perma-tec GmbH & Co. KG perma STAR CONTROL perma-tec GmbH & Co.

KG perma STAR CONTROL

EC Conformity Declaration
Operating Instructions
according to the Machinery Directive 98/37/EC and according to EMV
(Electromagnetic Compatibility) – Directive 89/336/EEC.

The manufacturer

perma-tec GmbH & Co. KG

Hammelburger Straße 21

D – 97717 Euerdorf STAR CONTROL

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 lubricator

Product name: perma STAR CONTROL
Type: S 60, M120 and L 250

The following harmonised standards were applied:

EN 292 – 1: 1991 Safety of machinery –basic concepts, general terms of

reference as regards design and construction –
Section 1: Basic Terminology, Methodology

EN 292 – 2:1991 Safety of machinery –basic concepts, general terms of

reference as regards design and construction –
Section 2: Technical terms of reference and specifications

EN 60204 – 1:1998 Machinery's electrical equipment

Euerdorf, 15 March, 2001

perma-tec GmbH & Co. KG

Peter Mayr, Managing Director Dr. Michael Weigand, Technical Management

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.

Lubrication Systems Lubrication Systems

perma-tec GmbH & Co. KG perma STAR CONTROL

This operating manual is valid for the lubricator

perma STAR CONTROL in sizes S 60, M 120 and L 250.

PLC – connection plan with three output signals

© 2003 perma-tec GmbH & Co. KG

Without the specific approval of perma-tec GmbH & Co .no part of this documentation can
be copied or made available to third parties.

We have taken great care when compiling all the 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.

12.3
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: 09 / 2004

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Table of Contents

1 Various 1

1.1 About this Operating Manual 1

1.1.1 Terms Used 1
1.1.2 Usage of Safety Instructions 1
1.1.3 Danger Signs 1
1.1.4 Tips 1
PLC-connection plan with two output signals

1.2 Delivery 2
1.3 Lubricator perma STAR CONTROL 2
1.3.1 Markings 2
1.3.2 Intended Usage 2
1.4 Legal Requirements 3
1.4.1 Liability 3
1.4.2 Warranty 3

2 Safety instructions 4

2.1 Persons Responsible for Safety 4

2.2 General Safety instructions 4
2.3 Safety Information for perma STAR CONTROL 5
2.3.1 Safety During Installation and Maintenance 5
2.3.2 Safety When Handling LC-Units 5

3 Technical data 6

3.1 Data Sheet: power supply 6

3.1.1 Cable construction 6
3.1.2 Values 6
3.2 Product specifications 6
3.2.1 Pin assignment 6
3.2.2 Components 7
12.2

3.2.3 Function 8
3.2.4 Reference table for discharge amount per discharge cycle 8
3.3 Weights and measurements 8
3.4 Operation Conditions 9
3.4.1 Temperatures 9
3.4.2 Ambient Conditions 9

4 Storage 9

4.1 General Storage Information 9

4.1.1 Ideal Storage Conditions 9
4.1.2 Storage Periods 9

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5 Starting and operating 10

5.1 Preparation 10
5.2 Before Operation 10
5.3 Initial Operation 10
5.4 During operation 11

6 Changing the LC-unit 12

6.1 General Note 12

PLC-connection plan with one output signal

6.2 How to change the LC-unit 12

7 Drive unit settings 13

7.1 Function Display 13

7.2 Circuit Board Settings 13
7.2.1 Setting the Discharge Period an the Discharge Amount 14
7.2.2 Setting the Volume of the LC-Units or Impulse Mode 14
7.3 Table of Discharge 14
7.3.1 Examples for determining proper dip switch settings to achieve
optimal lubrication 15
7.3.2 Changing the discharge volume after the perma STAR CONTROL
has been in operation/reset function 16
7.4 Impulse Mode ( possible only with LC-unit M120) 17

