Translation of the Original Operating Instructions perma PRO C 250
Contents
1. Set LC unit size Set discharge period Either Months Weeks or Days Set discharge period Go to Days or Weeks Activate outlets Activate outlet 1 Outlet 1 activated Outlet 2 activated if desired other outlets may be turned On Off the same way PIN first digit enter for initial configuration or after a PIN reset otherwise setting is complete PIN second digit enter for initial configuration or after a PIN reset Configuration finished N TRO CONFIGURATION MENU perma PRO C Caption for Chart on Left Side Instructions should be followed from top to bottom and from left to right also refer to chart 3 The instructions correspond to the operating sequence on the turned off lubrication system perma PRO C Configuration is also possible if perma PRO C is On Configuration sections see vertical bar chart 6 INTRO INTRO informs INFO and asks for the current PIN PIN entry Settings can be changed in the configuration menu with its different sections LC Time Outlets PIN CONFIGURATION MENU LC You can change the PRO LC unit size from LC250 to LC500 and back by pushing the SELECT button refer to chapter 7 1 and 7 2 Time The discharge period can only be set in one type of calendar unit i e either Months Weeks or Days When the highest unit is reached counting starts again with number I except with days OL Impulse Mode refer to chapter 6 10 Out2. 6 5 The World of Automatic Lubrication perma PRO C 8 Trouble Shooting 8 1 Error Messages on the Display Possible errors of the lubrication system and the application are detected by the electronic control system and are indicated on the display If an error is displayed the system is switched OFF until the cause of the error has been eliminated and the error message has been acknowledged Error messages are acknowledged and reset by pushing the SELECT button 8 2 Fault Signaling via the Connected Control System In case of a malfunction the connected control system of your equipment merely indicates an unspecified malfunction since the control system only receives a Low signal from the lubricator This means that if your control system indicates a malfunction you have to use the display of the lubricator to determine the cause of the malfunction refer to chapter 8 1 8 3 Trouble Shooting Guide If there are malfunctions during the operation of the lubrication system please check for possible causes using the following chart refer to chart 8 Every time that an error message is displayed the red LED is also blinking Clear the blockage and acknowledge the fault by pushing and holding down the SELECT button A Lubricator has been switched off Drive mechanism is defective Exchange the drive unit System does not detect ae the PRO LC unit No PRO LC unit installed Install an PRO LC unit Excess motor current of
3. F 10 C 20 C 0 F tube length in meter Application area for Application area for x out of specification range standard grease Low temp grease no warranty The dashed standard grease and dotted low temperature lines show the maximum values allowed If your application is out of the specification range shown in this diagram please contact your local distributor perma tec cannot be held liable for these applications Example 1 The application temperature is 5 C 41 F What is the maximum tube length allowed for standard grease Correct Answer 3 m max tube length for standard grease 5 m max tube length for low temp grease arrow 1 meets the dashed line of the standard grease range at 3 m 2 You want to use a 4 m tube Up to which temperature can the system be used Correct Answer 10 C 50 F with standard grease 5 C 23 F with low temp grease arrow 3 meets the dotted line of low temp grease at the 5 C mark and the dashed line of the standard grease at the 10 C mark perma perma tec GmbH amp Co KG 3 1 Design of the PRO C Lubricator Lubricators are available as 250 cc and 500 cc versions and they can be supplied with the lubricant requested by the customer They consist of refer to figure 2 Protection cover for the drive unit re usable PRO LC unit Lubrication Canister can be supplied as 250 cc and 500 cc versions with the lubricant requested by the customer Usage of perma
4. System Off 6 7 Determining the Discharge Period Without Impulse Mode 6 8 Settings and Display 6 9 Calculation of the Remaining Discharge Period 6 10 Impulse Mode via the Connected Control System 7 Replacement of the PRO LC unit 19 fA Setting the Volume of the PRO LC unit 7 2 How to Replace the PRO LC unit 8 Trouble Shooting 21 8 1 Error Messages on the Display 8 2 Fault Signaling via the Connected Control System 8 3 Trouble Shooting Guide 9 Accessories and Spare Parts 22 10 Disposal 24 11 Service 24 12 Declaration of conformity for perma PRO C 25 perma perma tec GmbH amp Co KG 1 1 2 Miscellaneous About this Operating Manual This operating manual is intended for the safe operation of the perma PRO C automatic lubricator It contains safety instructions which must be adhered to Everyone who works on or with the lubricator must have access to this operating manual during their shift They must also pay attention to all relevant instructions and notices The operating manual must always be kept complete and in easy to read condition Terms Used Lubrication system perma PRO C In the following text the lubrication system perma PRO C will either be called lubricator or by its name perma PRO C Lubrication Canister In the following text the Lubrication Canister will be called PRO LC unit The user can order the PRO LC unit with different lubricants and in sizes 250 cc and 500
