Centralized Lubrication Systems Two-Line System Planning Manual # posttach 1263 Heinrich-Hert2-Ste D-6909 Walldort/B. Tel, (06227) 33-0 Fax (06227) 33259: Telex 466088| How a Two-line System works. hg andamental operation principle of the two-line system does not alter, any the components of the Pretelone tee apetted of controling the altomation of ilow/preeaure in the two malt tos chavo Treen te following isa detaied explanation of the operaiton of a typical autornulle imovine Grease lubrication system, which incorporates an electrical change-over vals. |dormant lubrication pump unit and the elactrically oporated change-over valve sce connected viaa | fo the indiveted fe ahd a permanent ralict ine, two main ines thea eer as oe change-over valve orthe nada! lubricant metering devices in parallel, via sullabie bier Connection lines. Atthe end Se symai lines the pressure controls ara connactod, compriaine eine adjustable pressure switches NG. if cequired, a main line pressure monitor unit, Henen tho centrat lubrication pump is operated, lubricants deltvered through the permanent pressure Ip camig tte change-over valve Into one of the main lines of ihe syores The other main line of the systern {B connected to the pump roservole via the change-over vee asks Pormanent relief line, the (Gurr gill continue ta deliver lubricant and the pressure wil ene #@ in the main line until 4 the {olal lubricant low resistance fs avercome and the elovant meee Gilferential Is obtained between inanite main lines at the end ofthe ayatom, At this polit, af noes eer perating pistons within tha rea tual metering devices have been actuated andmeasured aan te lubricant have been delivered to the lubrication points. (hen all of the metering davices have been operated, half of the total quantity of lubrication points tho lube Pt9 the system have becn supplied with libricant. The saen ‘operating pistons within Gayebicant metering devices ara n the extreme position of rary nes ‘avoiding any further lubricant ; tant a ite lubrication Systom ta nycrauitcaly closed af this tent 9 Ne Prossure continues to rise | Fo in ocKINS pressure set on tho final presgure suillch ie roaches Be ipunal pressure switch sends an stecrical signal tothe change esr valve, and the reversing process Sr neiated via the electric contral box which changos overine lew ct ne lubricant in the two main lines Gidhe sysiom. The provious pressure lina becomes ins rele! ine aed te revious reliaf lina becomes {ie new pressure ling down-stream of the change-over val, A tRemP motor will bece-enaraised anlthe timing olay for timing ihe Preset pause timawill beactivated, Atthis stage a half lubrication cycle is completed prseetnG Preset pause time af tha timing relay has expired, te pump motor is ‘energised anceagain, the lubroatensotor le de-eneraised and the timing rolay Is actuated for fre sent Pause time, One complete besrcation pulse has now been achieved and all he lubsieation poems ‘Connected into tite system have been supplied with a measured quantity of lubricant. ihe Mowing system is equipped with a monitoring system, this hasaleo to the installed at, ornaar, the sth the sont dine and its function fa fo monitor ine pressure changes in tame lines in conjunction with the separate tims delay relay, i ss pRny reason, the foqulrod maximum and minimum pressures are not boing achieved, a visual of gelay, ° W2mING System is oparatad as soon as the preset time has cise ic Separate time delay : relay. ieencaltoring syatom is permanently checking the ubricalion system against fracture of the main tino, || | Ialure of the change-over velve ang meena Limer fallura of the central puimp; clogging of ths in en filter and luck of lubricant in the pump reserve eleLINCOLN-HELIOS Two-Line System with electrically operated change-over valve and warning systemAUTOMATIC TWO-LINE PUMPS AND SPECIFICATIONS ZPU10 Output = 1.8 kam (approx. 