8 Trouble shooting 18

9 Disposal 19

10 Accessories for perma STAR CONTROL 20

10.1 Accessories 20
10.2 Replacement Parts 20

12.1
11 Service 20

12 PLC-connection plans

12.1 PLC connection plan with one output signal 21

12.2 PLC connection plan with two output signals 22
12.3 PLC connection plan with three output signals 23

EC – Declaration of Conformity

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10 Accessories for perma STAR CONTROL 1 Various

Accessories and replacement parts must meet the technical requirements. This can 1.1 About this Operating Manual
be guaranteed by using original parts from perma-tec.
♦ This operating manual is intended for the safe operation of the perma STAR
CONTROL automatic lubricator. It contains safety instructions which must be
10.1 Accessories adhered to.
♦ Cable with plug ♦ Everyone who works on or with the lubricator must have access to this
♦ Support adaptor (thread G1/4 inside and outside) operating manual during their shift. They must also pay attention to all relevant
♦ Support adapter/support cup (thread G1/4 inside and outside) instructions and notices.
♦ perma STAR – CLIP
♦ Bracket with insert or oil throttle ♦ The operating manual must always be kept in complete and easy to read
♦ 400g grease cartridge or oil filled in a container condition.
♦ Lubrication Maintenance Plan
♦ Additional accessories as required 1.1.1 Terms Used

10.2 Replacement parts ♦ Lubricator

♦ LC-unit (thread R1/4) in size: In the following text, the ”lubricator” will either be called ”lubricator” or by its
- S 60 (60 cm³) name ”perma STAR CONTROL”.
- M 120 (120 cm³)
- L 250 (250 cm³) ♦ Lubrication Canister
♦ Drive unit
♦ Cover for drive unit In the following text, the ”Lubrication Canister” will be called LC-unit.
The user can order the LC-unit filled with different oils and greases and in sizes
11 Service S 60, M 120, and L 250.

Please contact your local supplier for availability and cost of the following: 1.1.2 Usage of Safety Instructions

♦ Returning of the empty lubricator for environmentally safe recycling or disposal. All safety instructions in this operating manual are standardized

or 1.1.3 Danger Signs

Attention Danger!
♦ exchange of LC-unit
This sign warns you of any danger to people’s health, life-threatening injuries,
♦ setting the desired discharge period
and death.

1.1.4 Tips

This sign alerts you to application tips which will help you in doing certain
things quicker and safer.

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9 Disposal
1.2 Delivery

♦ Perma STAR CONTROL can be ordered and delivered according to customer Help us in protecting the environment and saving resources by recycling valuable
specifications in regards to type of grease and oil, size / content of LC-unit. raw material. Please follow the individual waste disposal regulations in your
♦ Upon delivery, make sure to check if the delivered goods correspond to your country.
order. perma-tec GmbH & Co. KG will not accept liability for subsequent
claims of any shortcomings.
♦ Please immediately forward any claim
of noticeable transport damage: directly to the forwarder
of noticeable faults, shortcomings or defects: directly to your perma
distributor.

1.3 Lubricator perma STAR CONTROL

1.3.1 Markings

♦ The lubricator perma STAR CONTROL is clearly marked with a label on the
drive system and a label on the LC-unit
♦ CE Mark on the drive unit and the LC-unit
♦ Manufacturer:

perma-tec GmbH & Co. KG

Hammelburger Straße 21
D – 97715 Euerdorf, Germany

Internet: www.perma-tec.com
e–mail: [email protected]

1.3.2 Intended Usage

♦ The lubricator perma STAR CONTROL

Is a machine controlled lubricator (ON/OFF function is directly tied to the

machine or equipment). When turned on, it immediately supplies all
lubrication points with oil and grease, at a pressure build-up of max. 5 bar
(75 psi), permanently, 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.
Is intended for use on machinery and equipment where lubrication is only
to take place when the machine is running, and where a status report to
the machine is desired.
Is only to be used for the ordered purpose and purposes confirmed by
perma-tec.

