of the injector metered
volume
The GVP lubrication system is delivered with a fixed metered volume. It is possible to modify later this metered volume. Four different metered volumes are available: 0,33 ; 0,5 ; 0,75 or 1 cm
3
/stroke.
The metered volume is adjusted by means of reversible metering
stops. They modify the stroke of the metering piston of the injector,
thus the metered volume. Each injector has two reversible metering
stops († fig. 15), one is mounted in the injector, the other delivered
separately.
!
A number of washers screwed on the injector indicate the
metered volume of the GVP system († fig. 16). There-
fore change the number of washers when modifying the metered volume.
• 1 washer = 0,33 cm
3
• 2 washers = 0,5 cm
3
• 3 washers = 0,75 cm
3
• 4 washers = 1 cm
3
Injector GVP system
1 Injection head
2 Injector
3 Lubricant inlet
4 Injector carriage
5 Injector cylinder
6 Locking nut between cylinder and injector
Fig. 17
1
2
3
5
4
6
Fig. 16
1 cm
3
0,5 cm
3
0,75 cm
3
0,33 cm
3
Fig. 1520Fig. 18
Fig. 20
Fig. 21
The lubrication system GVP must be disconnected from
the power supply and not under pressure when modifying
the metered volume. Therefore turn off the power supply and
depressurize the system.
• Check the GVP unit is off and the air supply closed.
• Loosen the locking nut with an open end wrench (H.19)
(† 1 fig. 18) while holding the injector and remove the cylinder
from the injector.
1
2
Fig. 19
1
1
!
Lubricant might flow away when removing the cylinder
from the injector.
• Once it is removed you can see the metering stop in the injector
(† 1 fig. 19)
• Remove the metering stop († 1 fig. 20) with a pliers
• Put the selected metering stop for the new metering volume in
the cylinder. The side of the stop for the metering volume must
point towards the injector.
• Put the O-ring Ø10×1 († 2 fig. 21) on the metering stop
(† 1 fig. 21)
• Insert the cylinder head in the injector
• Tighten the locking nut
1
21
DANGER!
The lubricant inlet pressure for a GVP lubrication system
must not exceed 25 bar.
6.4.2 Lubrication system bleeding
Fig. 22
1
Fig. 24
1
2
3
Bleed first the lubricant supply pump before bleeding the lubrication
system.
• Check the pump is correctly mounted on the lubricant drum.
• Open the bleed valve († 1 fig. 22) of the pump.
• Use the manual control of the solenoid valve († 1 fig. 23) of the
air control unit to force the operation of the pump
• Wait until lubricant comes out of the bleed valve without air
bubbles.
• Stop the pump
In the case the pump supplies several GVP units, each unit must be
bled.
• Disconnect the supply line from the lubricant treatment unit
(† 2 fig. 24) of the GVP unit.
• Use the manual control of the solenoid valve († 1 fig. 23) of the
air control unit to force the operation of the pump
• Wait until lubricant comes out of the supply line without air
bubbles.
• Stop the pump
• Connect the supply line to the lubricant treatment unit
(† 2 fig. 24)
At the end of the bleeding operation, the lubricant pressure gauge
(† 3 fig. 24) on the GVP unit must indicate a pressure between 20
and max. 25 bar. If necessary adjust the pressure with the lubricant
regulator († 1 fig. 24) on the GVP unit.
!
The supply system shown here to describe how to bleed
the lubrication system is given as example. This is a pneumatic drum pump controlled by an pneumatic control unit. According to the application, the supply system may be different.
For further information, please refer to the technical documentation delivered with the lubricant supply system.
Fig. 23
1
22
7 Shutdown
7.1 Temporary shutdown
You can temporarily shut down the described product by disconnecting the electrical, pneumatic, and/or hydraulic supply connections.
For more information, see the section Safety instructions in this in-
stallation instructions.
If you wish to shut down the product temporarily, refer also to the
instructions in the section Transport, delivery, and storage of this
manual.