5. and secure it with the three pre drilled holes see attached template Place the PRO LC unit inside the cover and remove the plug of the PRO LC unit Push the PRO LC unit into the cover until lubricant comes out of the opening Place the PRO LC unit with its cover on the drive unit Make sure that the catch locks and that the teeth of PRO LC unit and drive unit interlock Turn the cover clockwise until the bayonet catch locks Connect the perma PRO C to your control system using the connecting cable Determine the Discharge Period refer to chapter 6 7 Refer to the manufacturer s guidelines about the lubrication point that you want to lubricate in order to determine the required lubricant amount in cc per one hundred operating hours Refer to chart 4 chapter 6 7 chart 5 and find your required lubrication volume Based on that the chart will show you the required PRO LC unit size the setting of the discharge period and the setting mode You may also refer to our perma SELECT program which can be downloaded from our web page free of charge It helps you in selecting the correct settings Setting of LC unit Size Discharge Period Outlets and PIN refer to chapter 6 8 Hold down the MODE SAVE button until the set time is displayed Hold down the MODE SAVE button again until you reach the current PIN PIN cannot be changed here PIN setting at delivery is 0 Hold down the MODE SAVE button again
6. details contained in this documentation However we cannot rule out discrepancies and we reserve the right to make technical changes to the product without giving advance notice We do not assume any judicial responsibility or liability for damages which may ensue as a result We will include any necessary changes in the next edition Compiled and printed 11 02 2009 The World of Automatic Lubrication perma perma PRO C Table of Contents The Lubrication System perma PRO C 1 Quick Reference Guide 2 Content 3 1 Miscellaneous 4 1 1 Delivery Content 1 2 Storage 1 3 Markings 1 4 Intended Usage 1 5 Legal Requirements 2 Safety Instructions 6 2 1 Persons Responsible for Safety 2 2 General Safety Instructions 2 3 Safety Information for perma PRO C 3 Technical Data 7 3 1 Design of the perma PRO C Lubricator 4 Assembly and Mounting of the Lubrication System 9 4 1 Mounting of the Drive Unit onto a Fixing Device for Wall Mounting 4 2 Assembly of the Lubricator 4 3 Connect the Connecting Cable to the Lubricator 5 Display and Control Elements of the Lubrication System 12 5 1 Display Elements 5 2 Function Indication on the Display 5 3 Function Indication via the LEDs 5 4 Function Indication via the Connected Control System 5 5 Control Buttons 6 Operation and Control 13 6 1 Preparations 6 2 Prior to Operation 6 3 Setting into Operation 6 4 During Operation 6 5 Switching the Lubrication System On 6 6 Switching the Lubrication
7. management and authorized documentation representative see manufacturer address This declaration certifies conformity to the directives referred to but it is not a warranty of qualities The safety instructions of the operating manual are to be observed Directive 98 37 EC is valid until and including the 28 of December 2009 Directive 2006 42 EC is valid as of 29 December 2009 Nea perma perma tec GmbH amp Co KG perma PRO C perma tec GmbH amp Co KG Hammelburger Str 21 97717 Euerdorf Germany Tel 49 0 9704 609 0 Fax 49 0 9704 609 50 E mail info perma tec com Homepage www perma tec com The World of Automatic Lubrication 09 02 11
8. pro PRO LC units only Drive unit consisting of a gear motor a pump system the connector for the connecting cable and an electronic unit for the control system re usable Connecting cable for linking the lubricator and the control system of your equipment e g a PLC figure 2 The World of Automatic Lubrication perma PRO C 4 Assembly and Mounting of the Lubrication System 4 1 Mounting the Drive Unit onto a Fixing Device for Wall Mounting Attach the supplied mounting device to the drive unit using the two enclosed hex head bolts M6 x 16 and the two washers Screw the mounting device with the drive unit onto a support of your system The boring template of the three mounting screws 141 5 x 45 can be seen below in picture 3 or on the template that is included You have to use at least three hexagon screws M6 x 25 e g on metal ground Before you connect the outlet of the drive unit to the lubricant tube you have to make sure that the lubrication points and the complete lubricant tube is pre lubricated with the same lubricant that is contained in the PRO LC unit For that perma tec offers a 400 g lubrication cartridge for manually operated grease presses with the requested lubricant Connect the lubricant tube connection G3 8 outside or G1 8 inside to the outlet of the drive unit and install the tube correctly between the outlet and the lubrication point The lubricant tube must not be longer than five met
9. to be used with settings and variations recommended in this operating manual Any other usage setting addition and variation is considered to be inappropriate 1 5 Legal Requirements Liability The information data and tips stated in this operating manual were up to date as of the printing date No claims for already delivered lubricators perma PRO C can be made based on the information pictures and descriptions perma tec GmbH amp Co KG can not be held liable for damages and malfunctions caused by inappropriate usage unauthorized alterations to the drive system or the PRO LC unit inappropriate operations on or with the lubricator incorrect operation and settings of the lubricator incorrect settings of time and size of the lubricator ignoring the operating manual Warranty Warranty terms and conditions see terms and conditions of sale and delivery appertaining to perma tec GmbH amp Co KG Lodge any warranty claims with your local supplier immediately after the defect or error has been identified The warranty expires in all instances where no liability claims can be enforced perma perma tec GmbH amp Co KG 2 2 2 3 A A Safety Instructions Persons Responsible for Safety The operator or his safety officer must warrant that all the relevant regulations instructions and laws are adhered to that only qualified personnel will work with and on the lubricator th