110 in®/h, Max, Prossure~ 300 bar (4,400 psip zPuB Output 6 kg/h (360 In*/hy Max. Pressure =300 bar {4,400 psi)"OPERATION AND SELECTION OF CHANGE-OVER VALVES LINGOLN-HELIOS offer two types of change-over valve, | 1, Sell-rovarsing pressure onerated Electrically operated Both types perforin the same function: First hall cycle uty Second hall eycle Tee Tate | uti, Self-reversing pressure operated change-over valves: ‘The pressure at which the valva is required to change over is pro-sot on the pilot rolfel adjusting screw on the top of the unit. This pressure Is assessed during commissioning of the system, and is generally recommended to be approximately 30 bar (440 psi) higher than the witnessed pressure required at the pump to operate the terminal metering device in the system. For adverse ambiont conditions and Considerable variations of temperature, \hls pressure seiting should be increased accordinaly. Under normal circumstances, this arrangement will ensure that the change-over valve will only operate after all metering devices been actuated in the system. A conirol pin actuates a switch to provide tho electrical signal for the electrical control system to start and stop the pump, generally as Goscribad previously ‘The solf-reversing, pressure operated chango-over valve provides a very practical and economical method of controlling the change-over process of an automatic two-line system. However, really requires to be oporated with an end of main ling elactrical presaure manitoring arrangement in order to ‘monitor that the main ines remain undamaged and without lenks, whlch; as can be appreciated, would ot ba monitorad by the chango-over valve alone, This type of change-over control is also generally limited to a system with one pump and one change- over valve, where all the connected lubrication points will receive lubricant during the same cyclo of lubrication. ; | |Electrically operated change-over valves: 3 DMain tines Tho pressure at which the electrical change-over valve operates Is controlled by.the pre-set pressure switch located at the end of the main tine system. Because of the control signal emanating from the end of the two main tines, inherent monitaring of the main pine lines Is provided, ita separate time delay talay also monitors the time taken for actuation in relation to the known normal time. However, once again, this type of change-over control should be ideally operated in conjunction with an end of main line maximum and minimum olectricat monitor unit. This is because itis important to monitor that Not ‘only does the pressure rise in the pressurlsed main line to the required valve, but alsa, when the line [s subsequently relieved, the presaure falls sufficiently to provide the required minimum pressure differential of 50 bar (730 psi) between the two lines at the emd of he system. This type of electrical change-over contro! is also ideally suitad for designing lubrication systems having @ single pump unit, together with two or more different aldctically operated change-over valves, each having ils awn separate lubrication cycle requency.TWO-LINE METERING DEVICE MODELS AND OPERATION LNCOLN-HELIOS supply gonorally ane range of two-line metering device called the "VS" serles, Each gt the three sizes of metering device operates in the same manner, and cifers prineipslly only in the outlet quantitiy of lubricant delivered per oullet and lubrication cycle. ‘The operating principle Is.as follows: Stage? | Prossurlod lubrcant ls eupptid to t RY {He metering unt via rain br i The central piston {stats moving Inthe detction of erow A, cepa? ing ihe lubricant in Hon ot tha nto pison in a valved main linet stage 2 hon a ont rinon uncovarelno connection pasa 2} tara arto (othe sys ahve the lagenaing sien fa} ioby displacing corn nt | cemmmnvetnes fa a aoa crere— Ve 25[ 2e| 25] comueinesMETERING DEVICE SELECTION CHARTS: FLAT BEARINGS/ | | METERING DEVICE SELECTION CHARTS FLAT BEARINGS: to 2 30 9 50 60m 40 90 100 PEPTLET Te 50 75 100 us 150 IS 2a 798 150Us not possible to bo particulary spectic inthe selection of lubricant metering devices for these types of bearings. ln goneral torms, the lubrication requirement for anti-friction bearings is much less than for equivalent sizes of plain bearings. However, for tho purposes of planning a two-line centralized lubrication system far lubricating antl- friction bearings, the following guide will provide satistactory resulls: Anii-friction hearings to be connected into an automatic two-line centralized lubrication system MUST. have a provision within the basic desiga, or as a subsequent allachment, to allow the used grease !o discharge trom the bearing housing. ((e: labyrinth, relief bore or aver-llow valvo). When such anti-riction bearings are connacted into aa autamatic two-line lubrication system, they naturally be oparating with their entira internal volume full of grease. For this reason, itis a general rule that the rate of shear of this grease must be