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Is only to be used for operating conditions recommended in this operating

8 Trouble shooting manual.
Is only to be used with settings and variations recommended by this
In case of malfunctions during operation, please check the following chart for operating manual.
possible causes and corrective actions. If the malfunction is not listed, please
contact your perma distributor.
Any other usage, setting and variation is considered to be inappropriate.

Malfunctions Possible cause Solution

1.4 Legal Requirements
- Wrong cable connection Connect cable according to
pin assignment
Check pin assignment 1.4.1 Liability

♦ The information, data and tips stated in this operating manual were up-to-date
- Break in cable Check voltage at plug, attach as of the printing date.
perma STAR CONTROL new cable No claims for already delivered lubricators can be made based on the
does not function
information, pictures and descriptions.
- No power supply Check power supply
Too many perma STAR ♦ perma-tec GmbH & Co. KG can not be held liable for damages and
CONTROL connected malfunctions caused by:

- Relay defect in machine Change relays inappropriate usage;

unauthorized alterations to the drive system or the LC-unit;
perma STAR CONTROL - Setting of “VOL” switch
signals “system functions different than attached LC-unit inappropriate operations on or with the lubricator;
OK” (green LED), although Replace with full LC-unit incorrect operation and settings of the lubricator;
LC-unit is empty. - Partly filled LC-unit was replaced
by an almost empty LC-unit incorrect settings of time and size of the lubricator;
ignoring of the operating manual.

perma STAR CONTROL - Clogged tube and/or onnection Clean tube and connecting
signals “system parts parts, then shut off and restart
malfunctions” (red LED) - Counter pressure too high perma STAR CONTROL (refer
to chapt. 7.3.2) 1.4.2 Warranty
- Wrong setting of “VOL”-switch Correct switch setting
perma STAR CONTROL - Wrong setting of “TIME” – switch Correct switch setting ♦ Warranty terms and conditions: see terms and conditions of sale and delivery
discharges too fast (refer to chapt. 7.3.2) appertaining to perma-tec GmbH & Co. KG.
♦ Lodge any warranty claims with your local supplier immediately after the defect or
perma STAR CONTROL - Setting of “VOL” switch
different than attached LC-unit error has been identified.
signals “end of discharge”
(red and green LED), Replace with full LC-unit ♦ The warranty expires in all instances where no liability claims can be enforced.
- Almost empty LC-unit was replaced
although the unit is not by a partly filled LC-unit
empty

perma STAR CONTROL

does not discharge the - Changing of the Dip-switch-setting Refere to chapt. 7.3.2
correct amount was done incorrectly

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g) As soon as the motor runs, release the white peg and unplug the power connector
2 Safety instructions h) Set the dip switch “TIME” and “VOL” to the desired position
i) Again, push and hold the white peg on the bottom of the drive unit
j) Attach the power connector to the drive unit
2.1 Persons responsible for safety k) After 3 seconds, release the peg and unplug the power connector
l) Mount the drive as described under point 6.2
♦ Operator
NOTE: Changing the discharge volume as described above may result in an
The operator is any individual or legal entity who or which uses the lubricator or incorrect LED display of “LC unit empty” which depends on how empty the
on whose authority the lubricator is used. attached LC unit was before the discharge volume was changed.
Therefore it is important that you manually monitor the End of discharge period.
The operator or his safety officer must warrant,
- that all relevant regulations, instructions and laws are adhered to;
- that only qualified personnel will work with and on the lubricator; 7.4 Impulse Mode (possible only with LC-Unit M120)
- that the operating manual is made available to the personnel for all
work done with and on the lubricator, and that the personnel adhere to
it; Discharge amount in cc (1 cc = 0.9 g lubricant)
- that unauthorized personnel are not allowed to work with and on the
lubricator; per Impulse
- that the safety regulations are adhered to when mounting the Dip switch “VOL”
lubricator or during maintenance.