When placing the product back into operation, refer to the information in the sections Installation and Commissioning of this
manual.
7.2 Permanent shutdown
All country specific legal guidelines and legislation on the disposal of
contaminated equipment must be observed when shutting down the
product for the final time.
!
CAUTION!
Lubricants can contaminate the ground and watercourses. Lubricants must be used and disposed of in compliance with
the rules. Instructions and local regulations must be observed
when handling lubricants.
The system can also be taken back by SKF for disposal if the costs
are covered.
23
SKF products are low-maintenance. However, to ensure that they
function properly and to avoid risks right from the startup, all joints
and connections should be checked to make sure that they are
properly fitted.
8. Maintenance
!
CAUTION!
Working on products that have not been disconnected
from the power supply can cause serious injury or death to persons. Installation, maintenance, and repair work may only be
carried out by qualified experts on a product that is not connected to a power supply. The supply voltage must be turned off before any product components are opened.
!
CAUTION!
The described product may be under pressure when it is
being operated. The product must therefore be depressurized
before starting installation, maintenance, or repair work and before making any changes to the system.
Table 2
GVP system maintenance
Elements Frequency Instructions/Observations
Lubrication system 6 months On the AEP3 control unit, initiate an automatic greasing cycle to verify the
movements.
Cylinders 6 months Visual inspection (seals) and acoustic inspection (leaks)
Injector monthly Check condition of injection nozzle
Lines 6 months Visual inspection (seals) and acoustic inspection (leaks)
Air filters monthly Check state of cleanliness
Pump weekly Check pressure on pressure gauge
Reservoir According to frequency of
lubrication
Lubricant level monitoring
Refill the reservoir if necessary.
Linear guides 6 months Permanently lubricated
Check operating condition
Pick-up system 6 months Check condition of rollers (traces of wear)
24
9. Failures
Table 2 gives an overview of possible malfunctions and their causes.
If you are unable to rectify the malfunction, please contact SKF Service Center.
!
You must not dismantle the product or parts of the product during the warranty period. Doing so invalidates all
warranty claims.
All other work relating to installation, maintenance, and repair
must only be carried out by SKF Service.
!
Only original SKF spare parts may be used. It is prohibited
for the operator to make alterations to the product or to
use non original spare parts and resources.
Table 3
Failure analysis and remedy
Problem Possible cause Solution
No lubricant discharged from injector Problem with connection • Check the leaktight seal on the line and the
connectors
Minimum lubricant level for the feed pump reached• Check the lubricant level in the feed pump and refill
if necessary
A piston is not working No pneumatic feed • Check the connection on the pneumatic feed
• Check the pneumatic pressure and adjust if
necessary
Defective solenoid valve • Check the solenoid valve is functioning correctly
and if necessary replace it.
Defective sensor • Check the sensor is functioning correctly and
replace if necessary
The carriage is blocked Defective piston • Check the piston functions correctly
Mechanical blockage • Manually move the carriage to check that no
external elements are blocking it. Remove any
foreign element that could prevent the carriage
from working correctly.
• Check that the rail and the linear bearing guide
function correctly.
No pressure in the system Zero pneumatic pressure • Check that the pneumatic feed valve is open and
open if necessary.
• Check the pneumatic pressure and adjust if
necessary
Lubricant leak on the roller nipples Incorrect head-nipple alignment • Check the alignment and make adjustments as
necessary
Deformed or damaged nipples on rollers • Replace the nipples
No lubrication Nipple blocked (old conveyor or unit in extreme
temperatures)
• Clean or replace the nipples
• Check the other nipples at the same time.
Injector filled incorrectly. • Check that the grease has no air bubbles
• Check that the feed pump and the injector function
correctly.
DANGER!
All installation, setting, maintenance and repair works on
the lubrication system must be carried out only when the conveyor is off duty. Working closed to a running conveyor chain
may cause operator's injuries and/or important material
damages.
25
10 Spare parts
!
