Oil Lubrication Systems

OLA... Oil+Air Lubrication Systems Operating Manual Version 02

Contents Page 1

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Imprint

The operating manual is part of the scope of supply of a VOGEL Oil+Air Lubrication System. The manual has been edited in conformity with applicable standards and rules for technical documentation. © Copyright WILLY VOGEL AG reserves the right to make changes to adapt to technical improvement. Reprinting or copying even of parts of this man-ual requires the permission of WILLY VOGEL AG. Editor Dipl.-Ing. S. Schlenzka

Contents

Information Concerning the EC Declaration of Conformity and the Manufacturer´s Declaration........................2 Notes Concerning this Manual ...................3 Applications..................................................3 Safety Instructions.......................................4 Transport, Delivery, Storage .......................5 Design and Function....................................5

Principle Function of Oil+Air Lubrication....... 5 Design of the Oil+Air-Lubrication System ..... 5 Components and Operating Elements .......... 6

Compact unit (1) ......................................... 6 Control valve for compressed air (6) .......... 6 Pressure switch for minimum air pressure (8)................................................................. 6 Oil+air dosing unit (9)................................. 8

Function........................................................... 9 Types and Designations ............................... 12 Lubricants...................................................... 13 Compressed Air ............................................ 14

Installation ..................................................14 Setup ............................................................. 14 Electrical Connection.................................... 14

Compact unit ............................................. 14 Pressure switch for minimum air pressure15

Control and Monitoring of the System ......... 15 Systems without controller........................ 15 Systems with controller ............................. 15

Connecting the Lubricant Lines ................... 15 Installation of Nozzles ................................... 16 Compressed Air Connection ........................ 18

First Operation........................................... 19

Filling the lubricant container ........................19 Adjusting the Lubricant Consumption ..........19 Adjusting the Air Consumption .....................19 Setup Operation ............................................20

Operation ................................................... 21 Maintenance .............................................. 21 Failures....................................................... 22 Decommissioning...................................... 24

Temporary Shut-Down ..................................24 Final Decommissioning.................................24

Service........................................................ 24 Specifications ............................................ 25

Information Concerning the EC Declaration of Conformity and the Manufacturer´s Declaration Page 2

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For the product designated below: Oil+Air Lubrication Systems Series: OLA xx-xxxxx we herewith certify that it conforms to the pertinent safety requirements set forth in the following Council Directive(s) for the harmonization of the laws of the Member States... • Electromagnetic compatibility 89/336/EEC • Electrical equipment designed for use

within certain voltage limits (low voltage directive) 73/23/EEC

Notes (a) This declaration certifies the conformity with

the directives listed, but does not entail an express assurance of properties.

(b) The safety instructions in the documentation accompanying the product must be observed.

(c) Taking into operation of the certified products is not allowed until evidence has been provided that the machinery, vehicle or similar item, into which the product is integrated, conforms to the regulations and requirements set forth by the applicable directives.

(d) The operation of the products on non-standard line voltage as well as non-adherence to the installation instructions can affect the EMC properties and electrical safety.

We further declare that the above mentioned product: • is meant for integration into a machine / for

connection to other machinery according to the EC - Machinery Directive 98/37/EC, Annex II B. Taking into service is not admissible until evidence has been provided that the machine in which this part is installed or to which this part is connected, conforms to the regulations set forth in the EC directive 98/37/EC.

• with reference to the EC directive 97/23/EC concerning apparatus subjected to pressure this product must only be used as intended and according to the notes in the documentation. Especially observe the following:

VOGEL products must not be used in conjunction with fluids, group I (hazardous fluids), according to the definition of article 2 paragraph 2 of the directive 67/548/EC dtd. June 27th, 1967; and are not approved for application with such.

None of the products manufactured by VOGEL are approved for application in connection with gases, liquefied gases, gases dissolved under pressure, steams or fluids that will reach a steam pressure of more than 0.5 bar above the normal atmospheric pressure (1013 mbar) in the admissible application temperature range.

Provided they are used as intended, the products supplied by us will not reach the limit values set forth in article 3, paragraph 1, numbers 1.1 to 1.3 and paragraph 2 of the directive 97/23/EC. Therefore they do not come under the requirements set forth in annex I of that directive. Therefore, they are not marked with the CE mark concerning the directive 97/23/EC. They are classified by us to come under article 3 paragraph 3 of the directive.

VOGEL products must only be used as intended. Use or taking into operation of the products in areas with potentially explosive atmospheres according to the ATEX directive 94/9/EC is not allowed, regardless of whether these entail gaseous atmospheres or dusty atmospheres.

If required, you may request the declaration of conformity or manufacturer’s declaration for this product from our central contact address.

