ACCESSORIES

What is considered an accessory?

In general, our products are divided into broad categories of dividers/feeders, pumps and controllers. Products that do not fit into these categories, but are used in conjunction with these products, are considered accessories.

Can I use a high pressure line filter with grease?

No! Filter elements are too fine and will pass the oil in the grease, but not the soap thickener. This will quickly plug the element with soap.

Can I use a strainer with oil?

Yes! In fact, the 325 mesh strainer is intended for use with oil only and will quickly plug if used with grease.

Where do I find information on check valves?

Consult Bulletin #15825.

What are the pin connections for the 3-pin/4-pin/5-pin proximity switch?

See Bulletin #15600.

When do I use a FSM (Field Sensitive Magnetic) type switch vs. FSM_mech (Field Sensitive Mechanical) type?

(See Bulletin #15600)

The primary determinant will be the lifetime capability of the switch required by the application; normally cycle switch life is desired to be a minimum of 3 to 5 years of operation. Intermittently-applied lubrication systems might typically be operated only 4 times per hour for one switch cycle. These types of applications can use the more economical FSM_mech type of switch where its 10 million+ life rating will give years of reliable use. Re-circulating oil types of systems, however, can accumulate millions of switch cycles per year, so the longer lived FSM type of switch is the more logical candidate due to its 150 million+ life rating. There are both AC and DC control power versions of each type of switch available for MSP, MXP, and MGO applications.

CONTROLLERS

How do I wire and/or program my controller?

Click on links in table below or consult on line bulletins at http://lubriquip.graco.com/pdf/cat_main.htm

What would cause my WMP-III controller to act erratically?

Electrical noise from other signal wires being run in the same conduit as the cycle switch or other sources of electrical noise is the probable cause. Refer to the wiring instructions in Bulletin #14737.

What is causing my WMP-III controller to indicate "Lube Fault"?

Refer to "Fault Messages" in Bulletin #14752.

How do I determine monitor time?

First, determine the total lube volume per cycle required to satisfy system requirements.

Second, determine the volume compressed in the lube lines (assume 1%).

Third, determine the amount of time the pump must run to discharge the total volume.

Fourth, take this time value and multiply it by 1.5 to 2.0 to obtain the monitor time to be programmed into the lube system controller.

As an alternate, program monitor time for slightly less than the program time, and initiate a manual lube cycle. Record the time required to satisfy the lube cycle (pump running time). Multiply this time by 2 and enter it as the program monitor time.

I am using a WMP-III controller to monitor a circulating oil system – why does it keep going into fault?

The WMP-III controller is meant to be used with intermittent operating lubrication systems. It is not designed to be used on continuously operating systems. The correct product for a continuous operating system would be the Lube Sentinel II (See Bulletin #14701).

How can I get my WMP-III controller out of a continuous "Lube Fault" display?

To Reset Faults after the fault is repaired or corrected, press "Display Faults / 5" then press "Reset Fault / 6" to clear the flag. This needs to be done for each flag until all faults are cleared.

What control devices can I connect to a WMP-III controller?

The following connections can be made to a WMP III

What would cause my WMP-III controller to indicate time-out faults even though the lubrication system is cycling and lubricating all of the lube points?

(Refer to Bulletin #14752)

Note: Use shielded wiring and run controller wiring separate from other wires.

DIVIDER VALVES

How do I order an MSP divider complete with a modular zero leak valve?

The modular zero leak, including ordering information, is covered in Bulletin #10105.

What is the part number for the replacement coil for the MSP Shunt/Shutoff valve?

24VDC 492-120-146

115VAC 492-120-128

Why do you offer the MSP menu code with check valves installed in the outlet when the MSP base section has a built-in check valve?

The built-in check valves are adequate for most applications. However, with a cycle switch monitored system, back-flow must be eliminated to prevent the occasional false signal that could result from the valve piston being forced back by pressure in the output line. Check valves installed at the divider outlets provide additional assurance that back flow will not occur.