limited fo within a shat peripheral speed af 2 metras/ second (1.2. baaring having a shaft diameter of 200 mm, should have a maximum speed of 600 rpm). ‘There are naturally exceptions to this rula, as In the case of pre-filled grease lubricated antl-triction bearings within electric motors. These bearings will operate at speeds of up to 3000 rpm. However, stich bearings will be very accurately, bre-filled with an exact quantity of grease so as to leave at least 30% of the intarnal volume free within which the grease can move around and iinimise the creation of overheating caused by oxcessive intarnal shearing ofthe groase, Such bearings should nat be connected into an automatic centralized lubrication system. The actual figures and information for theindlvidual anti-friction boatidgs, In terms of total internal grease volume and the recommended time between each complete change of this lubricant, are available trom the bearing manufacturers. When thase ligures ara available and ara In ralation to the. ‘operating temperatura and conditions (sae following notes) the aclual {ubricant metering davica selection and lubrication cycle frequency can be easily calculated as follows: EXAMPLE: Bearing internal volume=38 cm* and recommended lubricant change frequency = 1.500 hours. Then t cm* could be suppliad avery 40 hours approximately, to provide the same result However, by selacting our smallest metering device giving 0.6 cm*/stroke & cyclo, it willbe seen thal a lubrication cycle time of 24 hours wil provide the required result, The foltowing graph, table and calculated example will enable a reasonable accurate calculation ta be made in the absence of the required information trom the bearing manufacturer in terms of recommet ved grease change frequency. With regard to the bearing total Internal volume, If this is not readily. available {rom the bearing manufacture, it must be assessed by practical experiment using a grease: gun of known culput valume per stroke, 59.000 mt 30.000 | — scope wirkw waice « —|——— 30.000 |— #®eaxaown witr occur x Wf (Wwaxicanr 1s. Hor cHaNGes i 19.000 * @ 5000 3 2.000 | aul = 2.000 |—, scope wrrnin waicn Toral vouUMe oF WanicanT Hust te 1.000 change 500 || = ee 200 200 ' agree 10 20°50 FACTOR" NOTE: npn 00 5 This table and information Is based on normal rane luhlum soap based grease a a temperatura up = BE. to 70°C and normal “clean” operating concitiona. He peepee vere Consul the further important nates in this section of the planning manual for guidance as to how ® =FacTonron TYPE higher temperaturos and extrome dirty or wet aeane conditions will afact the above ligures,Type of Bearing Factor "B" Radial-grooved ball bearing 48 Tapered ball bearing 14 ‘Axial-grooved ball bearing 12 Cylindrical rolter bearing (with cooting) 10 needle bearing ‘Taper roller bearing 0.8 Oscillating rottee bearing 06 Cylindrical roller bearing 05 | axiat rotter bearing 03 EXAMPLE A taper roller bearing having an Internal volume of 40 cm? is required to operate at 300 rpin, Therefore, to find the recommended grease change fraquency {if not supplied by the manu- facturer of the bearing) faktor "F" on bottom axis ‘of graph is calculated as follows: ra gene Inthiscase t= g00 ica $00 0g emis By reference to the graph and projecting up Irom the bottom axis at the value F= 1.6, it will ba found that a safe change frequency of 500 hours. 'a indicated, Therefore a total of 10 em! of grange must be changed every 500 hours, or 1 cm? avery 60 hours. By using our gmaltest metaring device Model VSM, giving 0.8 cm®/stroke and cycle, a lubrication cycle time of 30 hours will achieve the required reault HIGHER TEMPERATURE OPERATION ‘Tha aforementioned information Is suitable lor operating temperatures up to 70° C. For every 15° C leinperature rise above this value, the recommenced grease Irequency change time in hours should be halved. EXAMPLE — upto 70°C=graph hours 71+ 85°C = graph hours 2 86-100° G — graph hours 7 101-116° C= graph hours a ele, In general terms, operating temperatures above 150°C will demand special grease considerations. i iDIRTY AND/OR WET ENVIRONMENTAL CONDITIONS I the anti-iction bearing Is of a design which has open labyrinths on the outside and it has to operate {in abnormally dirty oF wot conditions, then the recommended grease change frequency in hours, must also be reduced In relation to the circumstances, Spacitic cecommencations in this respect are very difficult to