Information Concerning the EC Declaration of Conformity and the Manufacturer´s Declaration

Notes Concerning this Manual Page 3

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Notes Concerning this Manual VOGEL oil+air lubrication systems have been made in conformity with the generally recog-nized rules of technology and the applicable safe working practices and the rules for acci-dent prevention. Still hazards may be involved in their use, which can lead to injury of operators or other persons or damage to the machine or other property. To ensure trouble-free operation and prevent hazards, we kindly ask you to read the present manual carefully and observe the notes con-tained in it.

Text marked with this sign alerts to special hazards or work that must be performed with caution.

Please, use the table of contents to locate the desired information promptly and successfully. Note that this operating manual is a part of the system and must be handed to the new owner upon sale of the system.

Applications

All products of Willy Vogel AG may be used only as intended and according to the information set forth in the respective operating manual. We expressly emphasize that dan-gerous materials of any type, espe-cially materials which are classified as dangerous according to EC direc-tive 67/548/EEC article 2, paragraph 2, may be stored and transported and/or distributed with VOGEL products only after consulting Willy Vogel AG and receiving their written consent. None of the products manufactured by VOGEL are approved for applica-tion in connection with hot gases, liquefied gases, gases liquefied under pressure, steams or fluids that will reach a steam pressure of more than 0.5 bar above the normal atmospheric pressure at the maxi-mum admissible temperature.

Unless expressly stated for a spe-cific product, products made by VOGEL must nut be used in areas with potentially explosive atmos-pheres.

The oil+air lubrication system here described is used for controlled lubrication of components subjected to high or highest strain, e. g. bear-ings of high-speed spindles. Other use or use beyond this purpose is con-sidered unintended. VOGEL will not accept liability for damages resulting from such unin-tended use.

Only media suitable for the system type may be supplied. Unsuitable media can lead to failure of the sys-tem and consequential severe prop-erty damage and personal injury.

Further information concerning the lubricants are found in the chapter “Lubricants”, page 13. VOGEL will not warrant for damages resulting from use of lubricants other than those approved by VOGEL.

Safety Instructions Page 4

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Safety Instructions

Please observe the following safety instructions to ensure trouble-free functioning of the unit and prevent damage. Use the units only in technically perfect condi-tion for their intended use. Be aware of hazards and observe the operating manual. The safety mechanisms must not be damaged, dismantled, or in any way made inoperable, nor must they be replaced by parts which have not been expressly approved by VOGEL. The general rules and safety regulations for work with compressed air-operated machines, devices and systems must be observed. The system must be disconnected from the compressed air supply and electric voltage and depressurized before undertaking any work on it, e.g. cleaning, refilling with lubricant, etc.

The oil+air lubrication system may be subjected to pressure. Before extension work, changes, repairs etc. it must be depressurised, there-fore.

The installation, electrical connection and all interventions such as repairs, component replacement, etc. may be carried out only by adequately qualified and instructed personnel.

The electrical installation of the unit must be carried out exclusively by trained specialists. If the system is installed improperly, substantial property damage or injury of per-sons may be the consequence.

DANGER, FATAL INJURY Repair work must only be performed after a trained specialist has dis-connected the unit from power. Before removing the cap of the compact unit, the supply voltage must be switched off.

DANGER, FATAL INJURY Work on systems which have not been disconnected from power sup-ply can lead to injury of persons.

Qualified personnel has been trained, instructed and specifically ordered by the owner to perform the work. Due to their training and experience, these persons are familiar with the applicable standards, regulations, accident prevention rules and operating conditions. They are authorised to perform the respective tasks and capable of identifying and avoiding possi-ble hazards. The definition of what is a trained specialist and the prohibition of use by unquali-fied personnel are set forth in DIN VDE 0105 or IEC 364. Unauthorised alteration of the device and use of unapproved spare parts and auxiliaries are not allowed. Worn-out systems must be made inoperable and disposed of properly.

Transport, Delivery, Storage Page 5

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Transport, Delivery, Storage The oil+air lubrication system is packed according to market standards in conformity with the regulations of the respective country of destination and DIN ISO 9001. Transport pack-ages must be labeled with the note “Do not throw!”. There are no limitations for transport by surface, air or sea. The oil+air lubrication system is supplied fully assembled on an assembly plate. Upon receiving the package, please check the items for possible damage, and ensure the package is complete by checking the delivery papers. Keep the packaging material until any and all problems have been clarified. In general, the product should be stored in a dry and dust-free environment. The storage tem-peratures can be found in the specifications.