How does a Series Progressive divider valve operate?

The operational sequence of a divider valve assembly is defined as "progressive". The term progressive means that each valve section completes its piston stroke, discharging a measured amount of lubricant before the following valve section operates. As long as lubricant is supplied under pressure to the inlet section of the divider assembly, valve sections will continue to operate in a progressive manner. Whenever lubricant flow ceases, the valve pistons will stop. When flow resumes, it will start again at the same point in the discharge cycle. Divider valves are available with different diameter pistons and matched bores which also permit them to proportion flow.

What are the maximum cycle rates/per minute for the MSP, MXP, MGO dividers?

Can I put an MSP or MXP bypass section anywhere in the assembly?

Yes, as long as there are a minimum of three working sections in addition to the bypass.

How much volume do single & twin section divider valves dispense?

Nominal outputs are shown below. Actual outputs can vary depending on the operating conditions.

Can the new MSP modular zero leak valve be remote mounted?

Yes, with a combination of a standard inlet, two filter/zero leak bases, bottom feed end and special two section tie rods.

What pressure is required to cycle a Series Progressive Divider?

Divider valves are subjected to an initial test and tested again when built up into assemblies by the distributor. The maximum permissible cycle pressure is listed below. However, system operating pressure can be considerably higher due to the resistance to flow imparted by the lines and bearings.

What is the maximum number of valve sections that can be incorporated into an MSP Divider?

Typically, 8, however, we make tie rods as long as 12 sections which are in the Numeric Price List, but are not shown in the catalog due to their limited usage.

Are Lincoln, Farval & Dropsa Modular Series Progressive divider valve working sections interchangeable with MSP divider working sections?

Yes

Why do you need at least 3 working sections in a divider valve?

If there are only two working sections in a divider valve there is a probability that air, or back-feed from trapped pressure will cause the spools to center themselves stopping the self cycling action which will result in the divider valve not functioning.

In a divider valve assembly, does it matter what size sections are mounted 1st/2nd/3rd, etc.?

Largest section first is preferred. The main reason for this is the long internal flow path from the first piston to its outlet. Small outputs increase the difficulty of bleeding the first section and offer poorer feedback for a blockage signal.

What is the purpose of crossporting a Series Progressive divider valve?

Combining outputs (crossporting) on two adjacent Series-Progressive sections is intended to achieve a greater lubricant output volume to a single lube point than can be provided by a single section.

How do I crossport?

Crossporting is always done in a downward direction with inlet up as a reference point.

The MJ and MX series are crossported using a drilled jumper bar and two hollow bolts that mount in the indicator ports of adjacent working sections. The output is taken from the lower working section and the upper outlet is plugged.

The MSP, MHP and MXP are crossported using a plate that mounts between the upper adjacent working section and its sub-base. The output is taken from the lower sub-base and the upper outlet is plugged.

The MGO series is crossported at the factory by drilling a communicating passage between adjacent sections.

PUMPS

What is the purpose of the pneumatic fitting on my Modu-Flo grease reservoir?

Many people mistake the grease fill stud for an air connection.

The part number for the mating quick disconnect fill coupling is 506-322-000.

How much air volume is required to operate the AL-5, 25, 50 series pumps?

The volume information can also be found Bulletin #12000 for both the AL & HL series.

What is the useable capacity of the various Modu-Flo grease reservoirs?

These capacities are also shown in footnote #3 in Bulletin #12000.

How do I fill my Modu-Flo grease reservoir?

By using a manual or automatic pump with a coupling that mates to the fill stud at the base of the grease reservoir. The part number for the mating quick disconnect half is 506-322-000. Operate fill pump until all air is expelled from hose and coupler. Connect coupler to fill stud and slowly fill reservoir. Note, for the first time grease filling, or if the grease reservoir has been allowed to go empty, open the petcock in the bottom right side of the reservoir. Slowly begin to fill the reservoir, allowing air trapped under follower to exhaust out the open petcock. When grease free of air flows from the petcock, close petcock and continue to fill the reservoir until follower is at vent hole in reservoir tube (any remaining air and small amount of grease will exit vent).