provide, but this is very surely one of tne areas of system planning where any doubts should be aiven the benaiit of proiiding tao much lubricant rather than too little. In the extreme case of a victually “open” bearing operating In adverse conditions, tho graase requirement can be equal to that of an equivalent sized plain bearing measured by the shaft diamotor, ‘The foregoing information shows quite clearly that the tubrication requirements for ant(ictton boarings can usually be provided by the application of our smallest matering device model VSM. The only possible exception to this is when elther high temperatures and/or dirty/wel conditions are prevalent, Lubrication cycle frequencies which are generally much longer than Is required for plain Bearing kibrication, are general, but these cycle limos can he reduced by reducing the oufpul of he VSM metering device. The maximum reduction of effective volume with these VSM metering dovices is in the ratio of 1:8. Naturally, any subsequent reduction of metering device output volume will have a direct and equal effect on the originally caiculated lubrication cycle frequency, (Le. by halving the ‘output volume per cycle from the metering devices, the lubrication cycle frequency lime is also halved to achieve the same required end result), bearings of widely varying lubrication requirements are to be connected into a common lubrigation system (0.4 machine having a high temporature and normal temperatura zono} itis recommended that a’single pump system with two separate electrically controlled cireulls, having differant lubrication, oycles, be considered. GROUPING AND LOCATION OF METERING DEVICES. Aiter sizing the mataring davices requirad for the different bearings In relation to a Gomnicn lubrication oycle frequency, itis pretorable-to arrange the grouping of the metering devices in stich a manner that utilises the minimum number of actual metering device, subject to the genoral limit for the maximum feed line lengtt: (metering device to bearing Inlet) of approximately 6 in (20 ft), The epson for tying to uso ine minimum aumber of actual metering devices within tha system sto control the number of branch line connections that will be necesszry into the two main distribution pipe: lines. This procedure will naturally minimise the overall cost of the system and simplify installation, TOTAL METERING DEVICE USABLE VOLUME FINALLY, CALCULATE THE TOTAL METERING DEVICE USABLE LUBRICANT VOLUME 'FER LUBRICATION GYCLE BY REFERENCE TO THE CUTPUT AND CONTROL VOLUME TABLE FOR THE VARIOUS METERING Model Control Volumes: ‘Output vsM O.6.em* perouttot & cycle 0.8 cm? per outlet & eycie (0.04 in?) vs@ 0.6 em* per outta & cycie 2.9.cm® per ouilet & cycle (0,14 in?) vst. 0.6 cm? por outlet & cycle 5.0 om® pec outst & cycle (O.3tin’) TOTAL METERING DEVICE USABLE VOLUME (em) = TOTAL OF MAXIMUM OUTPUT VOLUMES PER OUTLET AND TYPE OF METERING DEVICE AND LUBRICATION CYCLE (cm) + TOTAL OF CONTROL VOLUME PER OUTLET ANO LUBRICATION CYCLE (cm), Convert this total to decimetres cubed (dm?) by dividing by 1000 (L:2. move decimal point three places to the tof, “Then convert to kilogrammes (kg) by assuming a specitic gravity of 0,9. Therefore, the total volume in {dim*) x 0.9 ~ Total capacity in kg. t |2ND STEP LAYOUT AND SIZING OF MAIN LINES AND BRANCH LINES The general maximuin operating pressure of LINCOLN-HELIOS two-line systeins is 300 bar (4,400 p.s.L) ‘Therefore, it is recommenciad to use cold drawn seamless steel tube to specification DIN 2391 and. compression-type pipe fittings. Howaver, good quality scale-free stoel pipe of adequate pressure rating and wall thickness, with high prossure forged steel threaded pipe fittings, may also be used, ‘The layout and routing of the two main lines should be given Careful consideration, so as to maintain tho minimum overall length of all main fines, and also {a keep all branch linas as short as possible to each metering device. NOTE: \tis the total distance fram the pump to the farthest metering device in tho aystem that determines the actual maximum prossure foss within the main ina, Therefore, one should always consider locating the pump unit in the most central position within the fubrication system so as to equalise and minimise the maximum pressure loss in the total system. The main factors effecting the sizing of the two main lines ar: 1. Pump oulput volume 2. Type and quality of grease lubricant 3. Minimum anticipated