OIL / AIR MIXING SYSTEM CENTRAL LUBRICATION

OIL / AIR MIXING SYSTEM USE Oil /air lubrication systems are used for permanent, regular lubricating and cooling of various machines and equipment with a mixture of oil and air. The system ensures continuous supply of lubricant mixed with a stream of pressure air. Pressure air cools the lubricated points and creates overpressure that prevents penetration of impurities from the outside. DESCRIPTION Oil and pressure air are mixed in special mixing devices, by pressure air dragging the small oil elements. Mixturing dividers allow air amount regulation and therefore the mixture character. Optimal and precise oil dosing is ensured by progressive distributors, the mixture of oil and air is being brought in piping to the lube points. When needed, the system can be extended by adding a nozzle, placed in the lube point intake. The basic module of the oil / air system consists of a central source of pressurized lubricant, usually UCF (T1, Z1) lubrication pump or SEO oil lubrication aggregate in customer´s execution and of the air-oil lubrication assembly itself, for typical number of 10 lube points (so-called lubrication box). In the case that there are more lubrication assemblies connected to one source of pressurized lubricant, the lubricant distribution system is equipped with electromagnetic closing valves which allow centralized controlling of lubrication assemblies, in various working regimes. Its connection varies upon specific conditions, a multi-outlet lubrication pump usually meets the requiremenets the most. The particular model and technical specifications must always be adapted to the specific conditions and needs of the defined technological equipment. With an advantage, typical executions of oil-air lubrication assemblies and standard lubrication pumps are used.

UCF LUBRICATION PUMP The UCF lubrication pump is supplied in various executions with a tank of 6, 8, 12, 30 and 63 l volume. The tanks are manufactured from steel brass. The number of outlets is variable, 1 to 3, also the quantity of lubricant supplied. Nominal dose is also variable, according to the execution, from 0.9 cm3/min to 20 cm3/min. In special executions, the dose of 75 cm3/min can be reached, by joining the working units into one outlet. The electromotors are supplied for 230/400 V 50 Hz AC and 290/500 V 50 Hz AC, other voltages are to be discussed with the manufacturer. The execution recommended for oil-air lubrication system is UCF 41100-3-100-1, with a tank of 63 l capacity, 1 outlet with regulable doze of 10- 20 cm3/min, safety valve, signalization of low and maximum level of oil in the tank, electromotor 230/400 V 50 Hz AC (can be different upon the customer´s request), for standard working environment, without risk of explosion. Adjusting safety valve, the pressure can be modified. It has a vaste branch ending back in the body of the lubrication pump and a manometer. In the same time, it serves as a securing element which prevents overcoming of the maximum pressure in the lubrication circuits, set by the regulating screw. This value can be visually controlled on the connected manometer.

OIL / AIR MIXING SYSTEM CENTRAL LUBRICATION

TECHNICAL SPECIFICATIONS – UCF LUBRICATION PUMP Maximum working pressure 300 bar Working pressure 250 bar Nominal output 20 cm3/min/outlet Regulating range of nominal dose 50 to 100 % Lubricant reservoir capacity 6, 8, 12, 30, 63 dm3

Number of outlets 1 to 3 Outlet pipe union M16x1.5 mm, tube outside dia. 10 mm Electric motor 230/400V, 1.05 A, 50 Hz AC, 0.37 kW

290/500V, 0.84 A, 50 Hz AC Alarm nominal voltage 24V 2 A DC Lubricant oil min. 50 mm2 s-1

Temperature of working environment - 25 to 40 0C Weight 30 kg

OIL / AIR LUBRICATION ASSEMBLIES Lubrication assemblies are the basic part of the system. Each lubrication assembly is equipped with a complete set of components and enclosed in a steel sheet box. Pressure oil coming from the central lubrication pump enters the protective box through the ball valve on the side of assembly which is also used to stop the oil intake manually. Inside the box, pressure oil flows through the FLO filter with replaceable cartridge into the progressive distributor. Before the distributor, there is a manometer allowing visual control of the system´s oil pressure. Typical execution of the assembly with 10 lube points is equipped with PRA 05-264 progressive distributor which secures precise oil dosing to all lube points. The distributor´s last working section is equipped with an inductive switch, signalling the course of lubrication process. Dosed oil is conveyed to oil / air mixing devices, always being joined one outlet from the doser to one section of the mixing device. Oil supply proceeds repeatedly with an optional cycle, remote-controlled by the lubrication pump working regime, eventually by the means of an electromagnetic closing valves. Each lubrication cycle starts with the start of oil supply to the distributors that gradually supply selected doses of pressure oil to the mixing devices. The doze of the last section is electronically signalled by the distributor´s inductive switch. Pressure air is conducted into the protective box through the ball valve on the side of assembly, allowing its manual closing from the central pressure air distribution. Inside the box, it proceeds through a compact assembly of reducing valve, cleaning filter, sediment separator with vaste outlet and electronical closing valve, which secures remote control of the pressure air supply. The distribution continues in a common air branch, on which all of the mixture dividers are connected. On the opposite end of air branch, there is a manometer and an end pressure switch for air supply control. The oil-air mixture is created in the mixture dividers, independently for each branch of lubrication system. The amount of air can be set individually for each mixture divider using regulating screw. After setting of air flow required, the screw is secured by a counter-nut. Specific setting of the mixture divider is to be done with regard to each lube point conditions and requirements. The mixture dividers are assembled on a fixed console. The mixture is conducted in distribution piping into the outlet fittings, situated on the bottom side of the protective box. To the fittings for tube of 10 mm outer diameter, piping from the lube points is joined. All the electronical connections are realized on the connection block, on the back side of the lubrication assembly protective box.

