Graco Single Line Parallel Lubrication System User Manual

Single Line Parallel Lubrication System

Multiple Point Lubrication Using Oil or Grease

L12100

LubriSystem

Automated Centralized Lubrication System that can be used in virtually any application where centralized operation is desired.

• Dependable

• Economical

• Versatile

• Adjustable injector outputs

• Up to 100 or more lube points

• Use with oil or grease

• Wide range of options

• Modular design

• Option of aluminum or stainless steel injectors and manifolds

INTRODUCTION

LubriSystem™ utilized one of three (3) types of pumps: a singlestroke air-operated pump; a multiple-stroke hand-operated pumpr; or a continuous ﬂ ow, electric motor pump. Fed from a lubrican reservoir mounted above, the pump output is delivered to oil or grease metering valves (called meters or injectors) which distribute lubricant to bearing points. Oil or grease (NLGI #1 or lighter) may be used with the hand-operated and air-operated pump. Oil or NLGI #00 or ligher grease may be used with the electic motor pump. Air-operated pumps require a solenoidoperated air valve and controller to activate the pump. Electic motor pumps use an electric motor (115 VAC is standard) and a solid-state timer device to activate the pump. The injectors are mounted in manifolds supplied by Graco. The bearing point injectors mount at the bearing point and require no manifold. Various accessories are available to simplify installation. An optional pressure switch or gauge may be added at the pump outlet port if required.

LubriSystem is referred to as a single-line, parallel system. This means that when the solid-state timer, controller or operator activates the pump, llubricant is forced down a single main line to manifolds, and from there through parallel lines from individual injectors to the lube points. If bearing point injectors are used, no manifolds are required. Instead, the single main line branches into parallel lines feeding the bearing point injectors. In both cases the injectores inject lubricant to a bearing shown in Figure 1. Once lubricant is dispensed at the lube points, system pressure is vented by the pump. This allows the injectors to prime themselves in preparation for the next lubrication cycle.

SYSTEM COMPONENTS

Pumps

of reservoirs allow a system to be designed precisely for your application. Reservoirs include a ﬁ ll stud fp reservoir reﬁ lling.

Timer

Solid-state timer can be set to control the solenoid or motor to initiate lube cycle at intervals of 1/2 minute to 32 hours.

Manifolds and Injectors

One manifold can distribute lubricant to as many as eight (8) injectors. Injectors come in six (6) sizes to meet a range of lube requirements. Bearing point injectors are fed directly from the pump through parallel branch lines and require no manifold.

Tubing, Hardware, Fittings and Accessories

LubriSystem utilezes tough 3/16 in and 5/16 in heavywall nylon tubing and brass ﬁ ttings for lube points. Mounting hardware and accessories such as reservoir low-level switches and injector indicator assemblies are available.

FEATURES AND BENEFITS

A more efﬁ cient method of applying lubricant, resulting in less machine downtime, increased productivity, and a safer work environment. In addition to these beneﬁ ts, LubriSystem also provides:

• Stainless steel injectors and manifolds available for corrosive environments

• Easy system design and modiﬁ cation

• Inexpensive components and installation

• Fast payback! In terms of savings in lube maintenance manhours alone, LubriSystem usually pays for itself within the ﬁ rst year

• Easy adjustability to meet a wide range of operating conditions

• Quick-connect ﬁ ll stud on pump permits complete reﬁ ll in minutes

• High-pressure pump can serve more points with longer tubing runs

• Pump construction internally relieves system pressure, requiring no extra cost in external valving

• Several reservoir sizes available to ﬁ t a variety of applications

• Visual indicator pin available fo system diagnostics

Positive displacement, air-operated pumps are available in two (2) pressure ratios. A manually-operated pump and an electric motor pump are also offered. Several different types and sizes

