Perma STAR VARIO Manuel utilisateur

The Expert in Lubrication Solutions

Installation Guide

perma STAR VARIO

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Blattformat: DIN A1

Maßstab: 1:1

4-6

Blattformat: DIN A3

Maßstab: 1:1

The content of this document has been compiled by perma-tec with mediculous care. Never-the-less, we cannot rule out deviations and reserve the right to make technical changes

to the product without any advance notice. We do not assume any judicial responsibility or liability for any damages which may ensue as a result. Necessary modiﬁcations will be

included in subsequent editions.

Compiled and printed: 01/2017

Mounting types

Preparation of lubrication point

Basic Guidelines

Direct mounting

Remote mounting with tube

Mounting of oil ﬁlled units

Pressure testing

Activation und installation

Identiﬁcation of lubrication system

Pressure test procedure

Schlauchanschlüsse

This Installation guide provides instructions for the installation of perma STAR VARIO and helps in

preventing basic mounting errors. The guide should be used with the operating instructions.

Drawings are only examples. There are many other possibilities for mounting, depending on local

conditions.

Disclaimers of corresponding operating instructions apply.

Installation guides do not affect validation of the operating instructions.

1. Basic Guidelines

• perma STAR VARIO is a single-point lubrication system. You must use a separate lubrication

sysem for each lubrication point.

• The connection thread of perma STAR VARIO is BSP R¼ male thread.

• Replace the application‘s grease ﬁtting with a suitable reducer. perma-tec offers a wide

assortment of reducers, extensions, tubes, brackets and other accessories. See our product

catalogue for the entire overview on perma accessories.

• Ensure that the lube point is preﬁlled with fresh lubricant before installation. perma-tec offers all

of its lubricants in 400 g cartridges for grease guns.

• Select the right lubricant for your application. perma-tec offers a wide variety of standard

lubricants for different applications. See our product catalogue for further information.

• All metal to metal connections must be glued together with Loctite® 243™.

• Fill grease lines and accessories with the same lubricant that is contained in the lubrication

system.

• When oil is used for lubrication, an oil retaining valve (104862) must be installed. This will prevent

oil leakage from the lubricator.

• For managing serveral lube points we recommend the use of a lubrication maintenance plan. You

can use the free perma MLP software (https://mlp.perma-tec.com) for online administration.

• Please check our product catalogue for more information on how to select suitable lubricant and

activation screw. You may also download our free perma SELECT APP which is a great tool for the

selection of the right lubrication system, lubricant and discharge period.

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2. Mounting types

2.1 Direct mounting

Direct mounting should be preferred for all lubrication points, to protect the lubrication system against

high pressure.

Reducer for thread

connection

Please use Support ﬂange STAR Gen 2.0 G1/4

male x G1/4 female (109420) for all angled or

horizontal installations.

Installation of perma STAR VARIO is possible in all directions (indoors and outdoors).

Protection cap can only be used for vertical installations (outlet at the bottom) or horizontal

installations.

When using oil ﬁlled LCs, mounting angle may not exceed 45°.

2.2 Remote mounting with tube

• Keep connection lines as short as possible and use tubes with an inside diameter of at least 6 mm.

Keep in mind that tube length and bore diameter of bearing housings affect pressure and discharge

period of the lubrication system.

• For installation of perma STAR VARIO use Mounting bracket 1-point G1/4 female (109663).

• Secure tubes with suitable fastenings (brackets, cable ties) to protect against damage and tearing.

• Depending on lubricant and ambient temperature, different tube lengths are possible, e. g.

 perma Multipurpose grease SF01: 5 m (+20 °C).

Reducer for thread connection

Remote mounting is recommended if,

• the ambient temperature of the lubrication point is permanently higher than +60 °C

• the lubrication point is exposed to high vibrations

• no direct access to lubrication point is possible due to safety issues (e. g. removal of protective

screens, safety walls or cages)

• it is difﬁcult or dangerous to access the lubrication point

• the lubrication system is exposed to mechanical forces (e. g. falling rocks)

Mounting bracket STAR Standard Duty

1-point G1/4 female (109663)

Hose connector G1/4 male for hose iØ 9.5 mm -

push-lock (101554)

Heavy Duty hose up to +100 °C oØ 16 mm x iØ 9.5 mm

(101555)

Hose connector G1/4 male for hose iØ 9.5 mm -

push-lock (101554)

Support ﬂange STAR Gen 2.0 G1/4 male x

G1/4 female (109420)

All metal to metal connections must be

glued together with Loctite® 243™.