Design and Function

Principle Function of Oil+Air Lubrication

Oil+air lubrication is a lubrication method fea-turing minimum volume dosage. The finely dosed lubricant is distributed in the form of streaks by air flowing inside a narrow lubricant supply line and is thereby transported to the lubricating point. By means of a nozzle, the lubricating point is continuously supplied with lubricant in the shape of fine drops. The lubricant volume required for each lubri-cating point can be dosed precisely, resulting in optimum lubrication conditions at the friction points. Design of the Oil+Air-Lubrication System

An oil+air lubrication system is comprised of the following components: • un-controlled or controlled compact unit (1)

with gear pump, lubricant container (2), the valve set required for relieving and pressure limiting, an oil pressure switch and a float switch for level monitoring. Depending on the version, a pressure gauge (4) is installed.

• control valve (6) for compressed air with pres-sure gauge,

• pressure switch (8) for minimum air pressure, • oi+air dosing unit (9) with integrated piston

feeders and mixing valves. The components are installed on an assembly plate and are supplied as a complete system. Figure 1 shows an oil+air lubrication system in standard version without controller. Depending on the application, further compo-nents may be integrated, such as • oil filter (with or without electrical contamina-

tion monitoring), • air filter, • additional pressure switches for lubricant and

compressed air supply, • additional float switches for filling level moni-

toring inside the compact unit. These components, however, are optional and not covered by this operating manual. Observe the respective technical documents supplied.

Design and Function Page 6

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Components and Operating Elements

Figure 1shows the oil+air lubrication unit. Figure 2 and Figure 3 show different oil+air dosing units. Compact unit (1) The compact unit (1) is comprised of the lubri-cant container (2), the gear pump, a float switch for level monitoring in the lubricant container, a pressure switch with optional pressure gauge for monitoring of the pressure in the lubricant lines and the valve set required for relieving and pressure limiting. Depending on the version, a controller may be integrated. In this case the pressure gauge may be missing, since the signals of the oil pressure switch are then processed by the controller. The function and operation of the compact unit and the controller are outlined in the respective operating manuals. Control valve for compressed air (6) The control valve for compressed air is used to set the air pressure precisely. This is required because the lubricant can only be dosed pre-cisely when the air pressure is maintained at a constant level. The pressure is set manually and can be read off at the integrated pressure gauge. Additionally, an air filter with water sepa-rator may be integrated (optional).

Pressure switch for minimum air pressure (8) The pressure switch monitors the supply air pressure. As soon as the air pressure drops below the set minimum value (see specifica-tions), the switch outputs a signal. This signal can be used to trigger an error message and shut off the entire machine. This is required because the lubricant can no longer be trans-ported through the lubrication lines to the lubri-cating points when the air pressure is too low. In some systems the pressure switch for mini-mum air pressure is connected to the integrated controller. When the air pressure drops, the controller outputs a warning signal and switches the machine off (also see technical documenta-tion of the controller).

Figure 1. Design of the oi+air lubrication system (schematic representation, subject to changes) 1 Compact unit 2 Lubricant container 3 Filling connector 4 Pressure gauge for oil pressure

(optional) 5 Compressed air connection 6 Control valve for compressed air 7 Pressure gauge for compressed air

supply 8 Pressure switch for minimum air

pressure 9 Oil+air dosing unit


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Oil+air dosing unit (9) The oil+air dosing unit (Figure 2) is comprised of a compactly designed valve block with maximum six (type MV50X, Figure 2, Pos. 11) or maximum eight outputs (MV20X-20 type, Figure 3, Pos. 11). If more outputs are necessary, further valve blocks can be connected in series to the oil+air dosing unit. In the oil+air dosing unit, the lubricant for each greasing point is charged and is supplied by the air stream over the oil+air greasing pipes to this greasing point. At each greasing point the air current can be regulated by air regulation screws (Pos. 10). The valve block of the MV50X type covers the range of small dosing quantities of 2 mm³ and 6 mm³. The dosing of the valve block of MV20X-20 type goes from 10 mm³ up to 160 mm³. In oil+air units (OLA) the valve blocks of both types can be installed together (see connection overview Figure 5). So the dosing range of 2 mm³ up to 160 mm³ can be supplied with one unit.

06 02 0606

A B A B

OIL

AIR9

10

11

13

14

16

Figure 2. Oil+air dosing unit MV50X (schematic representation, subject to change) 9 Oil+air dosing unit 13 Oil supply connection 10 Air-adjustment screws 14 Compressed air connection 11 Connection for oil+air lubricating lines 16 Pressure control valve


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Valve blocks of type MV50X have a mounted pressure control valve (pos. 16, Figure 2) with an opening pressure of 23 bar. It provides a self-employed ventilation of the main pipe. The pipe outlet of the pressure control valve is connected to the feedback of the container (see hydraulic system , Figure 5). The ventilation is carried out self-employed for each pump run and provides a bubble-free ventilation of the lubrificant to the dosing unit in MV50X.