ainblent temperature 4, Total distance Irom pump to farthest metering device In systam, PUMP OUTPUT VOLUME A ihis stage, itis not known what pump Output volume ls required because we have not calculated the compression volume raquirement par cyclo for the whole syatem, This compression volume fequirement generally accounts for up to 80% of the total pump output volume. per cyclo, However, we cannot calculate the compression volume requirement of the system until we know what size of main Tine we are golng to use, because tho volume af tne system will vary directly as the square, of the internal diameter of the main pipe ines, Clearly, we must make an estimation at this stage of the pump type we will use in order to progtoss, (we-study the pressure loss graphs, It will be soon that {ne actual pump output volume (horizontal axis) has a relatively Insignificant effect on the pressure loss value (vertical axis) for example, batwoon 30 cm#/min and 200 cm#/min output, the presaure less varies only approximately f bar/mette, ‘Therefore for the purpose of assessing the ritaia line size to be used, It Is recommended to use a pump output value‘of 100 cm?/min on the horizontal axis, ‘TYPE OF LUBRICANT Tha type and quality of the grease lubricant to be used Is normally indicated by ofther the manufacturer of the machine, the client or user of the machine. For this purpase, wa consider the NG. classii- cation number of the grease, which determines lls conelgtency or penetration class. However, the NUGI classification number does not give a full Indication of the actual pumpabilly of ‘he grease, This particular and vary important property a a grease lubricant varies with tho diferent manufacturers’ lypes and qualities, For this reason, it Is generally recommended to bias towards the plus side ofthe final pressure loss reading irom the following sample grapha: However greater experiance in handling difterent quality areases will provide more knowledge af their different pumpa~ bility characteristics, For example, greases having a lead basad extreme pressure additive (EP) will havo abettar pumpablily characteristic than those without. Conversely, some groasos havo. greater {tore content; particularly some of the lithium soap based greases, and this gives them a lower pumpa- bilty characterlatic: AMBIENT TEMPERATURES The minimum anticipated ambient temperature should be used as the basis for sizing main lines from the following graphs, Itthe machine fs within’@ factory building, itis to be expected that the temperatiure should not fall below: 0° G (50? F) in relation to what is a normally accepted minimum for the machina operator. However, tor machines that operate in en outside environment, the average recorded miniivm temperature should be used. For really cold condilions of, say, minus 30° G and below, normal soap based greases become very difficult to pump over any significant distance. At these temperatures, special extreme cold temperature greases must be used and special graphs would also be necossary MAXIMUM OISTANCE - PUMP TO FARTHEST METERING DEVICE ‘This clistance is the total ofall pipe runs of ane of the two main lines from the pump outlet to the branch take-off point to tha farthest metering device in the aystem. Be caratul to ensura that you hava identified the farthest metering device from the pump in ratation to the total pipe length.SAMPLE GRAPH WITH EP ADDITIVE GREASE TYPE = TYPICAL NLGI No. 2 TEMPERATURE =+20° ¢ 201 Wimfewd NP BLve MOTE os as OT pws EN TFT oT aH wey so vo PRESSURE DROP IN BARI METRESAMPLE GRAPH GREASE TYPE = TYPICAL NLGI No, 2 WITH EP ADDITIVE ‘TEMPERATURE =0° C Mintfen HY 3EMe MOTs wet e f ve G1 HH? oN ore} Or Het m7 NEL WHO PRESSURE DROP iN BARI METREoe Winona MI 249 Mors po ieee ipa eg SAMPLE GRAPH Loe ey ae COT Wasi t si cra. yu Mapedl, ge Or Ww ET eg acai gs Gi HoT; ae 28 0 : Sze : EET : E too a EE ag : BS ft ot 5 i ® of PRESSURE DROP IN BAR/ METREUSING THE SAMPLE PRESSURE DROP GRAPHS 1. Select the appropriate graph retating to the tyne of grease and the misimum ambient temperature applicable, 2. Identity the appropriate value along the horizontal axis in relation to a pump output of 100 em*/min, 3. Its recommended to select a size of maln line that will produce a maximum pressure dropin the distance “pump to last metering device” of approximately 165 bar (2,425 psi). Therefore, divide the known distance in metres from the pump to farinest the metering