How can we add a high level switch to a Modu-Flo Reservoir for auto fill?

There are no kits available for adding this feature to an existing reservoir. However, we have designed custom pump arrangements that provide this feature for both oil and grease. Contact a local Distributor or contact an Applications Engineer at 1-800-USA-LUBE for details.

Why does the "AL" pump only stroke 1 time?

The AL pump is not a self-cycling pump. The air pressure must be alternately applied and exhausted from the pump so that it can both discharge and prime. A 3-way air solenoid valve is used for this purpose in the single acting mode (spring return) and a 4-way air solenoid valve in the double acting mode (pressure return). The recommended interval for cycling the air valve/pump is three seconds on, three seconds off.

Is it possible to have a High Level Switch used with a Modu-Flo Reservoir?

Yes, there is no menu code assigned, however, we have high and low level switch arrangements for both oil and grease that can be designed into custom lube pump packages.

What is the difference between injectors and piston distributors?

Piston distributors use Elastomeric seals to accomplish internal piston sealing and valving. Injectors have some metal-to-metal fits. Both employ the same operating sequence and offer comparable performance.

Why do you have to vent an injector or piston distributor after completing a lube cycle?

An injector or piston distributor system is vented so the spring loaded piston within the device can return to its normal position and prime its metering chamber for the next lube cycle.

What is the difference between power prime & spring prime piston distributors or injectors?

The firing and priming actions are reversed for the two types of Injectors or Piston Distributors. Spring-prime Injectors dispense their lubricant under rising main line pressure that overcomes their spring loaded metering piston and then reset (prime) when the spring returns the piston after the main line’s pressure is vented. Pressure-prime Injectors reset (prime) when the main line pressure is rising and dispense their lubricant when the main line’s pressure is vented, allowing a compressed spring to force the metering piston forward dispensing the lubricant.

SPINDL-GARD/MILL-GARD (AIR/OIL)

When considering Air/Oil lubrication, at what speed should I choose High Speed Spindl Gard over Standard Spindl-Gard?

You would use the High Speed Spindl Gard when the DN value is 250,000 or higher. (DN = Brg. Bore in MM x RPM)

When would I use a Spindl-Gard system?

Spindl-Gard is recommended for applications where a small continuous flow of oil is necessary. It is dispensed through either a spray nozzle for gears or a small orifice for individual bearings. It is also used in applications where air flow will help to either cool the bearings or keep contamination away from the bearing.

How long can High Speed Spindl-Gard delivery lines be?

As a general rule, Air/Oil delivery lines can be up to 15 feet long, but should be no shorter than 2 feet long. (Refer to Bulletin #42110 "Spindl-Gard Operation and Service Instructions" for further details.)

Where do I find information on mounting Spindl-Gard nozzles?

Bulletin #42110 covers the installation and operation of both Standard Speed and High Speed Spindl-Gard systems including the nozzles.

What are the advantages of an Air/Oil system and why would I use one on a low speed application?

Air/Oil systems are ideal for delivering the very small, but constant volumes of oil required by high speed rolling element bearings (250,000 DN and above) such as found in high speed machining spindles. They also provide air pressure within the bearing housing which prevents the ingression of bearing destroying contamination (water, dust, chips, scale, steam), and the air flow cools the bearing. In addition, the much smaller volumes of lubricant used reduces both the cost of the lubricant and the eventual disposal costs for used lubricant. For these reasons, Air/Oil systems have been successfully applied to High Speed Machining Spindles, Paper Machine Dryer Can Bearings, Steel Mill Work and Back-up Roll Bearings, Continuous Casters, Forming Rolls, Fan Bearings and Large Gear Type Speed Reducers.