♦ Qualified Personnel
Impulse
Qualified personnel are persons who, by virtue of their training, experience, Mode
instruction and information concerning the relevant standards and provisions, 2.11
accident prevention regulations and plant and operating conditions, as received
from the person responsible for the safety of the plant, are entitled to carry out Dip-
1.06
the activities required at any time so that any possible dangers or hazards can switch
be identified and avoided. ”TIME”
0.53

2.2 General Safety Instructions 0.26

♦ We are not laying claim to completeness as regards these safety instructions.

Please contact your local supplier if you have any queries or problems.
♦ At the time of delivery, the lubricator is in line with state-of-the-art technology As soon as power (15 to 25 V DC , max. 30 V DC) is supplied, the perma STAR
and in principle is considered to be safe to operate. CONTROL will discharge the set amount once. Power must be applied at least until
♦ Dangers emanate from the lubricator for persons, the lubricator itself and this discharge has taken place (about 2 minutes).
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 In order to get another discharge cycle, the power must be interrupted for at least
intended to be used for; 15 seconds and then supplied again.
• the lubricator setting/ variation is incorrect.

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To Variation II: 120 cc LC-unit (M120)

⇒ 2.78 cc/100 h = 0.0278 cc/h ♦ The lubricators must be filled with the correct oil or grease and must be set to
⇒ 120 cc : 0.0278 cc/h = 4316.5 h operate correctly without causing any hazards to people when set, installed,
⇒ 4316.5 h : 40 h/week = 108 weeks and used for its intended purpose. This also pertains to their operation together
with the complete machine and its lubrication points.
The lubricant is sufficient for more than 2 years, not including additional ♦ Make sure to prevent material damage by putting certain measures in place in
operational breaks or any other machine standstills. the case that the lubricator malfunctions.
♦ Operate the lubricator only when it is in perfect condition.
To Variation III: 250 cc LCunit (L250) ♦ Retrofitting, changing, or reconstructing the lubricator is not allowed. perma-tec
⇒ 2.89 cc/100 h = 0.0289 cc/h must be consulted first.
⇒ 250 cc : 0.0289 cc/h = 8650.5 h ♦ The LC-unit should not be forced open.
⇒ 8650.5 h : 40 h/week = 216 weeks
2.3 Safety Information for perma STAR CONTROL
The lubricant is sufficient for more than 4 years.
2.3.1 Safety During Installation and Maintenance
Due to the stability of each individual lubricant we recommend variation I
♦ Ensure that all workstations and traffic routes are clean and safe!
with a 60 cc LC-unit.
♦ Ensure that the relevant regulations and guidelines are adhered to when the
Example 2:
installation or maintenance work is carried out in places where danger of falling
exists.
Given the same machine as in example 1, but with different and irregular
running times e.g. 4 hours on day one, 1.5 hours on day two, not running on ♦ Ensure that the relevant safety and operating instructions are observed when
days three and four, and 3 hours on day five. the lubricators are installed on machines or in factories (i.e. to stop the
machine).
You can determine the dip switch setting as in example number 1, but the total
discharge life of the LC-unit and exchange date cannot be determined. 2.3.2 Safety When Handling the LC-Unit

It is possible to calculate discharge periods of several years. Particular attention ♦ Avoid contact of oil and grease with eyes, skin, and clothing!
should be paid to these lubrication points. Monitoring is possible with PLC ♦ Avoid swallowing of oil and grease!
connection via the output signal “End of discharge”. Please pay special attention to ♦ Prevent oil and grease from getting into soil or sewer system!
the shelf life of the grease when you choose long lubrication periods. ♦ Observe safety data sheets of oils and greases!
♦ Oil and grease on traffic ways will increase the danger of slipping! Therefore,
immediately clean oil and grease from floors!
7.3.2 Changing the discharge volume after the perma STAR CONTROL has been in ♦ Only use original LC-units from perma-tec!
operation/reset function

a) Unplug the power plug from the lubricator

b) Unscrew the lubricator from the lubrication point
c) Unscrew the LC unit from the drive unit

d) Set the dip switch “VOL” to this position >

e) Locate the white peg on the bottom of the drive unit – push it in and hold it down
f) Attach the power connector to the drive unit