Using the oil+air dosing units of the MV50X type, only one pressure control valve (23 bar) can be mounted at the end of the unit (see hydraulic system, Figure 5).

Function

Figure 4 and Figure 5 show the hydraulic system of an oil+air greasing unit in different versions. The lubricant is filled into the lubricant container of the compact unit. The gear pump integrated into the compact unit pumps the lubricant to the oil+air dosing unit. The compact unit operates in cycles, that is, each lubrication cycle is followed by a pause. The pause times are con-trolled either by the controller integrated into the compact unit or directly by the machine´s con-trol system. The same holds true of the moni-toring of the filling level and the lubricant pres-sure.

AIR AIR

OIL OIL

9

10

11 15

12

13 13

15

14 14

Figure 3. Oil+air dosing unit MV20X-20 (schematic representation, subject to change) 9 Oil+air dosing unit 13 Oil supply connection (either right or left) 10 Air-adjustment screws 14 Compressed air connection 11 Connection for oil+air lubricating lines (either right or left) 12 Pressure measuring connection (M5) 15 Plug screw for installation of dosing units


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The compressed air is conducted via the pres-sure control valve to the oil+air dosing unit where it is mixed with the lubricant that has been dosed separately for each lubricating point. The lubricant dosed is then transported through the lubricant lines to the nozzles at the friction point. The air flow distributes the lubricant along the lines in streaks and it thereby flows along the lines. At the nozzles, the lubricant is dis-pensed in the form of fine drops and thereby applied to the lubricating point. The air leaves the lubricating point almost oil-free. The compressed air supply is monitored by a pressure switch. The switch signal, which comes either from the pressure switch directly or from the controller of the compact unit, is processed by the machine´s control system. If the compressed air pressure is too low, the machine must be shut off, because the lubri-cating points can no longer be supplied with sufficient lubricant.

MV204-20

xR

M

DS1

P2P1x

DS2

4-

Figure 4. Hydraulic diagram of an oil+air lubrication system with oil+air MV20X-20 dosing unit


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MV204-20

M

DS1

x

4-

DS2

4-MV504

23bar

MV504 4-

R P2P1

Figure 5. Hydraulic diagram of an oil+air lubrication system with oil+air MV20X-20 and MV50X dosing units


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Types and Designations

Table 1 explains the type code indicated on the nameplate of the system.

Table 1. Type key

Designation OLA 04 - 2 3 0 01 + 428

System designation

Number of oil+air connections

Controller

Container size

Filter

Version number

Voltage code

Controller: 0 - without 5 - IG54-20 2 - IG38-30 9 - other

Container size: 0 - without 3 3 litres 1 - below 2 litres 6 - 6 litres - plastics 2 - 2 litres 7 - 6 litres - metal 8 - > 6 litres - metal

Filter: 0 - without 2 - air filter 1 - oil filter 3 - oil and air filter

Version number: 01-99 - two-digit count number (determined by VOGEL)

Voltage code For details refer to the respective documents and the nameplate of the motor


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Lubricants

Only media suitable for the system type may be supplied. Unsuitable media could lead to failure of the system and possibly severe prop-erty damage and personal injury.

Please observe the notes of the machine manufacturer concerning lubricants to be used.

Lubricants with solid substance additives may not be used.

Do not mix different lubricants, since this may lead to damage and may require costly cleaning of the lubrication system. To avoid confu-sion, it is recommended to attach a note concerning the lubricant to be used to the lubricant container.

In units of type OLA mineral or synthetic as well as rapidly biodegradable oils may be used. The requirements upon the lubricants to be used are summarised in Table 2. Note that the properties of some lubricants may lie within the limit values indicated, but these may not be suitable for use with oil+air lubrica-tion systems because of some other properties. For instance, synthetic lubricants may be incompatible with the material used for seals.

VOGEL offers to test lubricants for compatibility with oil+air lubrication systems. Avail yourself of the advice of VOGEL employees. Keep in mind that oils and greases are generally considered environmentally hazardous and combustible substances and that their transport, storage and processing require that special safety measures be taken. Also observe the safety datasheet of the respective lubricant. For high-load operations and low speeds oils with EP additives are especially recommended. Oil of a viscosity lower than indicated in Table 2 should not be used, since their bearing capacity at higher loads may not be sufficient, which in turn may shorten the servicelife of bearings. Oils with solid substance additives must not be used, because solid substance particles could accumulate in the nozzle bores and choke these. Also bearing play might be critically reduced by attachment of solid particles to bearings.

Table 2. Admissible oils

Requirement Values

Recommended oil purity class*

13/10 (ISO 4406) or class 4 (NAS 1638)

Recommended ISO VG class*

32 ... 100 related to 40 °C

Operating temperature 40 °C ... 100 °C

Recommended additives EP additives

Inadmissable additives Solid substances

* Observe the notes of the machine manufacturer.