What size tubing should I use for an oil system?

Tubing size will depend on line length, flow rate & viscosity of the oil, but are typically 3/16" or 1/4" for secondary lines and 1/4" to 3/8" for pump to master. More specific information is available by contacting an Applications Engineer at 1-800-USA-LUBE.

How do I determine what pressure performance indicator to use for my system?

Estimate the system working pressure and add 50% to determine performance indicator range (not to exceed 80% of pump rupture disc pressure). If the relieving types indicators are used, those used at the secondary divider must be lower pressure than those used at the master. If the reset type, they can all be the same pressure.

What types of lines can be used to pipe a system?

Generally, rigid metal tubing or flexible hydraulic hose, however, plastic tubing may be used in low pressure orifice, piston distributor, or Series Progressive systems, where the operating pressure does not exceed 50% of the tubing burst pressure.

How do you decide whether to use Series, Single Line Parallel, Dual Line, etc.?

Type of system recommendation depends on type of lubricant, extent of system, number of points, and what kind of feed back the customer is looking for.

For Grease:

NLGI # 2 – The choices are either Series Progressive or Dual Line.

• If the system has over 164 points or is over 100 feet long from pump to bearings, use Dual Line, or Zoned Series Progressive.
• If the customer needs feedback from the system to signal blocked lube points or lines, use Series Progressive.
• If the customer requires easily adjustable volume to individual lube points, use Dual Line

NLGI #1

• Series Progressive, Single Line Parallel or Dual Line system can be used.
• Single Line parallel limited to 75 lube points with current equipment.
• If the customer needs feedback from the system to signal blocked lube points or lines, use Series Progressive.
• If the customer requires easily adjustable individual lube points, use Dual Line or Single Line Parallel.
• If the user requires broken line feedback, use Single Line Parallel (Bearing Point Mount), or Series Progressive plus Broken Line Indicators.
• If the requirements are for a system with simple add on capability, use Single Line Parallel or Dual Line.

Oil Only:

All the above systems will apply plus orifice type (Thrif-T-Luber) for small machinery or limited number of lube points (up to 45).

When do I use a soft seal check valve instead of a hard seal?

Use soft seal where air or gas is introduced to a component or lube point as in air/oil or gas compressor systems. The soft seal has better sealing capability for preventing the gases from displacing the oil in the lube lines.

What is "3rd staging" and why is it an unacceptable design practice?

In an acceptable "two stage system", the pump feeds a master divider (first stage) which in turn feeds the secondary dividers (second stage). In a three stage system, the secondary feeds the third stage dividers.

One of the positive attributes of a Series-Progressive distribution system is the ability to inform the operator/user of a blockage anywhere in the system by signaling a lube fault when the cycling activity stops due to blockage. A third- stage divider is sometimes so far away from the central pumping source, and/or cycles so infrequently, that the high pressure necessary to signal a blockage cannot be generated due to the compressed volume of lubricant in the lines between the pump and the blockage beyond the third-stage divider.

How do you determine whether to use oil or grease for lubrication?

The lubricant type is determined by the machinery or equipment builder. However, grease is typically used where lubricant is to be applied less frequently and where high temperature steam, water washout, or high levels of external contamination are encountered. All pumps and distribution systems are designed to use all types of oils and many will handle greases up to an NLGI #2 consistency rating as well.

What determines the frequency of lubrication (lube interval)?

A number of factors impact on lube frequency including lubricant type, bearing type and size and service conditions. As a general rule, it is best to apply the total lube volume in small increments on a frequent basis:

How do I determine which series of divider valve to use in my system?