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2.3 Mounting of oil ﬁlled units

2.3.2 Remote mounting

Oil brush Ø20 mm G1/4 female

(101396)

2.3.1 Direct mounting

perma STAR VARIO is not equipped with an oil retaining valve in the outlet. Usage of an external oil

retaining valve is recommended.

Remote installations of oil ﬁlled perma STAR VARIO require an oil retaining valve at the lowest

point of the application. This will prevent oil leakage from the lubrication system.

Oil retaining valve G1/4 male x G1/4

female up to +60 °C (104862)

Bracket (104864)

Support ﬂange STAR Gen 2.0 G1/4

male x G1/4 female (109420)

Mounting bracket STAR Standard Duty

1-point G1/4 female (109663)

Tube connector G1/4 male for tube oØ 8 mm straight

(101496)

Tube up to +80 °C oØ 8 mm x iØ 6 mm (101393)

Bracket (104864)

Tube connector G1/4 male for tube oØ

8 mm straight (101496)

Oil retaining valve G1/4 male x G1/4

female up to +60 °C (104862)

Oil brush 40 x 30 mm G1/4

female (101397)

Support ﬂange STAR Gen 2.0 G1/4 male x G1/4 female

(109420)

All metal to metal connections

must be glued together with

Loctite® 243™.

All metal to metal connections

must be glued together with

Loctite® 243™.

3. Preparation of lubrication point

2. Remove grease nipple or plug screw of connecting thread and check thread size.

3. Insert reducer and install tube and necessary accessory parts.

1. Prior to installation, lubrication point must be cleaned to protect against contamination.

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4. Lubrication point, accessory parts and tubes must be pre-ﬁlled with lubricant.

This enables the lubricant to immediately reach the lubrication point.

5. Preﬁll lubrication point and all grease lines for remote installation.

6. Use a tube preﬁll adapter to preﬁll lubrication point and grease lines.

Grease gun

(101455)

Hose with rotary joint, slide and hydraulic

coupling for grease gun (110199)

Tube preﬁll adapter

Tube preﬁll adapter for tube oØ 8 mm (101526)

Tube preﬁll adapter for tube oØ 6 mm (101532)

Hose preﬁll adapter for Heavy Duty hose (107633)

Tube preﬁll adapter for VA-ﬂex tubes (107634)

4. Pressure testing

For pressure testing please use perma STAR VARIO with Accessory set for pressure test (101480).

Be sure to use the same lubricant for both, preﬁlling and LC of perma STAR VARIO.

perma STAR VARIO

Gauge

Stop valve

Accessory set for

pressure test

Check counter pressure at lubrication point before installing the lubrication system to guarantee

correct function.

Most bearings require 0.5 - 2 bar pressure (without extension tubes). perma STAR VARIO can be

used for these lubrication points.

Accessory set for pressure test (101480)

(order lubrication system separately)

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4.1 Pressure test procedure

1. Remove grease nipple.

2. Screw reducer onto lube point and connect pressure testing set.

3. Connect perma STAR VARIO to the open outlet.

4. Turn machines on to ensure that lube point is in use and measuring of corresponding counter

pressure is possible (Caution: Observe accident prevention regulations).

5. Open stop valve.

6. Push SET button on perma STAR VARIO for approx. 10 seconds until

PU lights up on display to trigger an additional discharge/purge.

7. Watch the pressure on the gauge during the additional discharge.

If pressure exceeds 6 bar the lubricator will shut off automatically.

8. If pressure doesn‘t rise any more during the additional discharge,

max injection pressure has been reached. In order to ﬁnd out the

required system pressure you must wait another 5 minutes. The

gauge will then show the system pressure

9. If system pressure exceeds 2 bar you need to „purge“ the lube point

by using a mechanical grease gun. Proceed with steps 6 and 7.

10. If counter pressure doesn‘t decrease you need to either select a different lubricant or a different

lubricator. Please ask perma-tec to assist you in this matter

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