Installation Page 14

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Compressed Air

The air must be dry and filtered. For water sepa-ration, a water separator as offered in VOGEL´s pneumatic component delivery programme with semi-automatic drainage (if at all possible) is sufficient. The detailed requirements upon the com-pressed air are outlined in Table 3. The required air volume is stipulated as follows: for use of oils with viscosity higher than indicated in the rec-ommendations, or with higher adhesion, a higher air consumption must be expected.

Installation

Setup

The oil+air lubrication system should be installed protected from moisture and vibration, but easily accessible. The filling level of the lubricant container and an optional pressure gauge must be clearly visible. Also, sufficient space must be available to refill with lubricant and make settings. The system is fastened with the assembly plate to the machine housing. The installation dimen-sions and location of assembly bores are given in the customer specific drawing. Electrical Connection

Compact unit

The compact unit must be con-nected electrically by qualified, trained specialists that have been authorised by the owner to do so. If the compact unit is installed improperly, substantial property damage or injury of persons may be the consequence.

The compact unit is connected electrically by means of a plug to the line socket supplied. It is not necessary to open the compact unit to do so. If necessary, control lines must be fed through the cable union and then connected to the ter-minals on the inside. The wiring diagrams are printed on a sticker attached to the inside of the cap. The terminal assignment differs from unit to unit with the respective options. When inductive consumers are connected to the float switch or pressure switch, the contacts must be protected by suitable measures.

The supply voltage on site must agree with the information on the nameplate. Check the fusing of the circuit. Use only the original fuse with the required ampere value. If other fuses are used, damage to property or personal injury may be the consequence.

Further information concerning the compact unit is found in the operating manual for compact units.

Table 3. Requirements upon compressed air

Requirement Values

Input pressure min. 0.3 MPa max. 1 MPa

Required air volume (pipe with 2.3 mm inside diameter, recommended oil viscosity range)

1000 - 1500 l/h

With reference to the compressed air quality classified to ISO 8573-1

Particle count class 3

Maximum particle size 5 µm

Maximum particle count 5 mg/m³

Dew point under pressure

class 4 maximum: +3 °C

Oil concentration class 3 maximum: 1 mg/m³


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Pressure switch for minimum air pressure The pressure switch for monitoring of the supply air pressure is connected by means of a con-nector. Detailed information on this is found in the respective technical documentation. Control and Monitoring of the System

Systems without controller On systems without controller, the system is controlled and monitored by the machine’s control system. The following functions are controlled: • The pause time or the pump run time,

depending on the amount of lubricant required at the lubricating points (see chapter “First Operation”) and the requirements upon the operating mode of the pump motor (also refer to the specifications).

The following functions are monitored: • the minimum compressed air pressure, • the oil pressure or oil pressure build-up, • the filling level inside the lubricant container. The pause times or pump run times should be set depending on the amount of lubricant required at the lubricating points (see chapter “First Operation”). The minimum runtime of the pump (chapter specifications) and the required pump dwell time must be observed.

The pump dwell time is the period during which the pump continues to run after the required oil pressure has been reached, to ensure the dos-ing chambers of the dosing unit are supplied reliably with lubricant. The required oil pressure is reached when the oil pressure switch is acti-vated. The recommended pump dwell time can be extracted from the specifications. For monitoring of the oil pressure please note that a few seconds will always pass between start-up of the pump and activation of the oil pressure switch. We recommend to program a fixed monitoring time for pressure build-up, to ensure that an oil pressure error message is only generated after this time has run out. Rec-ommendations are found in the specifications. If the oil pressure is insufficient, the system must be shut off to ensure that the lubricant lines are not blown empty. Monitoring of the minimum supply air pressure and the filling level of the lubricant must be such that error messages are output if the supply pressure fails or drops, or if the minimum filling level is reached in the lubricant container. Be sure to program a buffer time in the machine’s control system to ensure that possible brief pressure fluctuations in the supply system will not trigger an error message.

Systems with controller In systems with a controller, control and moni-toring of the operation is taken over by the con-troller. Corresponding notes can be extracted from the operating manual of the controller. Connecting the Lubricant Lines

Only original parts made by VOGEL must be used.

Connect the lubricant lines as outlined in the diagram in Figure 6. The lubricant lines should be made of transpar-ent plastic tubes to enable visual inspection of the lubricant transport. The requirements upon the lines are outlined in Table 4. The lines may be installed with rising or falling inclination. Approx. 0.5 to 1 m before the nozzle (17), a spiral (16) is installed, which serves as lubricant reservoir. Upon shut-off of the com-pressed air, the lubricant distributed inside the spiral will collect at the bottom end of the wind-ings, thus no wait time is required to ensure that the lubricant is distributed along the entire lubri-cant line. The centre axis of the spiral should always be horizontal. Avoid changes of cross-section from lower to higher cross-section in flow direction. Design changes of cross-section smoothly.