10. until you reach the other setting menus LC unit discharge period outlets only with attached MP 6 and PIN change Change settings with a short push of MODE SAVE or SELECT 4 Impulse Mode via the Connected Control System refer to chapter 6 10 To start the impulse mode set the setting mode Days in the configuration menu of the lubricator to 2 Trigger a discharge with a discharge volume of 0 5 cc by switching on the supply voltage for the perma PRO C for a minimum operating period of 14 minutes The minimum shutdown period between two discharges is 20 seconds 5 Save Settings refer to chapter 6 8 Keep the MODE SAVE button pressed until display shows Starting perma PRO C refer to chapter 4 3 und Kap 6 5 Switch on the supply voltage DC 15 V to 30 V for the lubricator via your control system The remaining volume is displayed and the green LED is blinking r Stopping PRO C ausschalten refer to chapter 6 6 Switch off the supply voltage for the lubricator The display of the lubricator shows Bon perma tec GmbH amp Co KG perma PRO C This operating manual is valid for the lubricator perma PRO C with PRO LC units 250 cc and 500 cc 2003 perma tec GmbH amp Co KG Without the specific approval of perma tec GmbH amp Co KG no part of this documentation can be copied or made available to third parties We have taken great care when compiling all the
11. you have to switch off the supply voltage of the perma PRO C The display no longer indicates the remaining volume VOL but indicates instead When the lubrication system is switched off all of the settings are saved This means that if you start the lubricator again it will take up the operation at the point where it had been switched off The fault output sends a Low signal system not working to the control system figure 14 The World of Automatic Lubrication perma PRO C 6 7 Determining the Discharge Period Without Impulse Mode The discharge period is automatically factory set to six months according to the supplied PRO LC unit Upon request a factory setting of the discharge period required by the customer is also possible The size of the PRO LC unit is taken into account lf you want to determine the discharge period you need to know the required amount of the lubricant in cubic centimeters for 100 operating hours cc 100 h This information can be taken from the technical documents of the manufacturer of the lubrication point With this information you can determine the discharge period using the following chart chart 5 34 3 17 1 11 4 2083 3 1041 7 694 4 520 8 416 7 347 2 297 6 260 4 231 5 208 3 189 4 173 6 160 3 148 8 138 9 130 2 122 5 MST 109 6 104 2 99 2 94 7 297 6 148 8 99 2 14 4 09 5 49 6 42 5 3m2 33 1 298 27 1 24 8 22 9 23 19 8 18 6
12. 17 5 16 5 15 7 14 9 14 2 153 12 9 12 4 68 5 34 3 22 8 17 1 13 7 11 4 chart 5 Please take into account that in case of one or several additional discharges the remaining discharge period of the lubrication system must be recalculated refer to chapter 6 9 This also applies in case of a cut off of the lubrication system due to a long machine standstill e g weekends or annual holidays You should also note the result of your calculation of the remaining discharge period in your lubrication and maintenance schedule NI 3 4 9 4 3 3 8 3 4 3 1 29 2 6 2 4 2 3 2 1 2 0 leo 1 8 T 1 6 N O ia O1 OD 6 2 3 6 1 4 86 8 O21N NIN a a a oe a O Rilo Mm a wo a a gt aa on gt O o ajw l s ojololol olv The perma SELECT software helps you to determine the discharge period Visit our website www perma tec com for a free download of this software perma tec GmbH amp Co KG 6 8 Settings and Display see caption on page 17 change second digit Change from LC500 to LC250 v Change months Change days or weeks Outlet 1 On Off v S Outlet 2 On Off v Change first digit change second digit chart 6 The World of Automatic Lubrication Display at delivery with attached PRO LC unit Shows discharge period PIN reset Enter first digit of current PIN PIN 22 at delivery Enter second digit of current PIN
13. C unit Shows activated outlets i k Displays volume of LC unit S j 250 or 500 cc Number Shows remaining volume Remaining volume Ice icon discharge period outlet no of the PRO LC unit Indicates either that the temperature PIN and malfunction codes Shows the lubricant fell below 0 C 32 F icon blinking remaining in the PRO or that the low temperature shutoff LC unit in volume below 20 C 4 F has turned the system off icon permanent Drive Unit No function Setting of PRO LC unit size is done via menu on the display Interlocking teeth to position the PRO LC unit Catch for driving the spindle Connecting Cable Connecting cable For connecting the lubricator to the T control system Pin assignment 3 of the connector Pin assignment of cable connector The World of Automatic Lubrication Quick Reference Guide for the Lubrication System perma PRO C On this page you will find some important information for quick and easy operation and setting of the perma PRO C lubrication system Before the first installation of the perma PRO C and whenever you need detailed instructions you should read the complete Operating Manual which contains information that must be observed Make sure to follow the instructions giving in the chapter Safety Instructions Assembly of perma PRO C Exchange of PRO LC unit refer to chapter 4 and 7 Mount the drive unit on the mounting plate