OIL / AIR MIXING SYSTEM CENTRAL LUBRICATION

SYSTEM CONTROL AND MONITORING System control and monitoring is realized from the central controlling system of the technological device lubricated or by an independent control unit. The control unit is built with regards to specific needs of each lubrication circuit, control signalization is connected to the lights of control unit´s panel or / and can be connected to a control board of the technological device. The unit controls working time of the lubrication pump, closing valves (oil), electromagnetical valves (air), registers the feedback from oil level signalization, from progressive distributors´ inductive switches, from end pressure switches (air) and indicates errors in during the system´s operation. The control unit also allows to stop the whole system, using the emergency button on the front outer side of the control unit box. In specific case, when the lubrication circuit consists of the lubrication pump and only one lubrication assembly, the lubricant delivery can be controlled by the pump´s working regime only. When the pressure air is supplied continuously during the working time of the lubricated device, the air electromagnetical closing valve can be connected to the device´s central control unit (opened when the device starts working) and for the lubrication pump, AP2 control unit for central lubrication with progressive distributors can be used. DISTRIBUTION PIPING When designing correct dimensioning of distribution pipes, it is necessary to take into account many environmental influences and to observe several important principles so that the is always results in forming a continuous layer of oil on pipe walls, and particularly an optimum supply of oil/air mixture to the lubrication point. Lubricant and oil/air mixture distribution piping is formed by steel pipes with diameters of 12x1,5, 10x1,5, 8x1 and 6x1 mm, connected by standard hydraulic fittings. Central distribution of pressure air is usually performed by standard steel pipes with a diameter of 28x2 mm, also connected by standard fittings.

INSTALLATION, SERVICE AND MAINTENANCE During the installation, it is important to keep the piping clean, i. e. to remove barbs after cutting and other impurities from the pipes. All the electronic installation must be done in conformity with actual norms. When operated non-stop, it is recommended to control the lubrication system´s impermeability (both oil and air parts) once a month, together with the visual control of FLO filter cartridge. With an exception of refilling oil in the pump tank, the system does not require further maintenance. The pump must be filled to keep the minimum lubricant level at least in the body of the pump. If not, proper function of the pump cannot be guaranteed, foremost keeping the nominal doze because of pumping air into the working unit. When filling the lubricant, it is important to keep it clear without impurities – it is recommended to use some of the barrel refilling pumps (f. e. BPO) which also allow the automatization of refilling process.

OIL / AIR MIXING SYSTEM CENTRAL LUBRICATION

MIXTURE DIVIDER OVS 1 USE The OVS 1 mixture divider is a part of oil / air mixing system, which is used for permanent, regular lubrication and cooling of various machines, technologies and devices by a mixture of oil and air. The OVS 1 unit lubricates the lube points, in the same time it is cooling and creating overpressure which prevents the impurities from the environment to get into the lube point. DESCRIPTION The mixture divider consists of a body with G1/4 threaded inlets for pressure air and oil intake. Pressure air flowing into the outlet draggs the oil coming from the oil inlet and in the wider part of the outlet, it creates oil mist. Air flow is regulated by a regulating screw. After setting the required air flow, the regulating screw is secured by a counter-nut. Optimal oil dosing is secured by using progressive or two-line distributors which are part of the oil / air lubrication system. Specific setting of the divider is everytime upon the conditions and requests of each lubricated device. The divider is to be fastened using bolts in the anchor holes of diameter 6,5 mm or through M6x1 anchoring thread TECHNICAL PARAMETERS Maximum oil pressure 60 bar Air pressure 4 – 8 bar Lubricant oil, 20 – 400 mm2 s-1 Temperature of working environment 0 to 60 °C Weight 0,45 kg Assembly position horizontal