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To monitor the lubricant flow in the lubrication lines, VOGEL recommends to use a streak sen-sor GS4011 or GS6011. Installed downstream of the mixing point for air and oil, the streak sensor allows to monitor the transport of the fine lubri-cant flow along the lubrication line wall. Consult with VOGEL technicians concerning this or request our descriptive materials. Further information relating to connections are contained in the specifications. Installation of Nozzles

Supply of the lubricant to the bearings depends entirely on the type of bearing and the design features of the bearing´s location. On single-row bearings the lubricant can be applied to the bearing laterally. The nozzle bore should be on one level with the inner race. By no means should the oil+air flow be pointed directly at the ball cage. Figure 7 shows exam-ples of recommended lubricant supply configu-rations.

On bearings that entail a pumping action in one direction (e. g. angular conical ball bearings), the lubricant must be supplied in this direction. If possible, the lubricant should be supplied to the bearing by means of a special nozzle piece; its length depends on the size of the bearing. Alternatively, the lubricant can be supplied directly to the outer race via a supply bore. Ensure, however, that the lubricant is not sup-plied into the pressure zone between ball and outer race (Figure 8).

On double-row cylindrical roller bearings the lubricant should be sprayed into the bearing from one side on the same level with the outer race track. It will then be distributed almost evenly on both bearing rows (Figure 7). On antifriction bearings with an outside diameter between 150 and 280 mm it is recommended to install a second nozzle. If the bearings are even bigger, install even more nozzles.

Table 4. Key data for installation of lubrica-tion lines

Requirement Values

Minimum length up to the spiral 2 m

Maximum length of the spiral 10 m

Recommended lines 6x1 mm or 4x0.85 mm

Figure 6. Assembly diagram for oil+air lubrication lines; 9 - Oil+air dosing unit, 16 - Spiral, 17 - Nozzle


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If the lubricant is supplied through the outer race, a single bore is sufficient for most applica-tions. The air pressure indicated in Table 3 is gener-ally sufficient to penetrate the air turbulences caused by high-speed bearings. If a higher air pressure should be required in an individual case, this will not impair the function of the entire system. To prevent an oil sump from forming at the bottom section of the bearing, the lubricant supplied must be drained. To ensure this, it is recommended to provide a drain bore. As a guiding value for the diameter of the drain bore take six times the cross-section of the supply opening(s), but at least 5 mm. If you have further questions concerning instal-lation of the oil+air lubrication system, please contact your technical consultant at VOGEL. Figure 7. Recommended lubricant supply for diverse bearing types


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Compressed Air Connection

Ensure that the main air valve is closed before connecting the com-pressed air line.

Only original parts made by VOGEL must be used.

Information concerning the compressed air supply connection are found in chapter “Speci-fications”. Please note the requirements upon the com-pressed air listed in Table 3. If required, an air filter with water separator should be used to ensure that the required compressed air quality is reached. It is recommended to install a controlled valve into the supply line, e.g. a 3/2 directional valve, to enable shut-off of the compressed air supply in case of failures. When the compressed air supply is faulty, this helps to ensure that the lubricant supply lines will not be blown empty.

Figure 8. Lubricant supply through the outer race

First Operation Page 19

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First Operation

Filling the lubricant container

The lubricant container is filled with lubricant through the filling neck (pos. 3, Figure 1). The system must be started only approx. 15 min after filling, to ensure air bubbles in the lubricant can escape.

Do not mix different lubricants, since this may lead to damage and may require costly cleaning of the lubrication system. To avoid confu-sion, it is recommended to attach a note concerning the lubricant to be used to the lubricant container.

Adjusting the Lubricant Consumption

The lubricant consumption at the friction point must be determined by the machine´s manufacturer. Gener-ally it is defined in mm³/h.

This volume is subdivided into as many as pos-sible short cycle times with low dosing volumes.

Cyclemm

dh

Cyclesn

hmm

V33

Oil ⋅=

Cyclemm

d

hmm

V

hCycles

n3

3

Oil

=

n number of cycles per hour VOil lubricant consumption at the friction point

(Please note that several lubrication points may be present at one friction point or bearing location)

d dosing volume per cycle The dosing volume per cycle (d) depends on the version of the oil+air dosing unit. Example for a typical configuration:

Cyclemm

30

hmm

200150n

3

3

−=

hCycles

75n −=

The number of cycles per hour (n) found is used to determine the pause and pump run times. The minimum runtime for the pump and the pump dwell time must be taken into account (see chapter “Installation”). For systems with integrated controller, the adjustment of the pause times is described in the operating manual of the controller. Adjusting the Air Consumption

The air consumption depends on the amount of lubricant supplied, the number of lubrication lines and the specific properties of the lubricat-ing point. The operating pressure must be adjusted so that the required volume can be supplied in all lines; the pressure loss in the line and at the lubricating point must be taken into account. Base the correct adjustment for the air con-sumption on the information supplied by the machine´s manufacturer or on empiric data. The most important criterion is the visual inspection of the continuous and even flow of lubricant through the lines.