14. PRO C 6 10 Impulse Mode via the Connected Control System Discharge of lubricator PRO C can also be triggered via the attached control system In this case the lubricator discharges 0 5 cc lubricant to the lubrication point every time it is switched on For this you have to switch on the supply voltage via your control system for at least 14 minutes and then you have to switch it off for at least 20 seconds The minimum operating time of 14 minutes is due to the possibility to connect the perma PRO C to the distributor perma MP 6 This distributor is able to supply lubricant to up to six lubrication points This means that the distributor needs a minimum operating time of 14 minutes to be able to supply 1 0 cc lubricant to every open distributor outlet If operated as a single point lubrication system the minimum operating time is reduced to 1 minute and the discharge amount per impulse 0 5 cc For an activation of the perma PRO C lubricator via your control system you need to set the lubricator to impulse mode via the configuration menu refer to chapter 6 8 For this you have to select the setting UU Days in the setting mode Days refer to figure 17 figure 17 7 Replacement of the PRO LC unit The Following Must Always Be Taken into Account If the replacement of an empty PRO LC unit becomes necessary it will be indicated by a simultaneous blinking of the red and the green LED Additionally the display indicates
15. arried out by the system if temperatures reach 20 C 4 F You should also note the result of your calculation of the remaining discharge period in your lubrication and maintenance schedule If you have set the perma PRO C to impulse mode you cannot calculate the remaining discharge period since the value for the set discharge period SDP is not available In this case you have to pay attention to the information on the display of the lubricator and to the information indicated by the connected control system SDP RV Formel Rbp 100 SDP Set discharge period of the lubricator days weeks months RV Remaining volume displayed in Vol R Remaining discharge period days weeks months depending on SDP Example of a Calculation of the Remaining Discharge Period The perma PRO C with a 250 cc PRO LC unit was originally set to a discharge period SDP of eight months since the lubrication point needs 4 3 cc lubricant 100 h After two months the perma PRO C indicates a remaining volume RV of 15 Vol At this point the lubricator is switched off for six weeks e g machine standstill When it is switched on again you would like to determine when the PRO LC unit will be empty SDP RV 8 75 600 Rhen 6 100 100 100 This results in a remaining discharge period of six months After these six months the PRO LC unit will be empty and must be replaced by a new one The World of Automatic Lubrication perma
16. at unauthorized personnel are not allowed to work with and on the lubricator thatthe safety regulations are adhered to when mounting the lubricator or during maintenance General Safety Instructions Weare not laying claim to completeness as regards these safety instructions Please contact perma tec Customer Service if you have any queries or problems Atthe time of delivery the lubricator is in line with state of the art technology and in principle is considered to be safe to operate Dangers emanate from the lubricator for persons the lubricator itself and for other material assets of the operator if unqualified personnel operates the lubricator the lubricator is used inappropriately and for operations that it was not intended to be used for the lubricator setting variation is incorrect the lubricator is opened by force while in operation the lubricator is not mounted with the perma mounting device the tube connection to the lubrication point was not carried out and attached correctly Operate the lubricator only when it is in perfect condition Retrofitting changing or reconstructing the lubricator is not allowed perma tec must be consulted first Only original tube connections and connectors from perma tec can be used on or with the lubrication system since these will withhold high pressures of up to 25 bar 360psi Only an original connecting cable from perma tec can be used to connect the lubricat
17. cal equipment Protect live parts of the electrical equipment according to the voltage frequency and application type by insulation and by their position and arrangement o gt gt The World of Automatic Lubrication perma PRO C 3 Technical Data Volume of the PRO LC unit 250 cc 500 cc Length L 210 mm 260 mm Diameter D 92 mm 92 mm ij Weight empty 1 30 kg 1 37 kg Weight filled with SF04 1 53 kg 1 82 kg Discharge period 1 day to 24 months 1 day to 24 months Discharged volume per lubrication impulse 0 5 cc figure 1 Application temperature 20 C to 60 C 4 F to 140 F Maximum pressure build up 25 bar 360 psi Combination of these Maximum Values can only be Maximum tube length inner 5 mm realized by temperatures of 2 20 C 68 F At lower temperatures the Greases up to rated application is limited according to Lubricants i ubric consistency NLGI 2 the diagram below Power supply 15 V DC to 30 V DC Typ power consumption 120 mA Current at make can be up to 1 3 A chart 1 60 C 140 F 50 C Diagram showing dependency of application temperature oe _ and tube length inner 5 mm for perma standard grease 40 C and low temperature grease I 100 F i i T 30 C y d y 80 F o o 20 C D o gt w 60 F w 2 10 C a 40 F 6b 6b oc F 20
18. cc Usage of Safety Instructions All safety instructions in this operating manual are standardized Danger Signs This sign warns you of any danger to people s health or to subjects Tips This sign alerts you to application tips which will help you in doing certain tasks quicker and safer Delivery Content perma PRO C will be delivered according to customer specifications in regards to type of grease and size content of PRO LC unit You only have to assemble it and connect it to your control system e g a PLC using the connecting cable Furthermore you have to set the required discharge period at the lubricator and connect the perma PRO C to the supply voltage Connecting cable for connecting lubricator and control system Mounting device and screws included Operating instructions and EC Conformity declaration included Upon delivery make sure to check if the delivered goods correspond to your order perma tec GmbH amp Co KG will not accept liability for subsequent claims of any shortcomings Please immediately forward any claims of noticeable transport damage directly to the forwarder of noticeable faults shortcomings or defects directly to your perma distributor o gt a Storage When the lubricators are not immediately installed you must ensure appropriate storage conditions in dry dust free places with a temperature of 20 C 5 C 68 F 9 F Make sure that PRO LC units are not store