dovice into 165 bar, which will give the maximum preferred figure for pressure drop per metre, to be read off the vertical axis of the graph, ‘Then by projecting up irom the selected point on the horizontal axis and along from the preferred point on the vertical axis of the graph, identify with a pencilled cross the intersection of the lwo axes. The most suitable size of main line pipe for the particular set of conditions is than chosen byidentitying which fine (indicating the various internal diameters of tube or pipe availaite) runs the nearest to this, intersection and immediately beneath the intorsection, NoTE: ‘The reason for limiting the total pressure drop figure over thi distance “ump to the farthest metering device" lo approximately 165 bar Is that we must ensure that the pump has sufficient reserva capacity 16 ‘overcome the residual pressure which will be present in the other relieved main tine; an addilional pressure of approximately 50 bar (740 p.s..) Is also eequired to cycle the metering device and over- come tha normal bearing enity resistance. From experierica It has been found that a reasonable and workable eatimata is to assess the residual pressure remaining In the second relieved main line as being 30% of the total pressure drop liqura, which we have sald should not exceed approximately 165 bar. This astimate will be approximately correct when a minimum of 2 minutes exists between each haif lubrication cycle, For longer pause times, the use of this 30% estimate wil Introduce a calculated reserve. Therefore, It can be sean that the nump must be capable of producing a working pressure of 165 bar (total prossure drop) + 49.5 bar (say 50 bar) (residual prossure in vented line) + 50 bar (terminal distributor and bearing entry resistance) = 205 bar. It can alsa be shown thal, by racommeniding the Selection of 165 bar as the approximale maximum total pressure drop figure and also by suggesting the selection of the pine size ling thal falls beneath the Bctual graph intersection, there aro twa reserves incorporated. Thesa ave, firstly, that the pump is Capable of attaining 200 bar maximum working pressure (i. 95 bar reserve) and, secondly, hat the fclual pressure drop figure may be less then {65 bar by the amount the slected pipe size tine Is balow the graph intersection. itis theso reserves that can be Increased or decteased depending upon the @uality and pumpability characteristics of the grease belng used, IMPORTANT NOTE ‘These printed pressure drap graphs are jntencled to provide a basis for this system planning process. ‘They are reasonably accurata oniy for a typical IRhium soap based arease with EPadditive and an NGL ofassitication of No. 2. Is recommended ta obiain specific pressure drop araps for the typé of grease to be used from the manufacturer of the grease lubricant in order fo obtain an accurate result, Also, vory useful graphs and Information on the “steady tlow of greasa in pipes” can be obtained from the National Lubricating Groasa Institute (NLGI), 4635 Wyandotte Street, Kansas Cily, Missouri 64112, U.S.A. However, in the absence of any specific information, the printed sample graphs can be used with ‘caution, far most manufacturers’ types of NLGI No. 2 grease, providing due allowance is mado on the “plus” side, when finally selecting the size of tube or pipe to be used. BRANCH LINES TO METERING DEVICES As already explained, It is recommended to ensure that these branch lines are kept as shortas possible. Therefore, because the pressure.loss through these lines is not cumulative, itis normal practice fo Select for these linas.a much smallor tube diameter, which should ba in relation {6 the inlet port thread siza of the matering devices, Tha inlet port thread size of the VSM matering devices 1/8" BSP for 1/8" NEN and therefore, the maximum diameter of tube for this size of thread is gonefally 8 mm 0.0. (or S16" 0.0).3RD STEP CALCULATE COMPRESSION VOLUME REQUIRED PER CYCLE The compression volume within tha main line distributlon system is defined as that volume of lubricant which the pump must deliver Into the main fine In order to fll he volume which the grease lubricant feaves 2s it is compressed ta tha maximum operating pressure of ihe system. This compression volume is required in adaition to the total of the control and delivered valume of all metering devices, and must be delivered by the pump during each half lubrication eycle (1.6, twice per