First Operation Page 20

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Set the operating pressure at the compressed air-adjustment valve (pos. 6 in Figure 1). It should be set between 0.3 and 1 MPa (3 to 10 bar). The air consumption of the individual lubri-cation lines is set using the corresponding air-adjustment screw (pos. 10 in Figure 2 and Figure 3) at the oil+air dosing unit (pos. 9 in Figure 1). Note: It is not possible to shut off a lubrication output entirely using the air-adjustment screw; a mini-mum supply volume will always remain. Changing the air consumption of a lubrication line will always influence the air consumption of the remaining lubrication lines. When the compressed air pressure build-up is failing, the oil+air lubrication system and the machine must be shut off, to prevent insufficient lubricant supply to the lubricating points.

Setup Operation

• Close the compressed air control valve (pos. 6 in Figure 1).

• Remove the plug screws of the compressed air measuring connection (pos. 12 in Figure 3) at the oil+air dosing unit (pos. 9 in Figure 1).

• Switch the line voltage on and let the com-pact unit cycle until the lubricant drools bub-ble-free from the opening of the compressed air measuring connection.

• Reinstall the plug screw. • Open the compressed air control valve (pos.

6 in Figure 1) and adjust the operating pres-sure (0.3 - 1 MPa or 3 - 10 bar).

• Let the compact unit cycle until a continuous lubricant film has formed in the lubrication lines and fine lubricant drops escape from the nozzles.

• Watch the oil+air lubrication system and set the air consumption with the aid of the air-adjustment screws (pos. 10 in Figure 2 and Figure 3) or the compressed air control valve (pos. 6 in Figure 1). Especially watch for formation of an uninterrupted oil streak inside the lubrication lines.

Operation Page 21

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Operation

The oil+air lubrication system operates auto-matically. Nonetheless, the lubricant supply along the lubrication lines should regularly be checked visually and the air supply should be readjusted if required. Also regularly check the lubricant level in the lubricant container and refill lubricant if required, as outlined in chapter “First Operation”. Note: On oil+air lubrication systems with controllers, a pre-lubrication cycle is started upon each power-up, to ensure continuous lubricant sup-ply. If the system is switched on and off fre-quently, this may result in excessive lubrication.

Maintenance

VOGEL oil+air lubrication systems require little maintenance. However, in order to ensure faultless functioning and to prevent dangers from arising, check all connections regularly. If necessary, the compact unit can be cleaned with mild, material-safe (non-alkaline, no soap) cleaning agents. For safety reasons we recom-mend to separate the system from the com-pressed air supply and electric power supply before cleaning. If possible, leave hoses and cables connected while cleaning and close any openings to pre-vent cleaning agents from entering the interior. Interior cleaning is not necessary in normal operation and if compatible lubricants are used. If an unsuitable or dirty lubricant has been used, the interior of the lubricant container must be cleaned. Please contact us if this situation arises.

The lubricant container must not be disassembled; this would invalidate any warranty claims.

WILLY VOGEL AG assumes no liability for dam-ages which accrue from improper installation work on the minimum-quantity lubrication sys-tem.

Failures Page 22

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Failures

Table 5 provides an overview of possible fail-ures and their causes. You should contact us if the problem can not be rectified by taking the measures described here.

DANGER, FATAL INJURY Repair work must only be performed after a trained specialist has disconnected the system from power. Before removing the cap of the compact unit, the supply voltage must be switched off.

DANGER, FATAL INJURY Work on systems which have not been disconnected from power sup-ply can lead to injury of persons.

Table 5. Failures and their remedy

Problem Possible cause Remedy

No operating voltage applied to motor

Have an electrician do the following:

• check supply connection • check power plug or power cable

and correctly connect it • check operating voltage at the

motor • check fuse • check push-button, replace defec-

tive push-button

Motor too hot, the thermal protec-tion has been triggered

Correct on-time of motor (max. on-time see Specifications).

Pressure switch for minimum air pressure tripped

Missing or too low air pressure

Before any other work switch off power supply to the unit!

Pump motor does not start running when the operating voltage is switched on or when the DK button is pressed.