The MSP family of Series-Progressive dividers is the most commonly used and offer the best balance between output volume and economy. MXP and MGO types are progressively larger in physical size and output volume and are used in systems that require lube point hourly volumes that are much greater than the MSP’s capability. MGO and MXP divider valves are typically used in large stamping press recirculating oil lubrication systems that circulate oil continuously at rates measured in gallons per minute. The MJ family offers volume outputs in the same range as MSP, but are configured in smaller physical sizes that offer the machine builder a divider that will fit into spaces too small for a larger divider.

When designing a lube system, how do I determine bearing groupings?

The lube system designer must recognize where all of the lube points on a machine are located and when it is preferable to group them together to be serviced by a local secondary divider valve. Usually, the grouped points will be within a 5 to 6 foot radius, allowing one main supply line from the master divider valve to the secondary divider valve serving the grouped points. This avoids the alternative of running multiple lines to each remote lube point from the master divider valve. See Bulletin #20101, "Designing a Series-Flo System".

Under what conditions do I use more lubricant volume than the formulas indicate?

The lube point area formulas in Bulletin #20115 will yield lubricant volume recommendations that are adequate for normal/non-extreme working conditions. In the event that the application’s environment includes extreme temperatures, shock, contamination, or water washout conditions, the calculated values from Bulletin #20115 should be increased by Service Factors of 2X, 3X, or 4X, depending upon how many and to what degree the extreme conditions exist in the application. In some applications, such as high speed bearings or injection molding machines, less lubricant is desired and so a service factor of 0.75 to 0.25 may be used.

Third staging is not recommended, but sometimes it is still done. Why?

Third staging is sometimes used when the number of bearing points involved exceed the practical limit for two stages.

Another reason is that some lube points, either singly or in groups, may need very small amounts of lubricant relative to other lube points nearby, so a third stage can be designed to be fed from a secondary feeder and further reduce the output volumes to the values required.

Note, third staging should be employed only as a last resort.

Can you tee two or more divider valve outlets to the same bearing?

Yes, this arrangement will succeed in adding the outputs together to achieve a higher lube volume. A simpler method would be to crossport the two adjacent sections together and provide just one output line to the lube point, with no tee necessary.

What are advantages of a recirculating zero leak header system vs. a non-recirculating header system?

A recirculating zoned (Zero-Leak) header-line lubrication system continuously circulates the oil around a loop back to reservoir during idle periods, resulting in continuous purging of any air in the line and continuous filtering of the oil through the return line filter.

When should you use MD divider valves vs. MJ or MSP divider valves?

When the number of lube points in a group or total system is 6 or fewer and require equal amounts of lubricant. Also where physical mounting space limitations prevent the use of the larger MJ or MSP assemblies.

In oil systems, why do we recommend mounting divider valves in a vertical orientation (pistons horizontal)?

This is the best position to purge the divider valve of air. Further, if a divider valve is mounted horizontally (pistons vertical), gravity may cause all of the pistons to drift to the center position during off periods and be in a centered position when the next lube cycle is scheduled. The result will be a system lube fault caused by the blockage resulting from the centered piston(s).

When do you use a cycle switch -vs- proximity switches in a Series Progressive System?

Economics, cycle rate of the divider valve, expected switch life, system pressure and the size of the pistons in the divider valve stack are all considerations.

The use of cycle indicator activated switch requires the use of an indicating pin integral with one of the valve sections’ dispensing piston. Piston physical size limitations prevent the use of an indicating pin in the smaller valve sections. Therefore, Series-Progressive assemblies with small valve sections would not be candidates for the more economical cycle pin/mechanical switch type of cycle indicator. High cycle rate (above 60 CPM) and continuous operating systems are also poor candidates for cycle switch use, due to switch and indicator seal life limitations. Proximity switches are not limited to any size of valve section and also do not require the use of special valve sections equipped with indicator pins – they are simply and easily inserted in place of the piston enclosure plug on any side of any size valve section. The choice of using a mechanical cycle switch and mounting bracket versus a proximity switch for lube system cycling signals becomes a user-choice between the economy of the former versus the flexibility, convenience, reliability, and longer life of a proximity switch. (Refer to Bulletin #15600 for specifications.)