19. d longer than one year Drive unit protection 1 during storage do not remove cover disc 2 and plug 3 until right before you intend to use the lubricator see chapter 6 2 The World of Automatic Lubrication perma PRO C 1 3 Markings The lubricator perma PRO C is clearly marked with a label on the drive system serial number and a label on the PRO LC unit CE mark on the drive unit Manufacturer perma tec GmbH amp Co KG Hammelburger Stra e 21 97717 Euerdorf Germany Tel 49 0 9704 609 0 E mail info perma tec com Fax 49 0 9704 609 50 Homepage www perma tec com 1 4 Intended Usage The lubricator perma PRO C Immediately supplies all lubrication points with lubricant at a pressure build up of max 25 bar 360 psi consistantly precisely and independent of temperature Can be used for all lubrication points of sliding and roller bearings drive and transport chains sliding guideways open gears and seals Can be connected to the control system e g PLC of your machine Must be provided with the supply voltage from your equipment Should only be connected to used with original lubrication tubes from perma tec GmbH amp Co KG Is intended for use on machinery and equipment Is only to be used for the ordered purpose and purposes confirmed by perma tec GmbH amp Co KG Is only to be used for operating conditions recommended in this operating manual Is only
20. e lubricator the lubrication point and the complete connection tube must be sufficiently pre lubricated with the same lubricant that the PRO LC unit contains For this perma tec offers a 400 g lubrication cartridge for grease presses with the corresponding lubricant refer to chart 8b chapter 9 When installing the perma PRO C the supplied perma tec mounting device should be used When connecting the perma PRO C to your control system the supplied perma tec connecting cable should be used This connection may only be established by qualified personnel The lubricant tube must be installed and mounted correctly The length of the lubricant tube may not exceed a maximum of 5 meters and the tube must be a perma tec product Please check if the thread of the perma PRO C G3 8 or G1 8 corresponds to the connection thread of the lubrication point If this is not the case you can order a corresponding reducer or other parts from the perma accessory line A For the initial setting into operation of a perma PRO C the pump system in the drive unit is pre filled with SF04 from perma s standard range of lubricants An exception is made with regard to lubricants for the food industry A complete discharge of this pump filling is guaranteed after approx 10 discharges carry out additional discharges if necessary 6 2 Prior to Operation Check all parts of the lubricator for obvious damages Is the new PRO LC unit filled with the req
21. ers A Make sure that you assemble the connections and lubricant tubes correctly and tightly to avoid possible 4 leakage Hexagon screw M6 x 25 for wall mounting on metal amines 2 hex head bolts M6 x 16 maximum torque 3 Nm supplied for attaching the perma PRO C to the mounting device 141 5 2 hexagon screws M6 x 25 for wall l mounting on metal 45 figure 3 perma tec GmbH amp Co KG 4 2 Assembly of the Lubricator a Place the PRO LC unit inside the protection cover and remove the plug of the PRO LC unit refer to figure 4 Protection cover PRO LC unit Plug figure 4 b gt Push the PRO LC unit into the protection cover until lubricant comes out of the opening refer to figure 5 figure 5 The World of Automatic Lubrication perma PRO C c Place the PRO LC unit with its protection cover on the drive unit Make sure that the catch locks and that the teeth of the PRO LC unit and the drive unit interlock refer to figure 6 Turn the cover clockwise until the bayonet catch locks figure 6 4 3 Connect the Connecting Cable to the Lubricator Connect the four strands of the connecting cable to the control system e g a PLC of your equipment and pay attention to the pin assignment of the connector on the lubricator refer to chart 2 and figure 7 Insulate the connected strands correctl
22. icator LC lubrication period outlets The World of Automatic Lubrication perma PRO C 12 Declaration of conformity for perma PRO C EC declaration of conformity according to the Machinery Directive 98 37 EC and according to EMV Electromagnetic Compatibility Directive 2004 108 EC according to the Machinery Directive 2006 42 EC and according to EMV Electromagnetic Compatibility Directive 2004 108 EC The manufacturer perma tec GmbH amp Co KG Hammelburger Stra e 21 97717 Euerdorf Germany hereby declares that the product as described in the given statement conforms to the regulations appertaining to the directives referred to above including any amendments thereto which are in force at the time of the declaration Product description Automatic lubrication system Product name Lubrication system perma PRO C Type perma PRO C 250 and perma PRO C 500 The following harmonised standards were applied EN ISO 12100 1 2003 Safety of machinery basic concepts general terms of reference as regards design and construction Section 1 Basic Terminology Methodology EN ISO 12100 2 2003 Safety of machinery basic concepts general terms of reference as regards design and construction Section 2 Technical terms of reference EN 60204 1 2006 Machinery s electrical equipment Euerdorf 11 February 2009 perma tec GmbH amp Co KG Walter Graf Managing Director Egon Eisenbacher Technical