Only original SKF spare parts may be used. It is prohibited
for the operator to make alterations to the product or to
use non original spare parts and resources.
Table 5
Spare part list GVP-S-026-1
(† fig. 25)
Pos. Qty Order No. Designation
1 1 AC-4190 Linear ball guide size 25
2 6 GVP335-38 Capstan finger, length 38 mm
3 1 GVP432 Injection nozzle head
4 1 GVP1400-2 Grease injector
5 1 AC.4192356 Guide rail, size 25 length 356 mm
6 1 AC.3731.1 Pneumatic cylinder Ø 25, stroke 50 mm
7 1 AC.4174.1 Pneumatic cylinder Ø 40, stroke 50 mm
8 2 AC.4197 Magnetic solid state switch
9 1 RT200-GVP Swiveling connector
10 1 F12-450 Hose, length 450 mm
11 1 AC-4383-8 Connection block, 8 × M12 female
12 1 AC-4383-6 Connection block, 6 × M12 female
13 1 AC-4344 Limit switch
14 1 AC-4261-3.5B Pressure switch, set at 3,5 bar (air circuit)
15 2 AC.4193+924 5/2 single solenoid valve, 24 V DC, with cable 5 m
16 2 AC.4194+924 Connector, size 15, 24 V DC
17 1 AC-4305 Grease pressure reducer (20 bar)
18 1 UH2820-04 Manometer 0 to 60 bar
19 1 HK030.30R Safety valve, set à 30 bar
20 1 AC-4261-12B Pressure switch, set at 12 bar (grease circuit)
21 1 AC.4199 Filter regulator 0,5 to 8,5 bar
22 1 AC.2804 Manometer 0 to 10 bar
23 1 AC-4200 Valve module
24 1 AC.3732.1 Pneumatic cylinder Ø 25, stroke 250 mm
25 1 AC.4202.1 Flow regulating valve (exhaust)
26 1 AC.4203.1 Flow regulating valve (inlet)
27 1 GVP418 Ball pusher for injector
28 2 SY.9518.7 Inductive proximity switch Ø18 (only on GVP-S-026-1D+924)
29 1 GVP900 O-ring for injector
26
A - A
D é t a il m o n ta g e b u s e
( 1 : 1 )
A A
13
1
2
3
5
7
6
8
9
10
11
12
14
15
16
17
20
19
18
24
8
25
26
3 27
4
21
22
23
28
29
29
D é t a il m o n ta g e
d u d é te c t e u r
Fig. 25
Spare parts GVP-S-026-1D+924
27
Table 6
Technical data
GVP-S-026-1 system
Air feed pressure 5 to 7 bar
Injection volume 0,33 to 1 cm
3
(factory setting 1 cm3)
Operating temperature 5 to 45 °C
Lubricant grease NLGI grade 2
Chain max. speed 15 m/min max.
Lubricant inlet pressure 25 bar max.
Weight approx. 55 kg
Acoustic emission Cat. A (≤ 70 dB)
11 Technical data
28
29
® SKF is a registered trademark of the SKF Group.
© SKF Group 2016
The contents of this publication are the copyright of the publisher and may not be reproduced (even extracts) unless prior written permission is granted. Every care has been taken to ensure the accuracy of the information contained in this publication but no liability can be
accepted for any loss or damage whether direct, indirect or consequential arising out of the use of the information contained herein.
PUB 951-130-453-S026-1 E N · March 2016
SKF France
Lubrication Business Unit
204, bld Charles de Gaulle, B.P. 239
37540 St-Cyr-sur-Loire – FRANCE
Tel. +33 (0) 247 405 300 Fax +33 (0) 247 405 353
www.skf.com/lubrication
!
Important information on product usage
SKF and Lincoln lubrication systems or their components are not approved for use with gases,
liquefied gases, pressurized gases in solution and fluids with a vapor pressure exceeding normal
atmospheric pressure (1 013 mbar) by more than 0,5 bar at their maximum permissible
temperature.
skf.com/lubrication
Loading...