How do I select the correct pump for an application?

First determine the characteristics and requirements of the lubricant distribution system (Series-Progressive; Injector/Piston Distributor; Orifice) and then identify a pump type that will meet the requirements for the type of centralized lubrication system you will be using, (i.e., gear type for circulating oil, line venting capability for Injectors and Piston Distributors, piston type pump for grease, etc.). Then select a pump power source required to drive the pump according to user preference and/or type of power conveniently available at the application site. Finally, select the pump size for sufficient displacement to satisfy the total lube volume required per cycle. In general, the pump should satisfy the lube volume requirements in 1 minute, or less. With very large systems, the pump run time can be extended, but should not exceed 5 minutes.

What valve do you recommend for a shutoff valve (zone valve) on a grease header system?

On smaller header systems using NLGI #O or lighter grease and having short runs, you can use the MSP Shunt/Shutoff valve with either solenoid or the pneumatic operator. On larger systems with long runs, the pneumatic operator is recommended.

For heavy-duty applications using NLGI #1 or #2 grease, or where low temperature may be encountered, use a commercially available, heavy duty shutoff valve.

What can we use for electrical control at operating temperatures below –20°C?

Monitors and controllers utilize electronic components and Liquid Crystal Displays (LCD) for readout information. The speed and response time of LCD’s are affected by low temperatures and are generally limited to operating temperatures above –12^oC (+0^oF). For lower temperatures, the unit would need to be installed in a heated enclosure.

Why are both a cycle indicator switch and a pressure switch used in a Series Progressive system?

The cycle switch signal regulates lube volume (number of divider valve cycles) and results in a time-out fault when not received within the monitor set time.

A pressure switch is typically used for fault feedback when a cycle switch is not used, or when relieving indicators are used (blockage will not stop the system) and can provide additional diagnostics to identify the cause of a problem on any Series Progressive system.

How do you design a Series Progressive system?

The design of a Series-Progressive lubricant distribution system begins with the calculation of each lube point’s volume requirement. The formulas for estimating these requirements can be found in Bulletin #20115 and in the diskette file Lube Volume Calculator.xls issued with Technical Notice No. 99-194 (May 6, 1999). The system design can then be continued by following the procedures detailed in Bulletin #20101 (Designing a Series-Flo Feeder System). Additional information can also be found in Bulletin #20105 (Designing a System for Mobile Equipment).

What happens to the output of the secondary divider when you change a valve section on a Master divider that supplies that secondary and replace it with a smaller/larger section?

Assuming the system volume is controlled by feedback from a cycle switch mounted on the master divider, all points fed by that secondary will receive less lube if the replacement master valve section is smaller and more lube if it is larger.

If system volume is controlled by pump strokes, then all other secondary dividers (point groups) would receive less lube if the master valve section is made larger and more lube if made smaller.

Can a cycle switch be installed on a secondary rather than the master divider?

Yes, customers that desire to monitor line integrity from the inlet of the secondary back to the pump will put the cycle switch on the secondary.

How do I calculate the "equivalent area" of linear guide bearings?

Use the shaft diameter squared and multiply by three.

How does speed affect the lube requirement for a bearing?

The rotational speed of a bearing is not normally a factor in calculating its lube volume requirement unless the DN value (bearing bore in MM x RPM) is over 250,000. For applications where the speed (DN value) is above 250,000 constant delivery, air/oil systems such as Spindl-Gard™ and Mill-Gard™ are recommended and the lubricant volumes calculated from Bulletin #20115 are reduced as follows:

DN Value % Reduction

250,000 – 500,000 20

500,000 – 750,000 33

750,000 – 1,000,000 47

Over 1,000,000 50

How do you deal with lube requirements that are smaller than the smallest section size available?