lubrication cycle ~ in each of the main lines alternately), ‘The factor for calculating the compression valumo is expressed as a percentage of the total main syslem volurne (both lines) per lubrication cycle, This compression volume percentage will vary slighlly for different greases and at different pressures. However, for our purposes, the average system operating pressure will almost always fall within the range 170-200 bar (2800-2950 psi. For our general purpose too, we will select a percentage compression volume figure for one of the more compressible lubricants within this pressure range, vwihich will provide us with a reasonably standard percentage compression voluma figure for all ne applications. The liqure wa recommond to use ls: 1.8% of total main lina system valume per cycle (both lines) NOTE: Both lines must be considered for this calculation because both lines must be pressurised and raleased to completa each full lubrication cycle, ‘Therefore, calculation for tie volume expressed in dm? (decimetres cubed) of the total main line system (both lines), excluding branches to metering davices = (8.142 x {Internal dlameter (dim) }*x 10 x Total length of line in metres (both lines), 4 AOI ig to metering devicos Convert this total volume figure in dm® to kg (kllogrammes) by assuming a specie gravily of 0.9, ‘Therefore total system volume in (kg) total system volume in (din) x 0.9 ‘Therefore, compression volume raquired fram pump per cycle (kg) = 1.8% of Total System Volume =Total System Volume (ka) x1.8. NOTE: If flexible hoses are included in the main lines, the total tength of the hoses should be added together, ‘The above calculations must be rapeated and multipliod by 20.4TH STEP SELECT PUMP TO BE USED NOTE: STH STEP WITH THE SELECTED PUMP. ete. OUTPUT OF SELECTED PUMP TOTAL PUMP OUTPUT REQUIRED PER HOUR TO MEET LUBRICATION AMOUNTS AND FREQUENCY PAUSE TIMES (MINUTES) BETWEEN EACH PUMPING OPERATION TOTAL PUMP OUTPUT REQUIRED PER CYCLE (ka) = TOTAL METERING DEVICE USABLE VOLUME (kg) (See ist Step) + TOTAL COMPRESSION VOLUME (kg) (See 3rd Step) NOW, TOTAL PUMP OUTPUT REQUIRED PER HOUR TO PROVIDE THE AMOUNT OF LUBRICANT REQUIRED AT THE LUBRICATION POINTS AND AT THE LUSE FREQUENCY SELECTED = ‘TOTAL PUMP OUTPUT REQUIRED PER CYCLE (kg) x NUMBER OF CYCLES REQUIRED PER HOUR THIS CALCULATED PUMP OUTPUT REQUIREMENT IS THE THEORETICAL MINIMUM VOLUME REQUIRED. BE DELIVERED INTO THE SYSTEM TO COMPLETE TWO CONSECUTIVE LUBRICATION CYCLES EACH HOUR, WITHOUT INTERMEDIATE PAUSE TIMES, THEREFORE, THE ACTUAL PUMP SELECTED WOULD BE THE PARTICULAR MODEL HAVING AN OUTPUT JUST GREATER THAN THIS CALCULATED MINIMUM. CALCULATION OF PAUSE TIMES REQUIRED TO BE INTRODUCED, TO ACHIEVE THE REQUIRED AMOUNT OF LUBRICANT PER POINT, AT THE CHOSEN FREQUENCY, it must b@ remembered that the LINCOLN-HELIOS automatic two-line systems operate in the mariner: Pump operates for 4 lubrication cycle ~ pause time ~ pump operates for ¥, {ubrication cycle — pause time Therofore, one lubrication cycte will always Include two pause periads. TOTAL PUMPING THME"T jaNuTES) = Yx60 = Xka/h = Ykgft = 60." 2x No. of lubrication cycles required per hourEXAMPLE CALCULATIONS STEP 1 SELECTION OF METERING DEVICES time is the shortest frequency. will increase tha averall cost unnecessary. been salected accordingly (ie. 2 cyales per hour). GROUPING OF METERING DEVICES ment end, wil ba quite sufficient. TOTAL METERING DEVICE USABLE VOLUME PER CYCLE Output Volume VSL xX 4oullots= 4xScm%=20 om? VSG x 200 outlets =20 x2.3.cm? = 46 om? vs ullets Grand total 190.8 em? 1900 to convert to dia? = 0,13 cm /oycte Stoconvertioks ~ O12 ka/oycla ‘TOTAL METERING DEVICE VOLUME PER CYCLE ~0.12 kg By assessing the bearings to be lubricated and selecting the largest bearing (80° 0.x 20° L) and by pepcrting this tothe Metering Device Charis for plain bearings, it will be Seen that lh 30 minute or elo dinipGe lurtner soen that by refering the smallest bearing (4* D x 2" L) to the same chat, it comes just pithin the zone of over-tubrication. However, this small amount of over-lubrication is considered Garter Dural ng (eyresort to a one hour cycie time when not only the largest bearing will require a VSUx 2, but also the other larger bearings wil all require to move up to the next size of motaring dovien, akter pperetore, 220 minuta lubrication cycle frequency has been chosen, and the metering davices have The arrangement shown in the sample layout is quite