23. isture Exchanges should only be done in a dry place and it must be ensured that no moisture enters the drive unit a Turn the protection cover on the drive unit counter clockwise and take it off b Remove the empty PRO LC unit The display indicates LL and the red LED is blinking c Remove the plug of the PRO LC unit refer to figure 4 chapter 4 2 d Push the PRO LC unit into the protection cover until lubricant comes out of the opening refer to figure 5 chapter 4 e Place anew PRO LC unit on the drive unit turn it until the catch locks and the teeth of the PRO LC unit and the drive unit interlock The control system of the perma PRO C automatically recognizes the new PRO LC unit and the display indicates if the perma PRO C was switched off prior to the replacement of the PRO LC unit Or it indicates 95 Vol if the perma PRO C was switched on before the replacement You should only use completely full perma tec PRO LC units in order to guarantee a trouble free operation f The lubrication system continues to operate with the previous setting of the discharge period g Ifrequired change lubricator settings Refer to chapter 6 8 or to chapter 6 10 in case of an impulse mode of the lubricator If the lubricator was ON before changing the LC unit it will automatically resume operation with existing settings If the lubricator was turned Off it must be turned On again by supplying voltage refer to chapter
24. lets The activated outlets 1 6 are displayed with a filled in square in the display please refer to the operating instruction of the MP 6 distributor for more details If no distributor is connected configuration of outlets has no effect PIN We strongly suggest to enter a personal PIN in order to protect your settings from unauthorized access The PIN can only be changed during initial configuration or after a PIN reset A PIN reset short push of buttons left left right right left in the INTRO Info menu changes your personal PIN back to UZ The PIN reset was successful when the displayed time disappears for a second and then comes back on All other settings remain unchanged Save or Reject Changed Settings The display settings can be saved with a long push of the MODE SAVE button If you do not want to save your changes to setting that are currently displayed in the configuration menu LC Time Outlets PIN press the SELECT button until the display shows either for Off or the remaining volume of the PRO LC unit in VOL All other settings and already saved changes remain valid Automatic Termination of the Configuration Mode If you do not press a button in the configuration mode for 180 seconds the control system is automatically switching back to the previously set mode On or Off without saving the changes The settings existing prior to the change remain valid Additional Discharge With an addi
25. or to your control system and your equipment Ambient media especially chemically aggressive substances can attack seals and plastic gt Safety Information for perma PRO C Safety during Installation and Maintenance Ensure that all workstations and traffic routes are clean and safe Ensure that the relevant regulations and guidelines are adhered to when the installation or maintenance work is carried out in places where danger of falling exists Ensure that the relevant safety and operating instructions are observed when the lubricators are installed or serviced on machines or in factories e g to stop the machine Safety When Handling the PRO LC unit Avoid contact of lubricant with eyes skin and clothing Avoid swallowing of lubricant Prevent lubricant from getting into soil or sewer system Observe safety data sheets of lubricants You may also download data sheets of lubricants supplied by perma tec from perma tec s web page www perma tec com or ask your local supplier Lubricant on traffic ways will increase the danger of slipping Therefore immediately clean lubricant from floors with special cleaner Only use original PRO LC units from perma tec gt gt gt Safety When Working on Electrical Equipment Works on electrical equipment may only be carried out by qualified personnel Danger of sparking and fire hazard in case of a short circuit Do not work on live parts of the electri
26. perma tec GmbH amp Co KG perma PRO C J 7 Pi dia rad Ci eT hel PRO LC 250 Translation of the Original Operating Instructions perma PRO C 250 500 The World of Automatic Lubrication perma tec GmbH amp Co KG Lubrication System perma PRO C Protection cover With bayonet catch for quick opening closing Content Description of the filling date and the contained lubricant PRO LC unit Lubrication Canister Type Cartridge piston spindle Product type and size of filled with lubricant PRO LC unit Red LED Display Additional malfunction Informs about operating conditions indication malfunctions settings and the lubricant volume left in the Push Button MODE SAVE PRO LC unit Leads to the Configuration Menu and saves the selected settings Green LED Additional indication of the current operating condition Drive Unit Contains electronics motor and pump system Push Button SELECT To change settings Connection f distributor PRO MP 6 Connector Used for plugging in the connecting cable which connects the perma PRO C with the control system e g of a PLC Connection thread G3 8 outside and G1 8 inside for screwing into a lubrication point or for connecting a lubricant tube Display a Setting Mode Displays the current setting in days weeks or months Configuration menu _____ For entering the settings Outlets 1 6 a Size of PRO L