If the smaller bearings can be combined into a common group, the secondary/master divider relationship for this group can be set up to lubricate less frequently. If this is not possible, the small bearings will be over-lubricated.

In designing a Series Progressive System, why isn’t the divider valve section size chosen equal to the hourly requirement?

One reason is that it is generally best to lubricate with small volumes more frequently. A second reason is the basic ratio approach to system design used in Bulletin #20101 establishes the best fit of available valve outputs to required volumes using the fewest number of valve sections. This will result in the most accurate and least costly system.

How do I deal with a bearing(s) that are much larger than the rest of the group?

If a master divider + secondary divider distribution system is in use, the lube points with the largest hourly volume requirements may need to be serviced from the master divider in order to provide the larger required volumes. Alternatively, cross-porting two or more sections of a divider assembly together can achieve volume outputs that are beyond the range of a single valve section.

How do I determine how much lubricant to apply to overhead conveyor chain & wheels?

This is a function of the actual conveyor chain and wheels and environment and is determined by factory application engineers once they have the conveyor information. They will provide the system designed specifically for the conveyor. The actual lube intervals for the conveyor will depend upon the application, i.e., temperature, service, wash- down, etc. Conveyor applications assistance is available at 1-800-275-5574.

Why is the formula the same for ball bearings, roller bearings, needle bearings, when there appears to be different surface areas?

An adjustment for surface area can be made by treating medium length roller bearings as 1-1/2 rows and long roller and needle bearings as two rows.

How do I determine the correct amount of lubrication for my bearing/slide/etc. lube point?

Refer to the Application Engineering Guide Bulletin #20115 or the computerized Lube Volume Calculator.

How can I add or delete a lubrication point to a Series-Progressive lube system?

To delete a lube point, you can change a Twin Section Valve to a Single Section Valve or you can replace a Valve Section with a By-Pass Section as long as at least 3 working sections remain. To add a lube point you can change a Single Valve Section to a Twin Valve Section or you can add an additional section to the divider assembly. In either case, you may need to reconfigure the master divider valve. Remember that a single(S) section delivers two shots of lube to a single outlet.

How is a Series Progressive System designed for the wet end of a paper machine?

The same criteria would apply as for other Series Progressive systems. If it is a small machine, a master to secondary divider valve system will suffice. For larger machines, you may need to use a zoned system with Zone 1 for the Fourdrinier Drive Side, Zone 2 for the Fourdrinier Tending Side, Zone 3 for the Press Section Drive Side and Zone 4 for the Press Section Tending Side.

How do we calculate line pressure loss in a grease lubrication system?

The exact pressure drop in any given line size will depend on the inside diameter of the line, the flow rate, the temperature, the NLGI grade number and the formulation of the particular grease being used. The number of elbows and bends in the line will also increase the total pressure drop. However, the following when used with two simple rules of thumb will allow you to make a reasonable approximation of the pressure drop in the line.

1. Pressure drop is directly proportional to line length (pressure drop/FT x line length in FT = Pressure Drop in the line).

2. Pressure drop will approximately double for each 30° drop in temperature.

What kind of pressure will my system see with different oils or greases?

The pressure that any lubrication system cycles at is dependent on the size of the system, the length of lines, the number of elbows, and tees, the tightness of the lube points, the lubricant being used, and the operating temperature. As a rule of thumb, a typical oil system will cycle at less than 1200 PSI, and a grease system will cycle at less than 2200 PSI. If the systems cycle above these pressures, a closer examination of the system should be made to verify the cause of the high pressure.

How can I verify that my lubrication system is providing oil to my bearings?

There are several options to provide feedback that a lubrication system is in fact cycling, but to give a positive indication of oil flow to a bearing you must use a Lube Point Monitor which is a flow switch that can be mounted in the bearing inlet. It will provide an electronic signal every time it is cycled. A controller can monitor this signal and if a signal is not received during certain time interval signal a lube fault.