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3 Technical Data 7.3.1 Examples for determining proper dip switch settings to achieve optimal
lubrication
3.1 Data sheet: power supply In the “normal mode” (per 100 operating hours)

Example 1:
3.1.1 Cable construction:
A roller bearing is to be provided with 14 cc of lubricant every 500 hours of
Conductor cross-sectional dimensions: 4 x 0.25
operation: 14 cc ÷ 500 h = 0.028 cc per h = 2.8 cc per 100 h
Flexible cord construction: CU flex 32 x Ø 0.1 mm blk
Insulation: PVC Ø 1.3 + 0.05
The discharge table in chapt. 7.3 on page 14 shows that 3 different settings are
wall thickness abt. 0.32 mm
possible for each LC-unit size
Cable covering: PUR / black
Variation I: TIME VOL
3.1.2 Values
Line resistance: 79.9 Ω / km at 20°C (68°F)
Safe temperature: static condition: -25 to +70°C
(-13 to 158°F) 2.78 cc/100 h for a 60 cc LC-unit (S60)
dynamic condition: -5 to 70°C
(23 to 158°F) Variation II: TIME VOL

Cable is drag chain qualified, approved for the smallest bending 2.78 cc/100 h for a 120 cc LC-unit (M120)
radius 10 x D.
Variation III: TIME VOL
Power Supply 15 to 25 V DC (max. 30V DC); must be applied a minimum of 2
minutes in order to achieve the correct discharge time!
Typical current consumption 0.2A (Current at make can be 3 times that high). 2.89 cc/100 h for a 250 cc LC-unit (L250)
Maximum load on output 2 and 4 is 50mA.
At this point, you can calculate the total discharge life of the LC-unit (and the
3.2 Product specifications exchange date). Proceed as following:
2
4 The roller bearing to be lubricated is installed in a machine which runs 5 days per
3.2.1 Pin assignment week 8 hours per working day.
1
3 to Variation I: 60 cc LC-unit (S60)
⇒ 2.78 cc/100 h = 0.0278 cc/h
Pin assignment of plug ⇒ 60 cc : 0.0278 cc/h = 2158.3 h
⇒ 2158.3 h : 40 h/week = 54 weeks

Pin assignment cable colour signal The lubricant is sufficent for more than 1 year, not including additional operational
1 brown current + breaks or any other machine standstills.
2 white LED green digital
3 blue current -
4 black LED red digital

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7.2.1 Setting the Discharge Period and the Discharge Amount 3.2.2 Components

The discharge amount per 100 operating hours, or the discharge amount per ♦ Lubricators are delivered as requested by the customer in regards to size, and
impulse must be set with the raised dip switches “TIME” on the circuit board of the oil or grease filling. They consist of (see Picture 1):
drive unit.
(a) Plug
You may set/change the raised switches with the help of a small screw driver or
with your fingers. (b) LC – unit (Lubrication Canister), available with the requested lubricant and in
three different sizes (thread size R ¼ ″).
LC – unit is not intended for refilling!

(c) Drive unit, consisting of a tough gear motor and circuit board with serial
7.2.2 Setting the Volume of the LC-Units or Impulse Mode number imprinted (please always provide when calling customer service!). Re-
usable!
The size of the LC-unit or Impulse Mode must be set with the recessed dip switches
”VOL” on the circuit board of the drive unit. (d) LED function display

If the position of the code switch ”VOL” does not correspond to the actual size of (e) Cover, re-usable
the LC-unit, it will lead to malfunctions (see chapt. 8) caused by incorrect signals of
the control unit. (f) Cable with plug, re-usable

7.3 Table of discharge

Amount of discharge in cc (1 cc = approx. 0.9 g Lubricant)

per 100 operating hours / per Impulse

Dip switch “VOL” Dip switch “VOL”

S60 M120 L250 Impulse Mode

8.33 16.67 34.72 2.11
Dip
2.78 5.56 11.57 1.06
switch a b c d e f
“TIME” 1.39 2.78 5.79 0.53
Pict. 1
0.69 1.39 2.89 0.26

NOTE: Impulse Mode is only possible with LC-unit M120!