27. rease number PRO Cover for LC 250 2299 101 000 made of transparent plastic PRO Cover for LC 250 2299 102 001 made of aluminium for applications with ester containing lubricants PRO Cover for LC 500 2299 102 000 made of transparent plastic PRO Cover for LC 500 2299 102 002 made of aluminium for applications with ester containing lubricants PRO C M12 Cable 5m 2291 000 003 PRO C M12 Cable 10 m 2291 000 004 chart 9a The World of Automatic Lubrication perma PRO C PRO Mounting Device 27 008 007 Grease cartridge 400 g filled with on request to be used for pre filling grease lines with a grease gun Tube Connector G1 8a for tube 27 008 010 a 8 mm straight Tube Connector G1 8a for tube 27 008 011 a 8 mm 90 PRO tube 8 x 1 5 inner 5 mm 27 008 009 i with different lengths Reducer G3 8 G1 4 27 008 017 CD ROM with SELECT software on request calculation of the lubricant amount lubrication and maintenance schedule and operating instructions as PDF file chart 9b perma tec GmbH amp Co KG 10 Disposal Help us in protecting the environment and saving resources by recycling valuable raw material Please follow your local waste disposal regulations 11 Service Please contact your local supplier for availability and cost of the following Returning of the empty lubricator for environmentally safe recycling or disposal or Exchange of the PRO LC unit To pre set lubr
28. s not possible figure 16 Display with a blinking ice crystal in this example with 9 Vol In order to protect the system from damage the low temperature cut off of the lubrication system is automatically carried out by the control system and the built in temperature sensor If the temperature reaches or falls below 20 C 4 F the lubricator is switched off by the low temperature cut off and the ice crystal symbol is permanently indicated on the display The remaining volume is still displayed in Vol From this time onwards the lubricant is no longer discharged You have to take this fact into account if your system continues to operate in order to prevent damages As soon as the temperature rises and reaches 19 C 2 2 F or higher the control system switches the lubrication system on again The display shows the remaining volume and the blinking ice icon All discharges except additional discharges accumulated during the shut off will be caught up when the system continues operation at a max of two additional discharges with every regular discharge Calculation of the Remaining Discharge Period Please note that in case of one or several additional discharges the remaining discharge period of the lubrication system must be recalculated This also applies in case of a cut off of the lubrication system due to a long machine standstill e g weekends or annual holidays or in case of a low temperature cut off c
29. that the PRO LC unit is empty refer to figure 18 If the PRO LC unit is empty the connected control system of your equipment receives a Low signal and a malfunction is indicated figure 18 If you replace the PRO LC unit by an PRO LC unit of a different size a corresponding protection cover refer to chart 9a chapter 9 must be used Since the drive unit and the control board must be protected against moisture an exchange may only be carried out in dry conditions After the installation of the new PRO LC unit the control system continues to operate using the previously valid setting of the discharge period perma perma tec GmbH amp Co KG 7 1 7 2 Setting the Volume of the PRO LC unit The size of the PRO LC unit must be set in the configuration menu with the two buttons on the drive unit refer to figure 18 Please also refer to the operating chart chart 6 chapter 6 8 ATTENTION If the displayed setting does not correspond with the attached PRO LC unit size it will result in incorrect discharge amounts and wrong signals in the display Display LEDs figure 19 ATTENTION Whenever a PRO LC unit is removed from the lubricator and is replaced by another LC unit the control system assumes that a new completely filled PRO LC unit was attached Therefore NEVER attach a PRO LC unit that is not completely full How to Replace the PRO LC unit Drive system and circuit board must be protected from mo
30. the Lubricator has been switched off lubricator motor due to a blocked outlet Lubrication system has been Excess motor current of the Replace perma MP 6 switched off perma MP 6 distributor Clear the blockage and Excess motor current of the acknowledge the fault by lubricator motor caused by a pushing and holding down blocking of the displayed outlet the SELECT button Lubrication system has been Outlets of distributor not correctly Replace distributor switched off recognized epilace distributo Timeout while activating distributor Replace distributor Error at the displayed lubrication point Lubrication system has been switched off Connection cable damaged Replace connection cable Activate desired outlets Turn off power supply on Outlet configuration missing Outlets were not activated PRO C before you acknowledge error messages chart 8 perma tec GmbH amp Co KG 9 Accessories and Spare Parts Due to the high pressure of up to 25 bar 360 psi you should only use genuine spare parts and accessories from perma tec in order to ensure a reliable operation of the lubrication system This especially applies to lubricant tubes Spare parts and accessories must meet the technical requirements This is always guaranteed with genuine spare parts and accessories from perma tec PRO LC 250 222 XXXX 608 filled with lubricant XXXX grease number PRO LC 500 223 XXXX 609 filled with lubricant XXXX g
31. the operation You should pay special attention with regard to leakage and to the condition of the lubricator Check the condition of the lubricant tube and the connections regularly Check the filling level of the transparent PRO LC unit regularly After one or several additional discharges you have to calculate the reduced discharge period and note this on your lubrication and maintenance schedule If your control system indicates a malfunction you have to determine its cause directly via the display of the perma PRO C You can check for possible causes using the trouble shooting guide refer to chart 8 chapter 8 3 If the fault cannot be fixed please contact your local supplier for technical support gt Additional discharges and long machine standstills must always be taken into account with regard to the remaining discharge period of the lubricator Switching the Lubrication System On To turn the lubrication system on you have to switch on the supply voltage for the perma PRO C The indication on the display is replaced by an indication of the remaining volume e g 95 VOL with a new PRO LC unit see figure 13 The green LED starts blinking and the malfunction output sends a High signal system OK to the connected control system Switch on of the supply voltage by the control system figure 13 Switching the Lubrication System Off To switch the lubrication system off refer to figure 14