Another option, depending on the application would be to use an Air/Oil system. This system can detect both blocked and broken lines through the measurement of air pressure in the lines. Air pressure monitoring of line integrity, when combined with cycle switch monitoring of Series Progressive divider valve operation, can provide a positive indication of oil delivery to the bearing.

What should I do when I have a grease system with over 200 lube points?

Several choices:

1. Header system with feedback from each zone to a Multi channel controller such as the MPC.
2. Dual Line system feeding Series Progressive dividers with cycle switch input back to a PLC.
3. Dual line system with no feedback.
4. LubriSystem with motor driven pump such as the Lubemaster modified to include a vent valve if the grease is a fluid type.

How can I run several different oil or grease systems and supply each from one lube pump mounted on a barrel?

The systems need to be tied into a common header with zone shutoff valves for isolation. Control and monitoring of the zones will require a Multi-Purpose Controller, Flexi-Monitor or PLC.

What cycle switch should I use for my stamping press lube system?

This depends on the Electrical requirement, connection requirement, operating pressure whether it is a high cycling circulating system or a terminating system. The high cycling systems require switches that have a cycle life over 150,000,000 cycles. Systems with high pressure spikes require a 10,000 PSI rated switch. (See Bulletin #15600 for proximity switch specifications.)

When is a balancing valve required in a Series Progressive system?

A balancing valve is used when pressure differences between lube points or between two secondaries are in excess of 1000 PSI. The valves are adjustable and provide back pressure which brings the pressure differences closer together ensuring that the divider outputs will equal their nominal rating(s).

How can I detect broken lines in an application?

A broken line indicator is one option. Circulating oil press applications sometimes use two check valves, one at the divider valve and one at the bearing inlet, with a pressure switch between them to signal a broken line.

START-UP/TROUBLESHOOTING/REPAIR

How do I repair my Modu-Flo (AL-5, AL-25, AL-50, HL-5, HL-25, HL-5X) pump?

Consult Bulletin #42000.

What is the correct way to bleed a system on startup?

(See Bulletin #30103)

The most thorough and efficient method to purge the trapped air in a Series-Progressive distribution system is to start at each lubrication point and work back toward the central pumping source, purging each line and feeder assembly in reverse order.

On a parallel system, the plug at the last manifold in each branch line should be loosened and all air purged from the main lines. Tighten the previously loosened plugs and cycle the system until all bearing feed lines are full and purged of air.

How can I find out if a specific lubricant will work in a Trabon Series Progressive system?

We have tested a variety of greases for use in Series Progressive and Injector systems. These test results are available through a local distributor, or by contacting an Applications Engineer at 1-800-USA-LUBE.

The first test is to determine if the oil and soap in the grease sample tend to separate when used in a Series Progressive system. Separation can cause the divider valves, lines, fittings, or bearings to become plugged with soap.

The second test confirms the lubricant’s compatibility with the seal materials used in the LubriSystem and Grease Jockey pumps and injectors and establishes the lowest temperature at which it can be pumped and vented in the LubriSystem or Grease Jockey test system.

The tests are conducted under controlled laboratory conditions which may or may not approximate the operating conditions in a particular system. For this reason, the final selection of a lubricant should be based on the machine manufacturer’s recommendation plus the machine’s operating experience in the user’s environment.

We do not normally test oils, because there are no constraints to pumping oil as long as its viscosity, at the application temperature, does not exceed the maximum, or minimum viscosity ratings listed in the catalog literature for the particular pump, or dispensing device.

What lubricant do you recommend for my machine?

As a general rule, the machine builder should be contacted for his recommendation on the type and grade of lubricant to be used. We offer the WearMaster line of lubricants and when provided with the builder’s recommendation, plus the specific application parameters (temperature, environment, type of bearings, etc.), we can recommend and quote a WearMaster lubricant.

What could cause a Series Progressive divider valve to stop cycling?

This is a very broad question. There are many reason why a divider valve would stop cycling.