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7 Drive unit settings

3.2.3 Function
7.1 Function Display
In the LC-unit, a motor driven spindle pushes the lubricant out of the LC-unit. This
moves the piston and builds up pressure in the LC unit of up to 5 bar (75 psi). The The LEDs (Light Emitting Diodes) are on the circuit board and are visible through
automatic pressure shut off will turn the system OFF after several attempts when the transparent cover (see picture 2, chapt. 7.2).
the pressure exceeds 5 bar. The perma STAR CONTROL has a red and green LED. The following signals about
operating conditions/ malfunctions are displayed by the LED for the user:
There are two dip-switches on the circuit board. With the dip switch “VOL” you can
either set the LC-unit size or you can put the unit into the “IMPULSE” mode. With
the second dip-switch “TIME” you can either set the required discharge amount per LED Signal Meaning
100 operating hours, or the discharge amount per impulse (in impulse mode). green steady System functions OK
perma STAR CONTROL will discharge the set amount in several small discharge steady for less than 30 seconds STAR CONTROL is
cycles. Please refer to the following table for discharge amounts per discharge
red
with motor run discharging
impulse.
red steady signal for more than 30 Malfunction/Error
3.2.4 Reference table for discharge amount per discharge cycle seconds
green and
Discharge steady signal LC-unit empty, please change
pause discharge amount per discharge cycle red
period
S 60 cm3 M 120 cm3 L 250cm3
[Months] [h:min] [cm3] [cm3] [cm3] 7.2 Circuit Board Settings
1 1:30
3 4:37 There are two dip switches on the circuit board. The raised switches ”Time” are
0.13 0.26 0.53
6 9:17 used to set the discharge period, and the recessed switches ”VOL” are used to set
12 18:36 the size of the LC-unit, or to put the unit into the Impulse Mode.

3.3 Weights and measurements

Plug connection
Function Display
Weight LED (red/green)
Volume Diameter D Total lenght Weight filled
Type 3 empty
[cm ] [mm] L [mm] with SF01 [kg]
[kg]
S 60 71 142 0.310 0.360
M 120 71 165 0.320 0.430 Raised switch
L 250 71 215 0.360 0.590 “TIME”
R 1/4´´ circuit
board

D Drive LC - Unit
Recessed
switch “VOL”

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3.4 Operating Conditions

6 Changing the LC-unit
3.4.1 Temperatures

6.1 General Note ♦ Temperature range: – 10° C to + 50° C ( +14°F to +122°F )

♦ Within this temperature range, a regular discharge and a max. output pressure
up to 5 bar (75 psi) is guaranteed.
When the red and the green LED light up at the same time, the LC-unit is empty ♦ For temperatures higher than + 50°C (+ 122° F) and lower than - 10° C
and should be replaced. (+ 14° F), the correct function can no longer be guaranteed.

During the LC-unit exchange, it is possible to choose a different size and a different
discharge period for the new LC-unit by resetting the dip switches on the circuit 3.4.2 Ambient Conditions
board.
♦ The lubricators are protected against dust and water jets when the individual
Since the drive unit and the circuit board must always be protected from moisture, parts are assembled correctly.
the exchange must be carried out in a dry place!
♦ Ambient media, especially chemically aggressive substances, may affect
sealing rings and plastic materials.
6.2 How to change the LC - unit