self-explanatory, Howéver, the significant point to gotica is that VSG motaring desians have been chosen for the boarings 24" D x 18" l, although ney should have VSL metering devices on the 30 minute metering device chart, Tile ae been arranged in this way inorder to avoid having to include addlifonal VSL metering devices just for these 4 bearings; with the oxtra branch lines and costs that would be Ineurred, iKwil be noticed that the outlets of he VSG matering devices have been combined to daubla the oulput voluine for the bearings, which, because the graph shows the VSL salection ta be al Use lower adjlet, [nthe cases where tha VSM metering devices have combined oullets, thisis achieved by externally Sonnecting the two opposite faed lines with a tee tube connector. The output volume from tls paltot oullels must then be reduced to the minimum required by means of adjusting tho regulating screws Control Volume: 4x0,60m3=204 cm 20x08 om" 12 Em! 42x0.6om?— 25.2.6m" TotalSTEP 2 LAYOUT AND SIZING OF MAIN LINES AND BRANCH LINES The first feature to be noticed in the layout of this example Is that the pump is situated at the extreme: cad of tha main line, thereby increasing ihe pressure loss value within the main lina system, However, this has beon selected in this manner as an example which quite offen occurs when clionts require to have all hydraulics and pipework services Installed within a common area. It also makes it easier to appreciate that if the pump were abla to be relocated and connected into the centre of the 45 m long horizontal main line shown on the layout, the pressure loss could be considerably recluced, This would quite possibly permit a smaller size of main tine to be used and lead to a to totally ailforent and more economic layout, Therefore, for this example, the relevant information is as follows: 1. Pump output volume 100 cm®/min (as recommended) 2; Grease is an NLGI No, 2 with EP additive Minimum temperature is 0° C 4. Total distance from pump to farthost metering device = 60 metres. ‘Now, by following the instructions for using the prassure loss graphs, wo will arrive at the conclusion that the ling representing a main line tube size of 16 mm intemal diameter (20 min O/Dx 2 mm WALL THICKNESS) will almost exactly pass through the intersection of tha two co-ordinates, Whilst this size will be quite sufficient for this application, matric sized tubing of this size either may not be avaitable or the use of an alternative nominal bore pipe may he preferred. In this case, it would be recommendable to select the next line on the graph which runs immediately beneath ihe intersection, which will be the 3/4" nominal bore pipe (approximately 20 mr). For this example, we will assume the selection of 16 mm intemal diameter tube. BRANCH LINES ‘Aa indicated in the Planning Instructions, these lines can be reduced In size and Ina practical fela- tionship with that of tha metering device inlet thread sizes, The majority of the metering devices aro the model VSM and therafore 6 mm O.D.branch tubing will ba selected and would be quite sufficient, providing all branch lines are kept 28 short as possible. ‘i ¥ i | I i i i3RD STEP CALCULATE COMPRESSION VOLUME Total main lina system volume (dm®) = 3.142 x (internal diamoter dim? 10 x (Total fangth of Line (M) 7 3.102 x (0.16)210x256 4 = 51.48 dm? PLUS ~ 5% for branch lines 77.54.05 de Convert to kliogrammes by 0.9 2748.8 kg Therefore, Compression volume required per complete cycle 1.8% of 48.8 kg 48.8 x 1.8 =0.88 kg 100 4TH STEP SELECTED PUMP TO BE USED ‘TOTAL PUMP OUTPUT REQUIRED PER GYCLE (kg) = TOTAL METERING DEVICE VOLUME (0.12 ka) {TOTAL COMPRESSION VOLUME (0.88 kg) nidke ‘TOTAL PUMP OUTPUT REQUIRED PER HOUR (kg/h) ~ TOTAL PUMP QUTPUT REQUIRED PER CYCLE (1.0 kg) X NUMBER OF CYCLES REQUIRED PER HOUR (2) m2 kg Therefore, from this calculation, itis apparent thet we must elect to use the pump type ZPUB, having an. output of 6 kg per hour. 5TH STEP CALCULATION OF PAUSE TIMES TO BE INTRODUCED OUTPUT OF SELECTED PUMP =6 kgf TOTAL PUMP OUTPUT REQUIRED PER HOUR = 2 ka/h THEREFORE, TOTAL PUMPING TIME 260 6 20 MINUTES {(e.4 half cycles of § MINUTES EACH) ‘THEREFORE PAUSE TIMES = 80-20 BETWEEN EACH HALF-CYCLE 2x2 40 q MINUTES | | | |ae FEED. LINES 26°DW18'L CHANCHE~ OVER VALVE su UM LINES TAIN CINES: a 10" Oe 8, Fs 2 eDe rt BRANCH L ys SDednt APPLICABLE DATA GREASE = NLGI Naz | WirH ee ADOTIVE TEMPERATURE = 0° 5 UL vow | raatuesr METERING DEVICE