Pump blocked Remove pump, turn it manually; if it runs hard, replace the pump; turn motor manually, if it runs hard, replace the motor. Use only original VOGEL spare parts.

Wrong lubricant (see Specifica-tions)

Replace lubricant in the entire system. Remove old lubricant entirely before and dispose of it properly.

Pressure too high, pressure relief valve jammed or defective

Check pressure relief valve; replace if required.

Pump or motor jammed Clean pump or return system for repair.

Motor runs hard at too low speed.

Ambient temperature too low Increase temperature.

Failures Page 23

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Table 6 continued. Failures and their remedy

Problem Possible cause Remedy

Air in the main line Vent the line.

Line broken Repair the line.

Relief valve does not close Replace the relief valve.

Insufficient filling level Filling with lubricant

Pump or pump motor defective Replace, return pump or unit for repair.

No pressure is built up in the main line.

Motor does not run or runs hard See failure “Motor runs hard”.

No pressure build-up in the lubrication line, dosing valve(s) do(es) not shift.

Relief valve jammed (contami-nated)

Clean or replace the relief valve.

Decommissioning Page 24

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Decommissioning

Temporary Shut-Down

For temporary shut-down of the oil+air-lubrica-tion system separate the entire system from compressed air supply and electric power sup-ply. For long-term shut-down we recommend to pump empty the lubricant container. Final Decommissioning

If you should terminally decommission the oil+air lubrication system, please observe the legal regulations for disposal of oil-contami-nated equipment. The system can also be taken back by VOGEL for disposal, provided the costs are covered.

Service

If you encounter problems or have questions, please contact our technical sales and service centre or our representations. You can find a list with current addresses on the Internet at: • www.vogelag.com

Specifications Page 25

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Specifications

Table 6. Specifications

Designation Unit Values

Entire system

Dimensions W x H x D with assembly plate mm depending on version (see customer drawing) Weight (filled) kg depending on version (see customer drawing) Number of oil+air outputs - 1 ... 24 (inquire for > 24)

Compact unit

Container volume, nominal l 3 or 6 (inquire for special sizes) Flow volume l/min 0.2 (inquire for special flow volumes) Operating pressure MPa (bar) 3 (30) Operating temperature °C +10 ... +60 Supplied medium - oil on mineral oil or synthetic basis, compatible with NBR and Viton Recommended ISO VG class - 32 ... 100 Opening pressure of pressure relief valve MPa (bar) 3 (30) Enclosure type - IP 54

Motor

Operating mode (to VDE0530) (e.g. for 1.25 min cycle time, the run time is 15 s, the mini-mum pause time is 1 min)

- Standard version: S3, 20 % (1.25...25 min)

Operating voltage, standard V 230 V 50/60 Hz or 115 V 50/60 Hz (inquire for others) Thermal switch - Standard version: installed Rated speed at 50/60 Hz min-1 2700/3300 Power consumption at 50/60 Hz W 105/125

Oil+air dosing unit

Number of oil+air connections per oil+air dosing unit Type MV20X-20 Type MV50X

pcs pcs

1 ... 8 1 ... 6

Specifications Page 26

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Table 6. cont. Specifications

Designation Unit Values

Oil pressure switch (part of compact unit)

Contact type - normally open contact Maximum switching voltage V AC 42 Maximum switching current A 2.5 Maximum contact load VA 30 Switching pressure MPa (bar) 2 (20)

Float switch (part of compact unit)

Function - opens when filling level is too low Maximum switching voltage V AC 48 Maximum switching current A 0.7 Maximum contact load VA 50

Pressure switch for minimum air pressure

Switching pressure MPa (bar) 0.1 ... 1; adjusted: 0.3 (1 ... 10; adjusted: 3) Switching capacity - resistive: 6 A at 24 VDC and 0.5 A at 220 VDC

inductive: 6 A at 24 VAC and 3 A at 220 VAC

Connection of oil+air lubrication lines

Oil+air output - M8x1, countersunk for double conical ring pipe union for pipe ∅4

Compressed air connection

Operating pressure MPa (bar) 0,3 ... 1 (3 ... 10) Air consumption (for pipes with internal diameter of 2.3 mm, oil to ISOVG 32...100)

Nl/h 1000 ... 1500

Compressed air connection - M10x1, countersunk for pipe ∅6

Control system

Recommended pump dwell time s 5 Recommended monitoring time for oil pressure build-up s 30

Notes

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Notes

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Notes

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Notes

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951-130-178 february, 2007

Willy Vogel Aktiengesellschaft A company of the SKF group Motzener Strasse 35/37 • 12277 Berlin • Germany PF 970444 • 12704 Berlin Phone: +49 30 72002-0 • Fax: +49 30 72002--111 [email protected] • www.vogelag.com • www.skf.com

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Oil Lubrication Systems

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