4 Storage
a) Unplug the cable from the perma STAR CONTROL
b) Completely screw off and remove the lubricator from the lubrication point
4.1 General Storage Information
c) Unscrew the cover from the drive unit
d) Remove the drive unit from the LC-unit When the lubricators are not immediately installed, you must ensure appropriate
e) Dip switch settings should be changed in cases where a different size LC-unit storage conditions in dry, dust free, sunlight-protected rooms indoors.
was used, or if a different discharge period is desired (see chapter 7.3.2).
4.1.1 Ideal Storage Conditions
f) Place drive unit on top of new LC-unit until the teeth of both units are locked.
♦ Dry
g) Screw the cover of the drive unit onto the LC-unit hand-tight ♦ Dust free
h) Remove plug from the LC-unit ♦ Temperature +20°C ± 5°C (+68°F ± 9°F)

i) For oil filled lubricators, make sure that the connecting thread of the lubricator 4.1.2 Storage Periods
is additionally sealed with a suitable, standard sealant and that the lubricator is
installed vertically (outlet pointing down)!
j) Screw the lubricator into the lubrication point hand-tight ♦ Up to one year
LC – unit: refer to filling date i.e. 03/06 = June 2003
k) Plug cable back into the perma STAR CONTROL
l) After a reset, perma STAR CONTROL will start with the corresponding pause ♦ More than one year
time. Drive Unit
Drive Unit Cover
Please note that the warranty will expire if above instructions are not Cable and plug
followed.

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5 Starting and operating ♦ Pre-lubricate the lubrication point with the same lubricant that is contained in
the perma STAR CONTROL (see Chapter 5.1.).
5.1 Preparation ♦ Check if the thread of the perma STAR CONTROL (R ¼) corresponds to the
thread of the screw point.
Before installing the lubricator, the lubrication points and any extensions must be ♦ In the switch cabinet, connect the cable according to the PLC-wiring diagram
adequately pre-lubricated with the same lubricant which is contained in the perma for the status display. The connection may only be carried out by qualified
STAR CONTROL. experts and must be carried out according to local standards
For this purpose, perma-tec offers a 400g lubricant cartridge for grease guns. (i. e. IEC, VDE etc.).
(see Chapter 10.1).
NOTE: Incorrect connection of the perma STAR CONTROL could destroy the
♦ We recommend the use of a support adaptor from perma-tec (inner and outer electronics.
thread G ¼ ) when installing the perma STAR CONTROL.
♦ For horizontal mounting positions we recommend the perma STAR CLIP ♦ Unscrew and remove the cover of the drive unit. Set the dip switches “TIME”
bracket to hold the lubricator in place. and “VOL” according to your calculations. Place cover back on drive unit and
remove the plug from the LC-unit. Screw perma STAR CONTROL onto the
5.2 Before Operation lubrication point (handtight). Plug the cable into perma STAR CONTROL.
♦ When you use an oil filled lubricator, all connecting threads must be
♦ Completely check the lubricator for visible damages! additionally sealed with a suitable, standard sealant and the lubricator must be
installed vertically (outlet pointing down).
♦ Check if the LC-unit is filled with the requested grease or oil!
NOTE: After a reset, perma STAR CONTROL will start with the corresponding
♦ Ensure that the cable is plugged into the perma STAR CONTROL. pause time.

♦ Ensure that the dip switch setting “VOL” on the circuit board of the drive unit 5.4 During operation
matches the attached LC unit size.
♦ Carry out regular performance checks during operation.
♦ Ensure that the dip switch setting “TIME” on the circuit board of the drive unit Check for possible leakages and the status of the lubricator!
was set according to user calculations. ♦ Regularly monitor the fill-level of the transparent LC-unit!
♦ In case of malfunctions during operation, please check the trouble shooting
♦ Oil-filled LC-units: Check if an oil throttle is attached.
chart in Chapter 8. If the malfunction cannot be corrected, please contract your
♦ Were all components properly assembled and screwed together hand-tight? perma distributor.

5.3 Initial Operation

Please make sure to refer to point 7.3.2 if the settings must be changed after
♦ perma STAR CONTROL is delivered with a pre-set discharge period of 6 months the perma STAR CONTROL was already put into operation.
and the LC – unit M120 (standard setting).
♦ On request, we can pre-set the discharge amount or discharge mode
according to your requirements.

Regardless of which option you choose, the operator must check the setting
again and carry out any desired changes before starting the lubricator
(see Chapter 7)!

Lubrication Systems 10 11