32. tional discharge a lubrication point can be supplied with an additional amount of the lubricant For an additional discharge the lubrication system must be switched on display shows the remaining volume and both buttons must be held down simultaneously refer to figure 20 figure 15 Lubricator On For an additional discharge press both buttons at the same time and hold them down An additional discharge is only possible at temperatures above 0 C 32 F figure 16 ice crystal is not visible and when the lubrication system is not currently conducting a regular discharge Every additional discharge reduces the remaining discharge period since an increased amount of the lubricant has been supplied This must be taken into account in your lubrication and maintenance schedule The time between two additional discharges is at least 30 seconds Each additional long push of both buttons simultaneously fig 15 during this time is being registered and will lead to even more additional discharges The system remembers a max of 5 additional discharges perma perma tec GmbH amp Co KG Low Temperature Cut Off of the Lubrication System The temperature range from 0 C to 19 C 32 F to 2 2 F is indicated by a blinking ice crystal symbol refer to figure 16 In this temperature range the lubrication system perma PRO C continues to operate without interruption Please note that in this temperature range an additional discharge i
33. uired lubricant Is the connecting cable connected to the control system of your equipment and is the supply voltage DC 15 V to 30 V applied Has the cover disc with plug been removed from drive unit See chapter 1 2 Did you assemble and mount all of the parts correctly and tightly perma perma tec GmbH amp Co KG 6 3 6 4 6 5 6 6 Setting into Operation Mount the drive unit onto a fixing device for wall mounting refer to chapter 4 1 Insert the PRO LC unit into the protection cover and close the complete system refer to chapters 4 2 b d Determine the discharge period refer to chapter 6 7 Set volume of PRO LC unit discharge period outlets of MP 6 and the PIN via buttons on display refer to chapter 6 8 or set the lubricator to impulse mode refer to chapter 6 10 Plug the connecting cable into the lubricator and connect the strands to your control system refer to chapter 4 3 Turn the lubrication system on by supplying voltage see chapter 6 5 Carry out an additional discharge refer to chapter 6 8 If the drive motor has started and the green LED is lit the lubricator has started to discharge The display indicates the remaining volume Vol of the PRO LC unit gt o gt a The operator must always check the customer specific settings and if necessary change them before the lubricator is set into operation During Operation Carry out regular inspections during
34. witched off by the operator If the lubrication system is switched off the display will always show two lines see figure 10 below figure 10 Function Indication via the LEDs chart 3 Function Indication via the Connected Control System The connected control system of your equipment can only indicate that the lubricator is working or that there is a malfunction If the perma PRO C is working the control system receives a High signal and for a malfunction a Low signal The World of Automatic Lubrication perma PRO C 5 5 Control Buttons There are two push buttons on the control unit refer to figure 8 which can be used for a menu guided change of the settings With the MODE SAVE button refer to figure 11 you can reach the configuration menu change the mode and save the modified settings for further operation With the SELECT button refer to figure 12 you can do the following increase discharge period Days Weeks Months each time you press the button increases the discharge period by one calendar unit change PRO LC unit size activate MP 6 outlets and set PIN BUTTON figure 11 figure 12 figure 11 figure 12 Selection ee Changing of Moves to new menu and Returns to original menu FUNCTION in current i l display values saves selected values without saving changes chart 4 figure 11 figure 12 6 Operation and Control 6 1 Preparations Prior to the installation of th
35. y Insert the 4 pole connecting cable into the connector of the lubricator refer to figure 6 Screw tight the connector socket of the connecting to the connector of the lubricator gt Pin assignment of the connector on the lubricator figure 7 chart 2 Error signal is low active negative logic perma tec GmbH amp Co KG 5 5 1 5 2 5 3 5 4 Display and Control Elements of the Lubrication System Display Elements The operating status of the lubricator can be determined via the green or the red LED and via the display at the control unit refer to figure 9 of the perma PRO C The perma PRO C offers a menu guided setting Changes of the settings are shown on the display Error messages e g in case the pressure in the lubricant tube gets too high are also indicated on the display MODE LCD SAVE push button ed LED green LED SELECT Connector for push button distributor MP 6 figure 8 Function Indication on the Display The display is located on the control unit of the perma PRO C refer to figure 8 chapter 5 1 The display shows settings operating conditions and error messages of the lubricator In case of an error free operation of the lubrication system the display shows the remaining volume of the mounted PRO LC unit in percent volume Vol Figure 9 shows an example of the displayed information if the PRO LC unit 500 is new and full figure 9 The display cannot be s
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