Page 1

HAND-OPERATED

PUMP

SEE PAGES

9 THROUGH 12

L12100

BEARING

AIR-OPERATED

PUMP

SEE PAGES

4 THROUGH 8

SOLENOIDOPERATED AIR VALVE

ELECTRIC

MOTOR

PUMP

SEE PAGES

13 THROUGH 160

INJECTOR

MANIFOLD

BEARING POINT INJECTOR

BEARING

FEED LINES

Figure 1. LubriSystem Diagram

Page 2

L12100

SYSTEM OPERATION

As shown in Figure 1, when the electic motor or solenoid-operated air valve receives a signal from the timer, or when the operator actuates the handle, the pump is activated. The pump dispenses lubricant either into the mainline tubing which distributes the lubricant to the manifolds, feeding each injector, or to lines supplying bearing point injectors. Each of the injectors is sized to measure and dispense the proper amount of lubricant based on the size of the bearing. Details of the operation of each component are included in this brochure.

INTERCHANGEABLILITY

LubriSystem components are functionally interchangeable with other commonly used single-line, parallel injector systems. Air inlet and lube outlet ports are 1/4-8 NPT, typical of most other pumps in the ﬁ eld. Injectors have a 3/16 in tube connection as standard. An accossory indicator/adaptor allows 1/8 in tubing to be connected to the outlet. Mounting dimensions of LubriSystem components are very close to theose of other systems. And, if some components, there is a direct interchangeability in form and ﬁ t as well as function.

APPLICATIONS

Typical applications of LubriSystem include the following:

• Mobile Equipment

- Front End Loaders

- Haul Trucks

- Blast Hole Drill Rigs

• Packaging Equipment

- Palletizers

- Stackers

- Wrappers

- Paving Equipment

• Plastic/Rubber Industrial Equipments

- Tire Presses

- Injection Molders

• Food Processing Equipment

- Peelers

- Washers

- Mixers

- Ovens

- Conveyors

- Can-making Machines

• Lumber Equipment

- Debarkers

- Edgers

- Slasher Decks

- Planers

- Stoker Grates

- Saw Guides

- Winders

- Presses

Page 3

AIR-OPERATED PUMPS

DESCRIPTION

LubriSystem air-operated pumps (Figure 2) are available in two lube-to-air power ratios to meet your system requirements. The standard pump has a 9:1 ratio while the high-pressure pump provides a 24:1 ratio. Output per stroke is 1.5 cubic inches (24.59 cm³) for standard pumps and 1.4 cubic inches (22.95 cm³) for high-pressure pumps. Both pump bodies are made from strong, lightweight aluminum and are furnished with a corrosion-resistant coating. This coating provides a tough, durable, impact-resistant ﬁ nish which is exceptionally resistant to corrosion; excellent for salt spray or humid environments. Pump piston and cylinder bore are precision machined and ﬁ nished to minimize wear and discourage corrosion.

Reservoirs in several different sizes are available in transparent plastic. All reservoirs mount directly to the pump and are easily interchangeable. The level of lubricant in the reservoir is easily checked due to the transparent plastic.

L12100

Figure 2. Air-Operated Pump

SYSTEM SIZING AND CALCULATIONS

* To check that a system is not oversized for a pump, the following calculations need to be performed:

1. Sum the output volume of all injectors used in the system.

2. Add the number of injectors used in the system and multiply by .004 cu. in. This is total volume required to re-prime the injector.

3. Total system requirement is the sum of 1 and 2, and should be less than 50% of the total output per cycle for the pump selected. (The 50% is a rule of thumb to allow for line expansion and ﬂ uid compressibility.)

If totals are more than 50% of pump output, the following steps can be taken:

1. Select smaller injectors and increase system cycle frequency.

2. Split the system up and use 2 or possibly more pumps.

Page 4

L12100

All reservoirs used with grease are equipped with a spring-loaded follower which provides a positive, air-free supply of grease to the pump. Pumps are equipped with a ﬁ ll stud and strainer to allow easy ﬁ lling of the reservoir from a supply source. Oil reservoirs are also equipped with a ﬁ ll cup and strainer, allowing easy reﬁ lling from an oil can. Optional low-level switches, timers and solenoid-operated air valves are available to custom design your application.

The solenoid-operated air valve, designed for use with airoperated pumps, is controlled by a solid-state timer or other electronic controller. The solenoid is a 115 VAC, three-way, normally-closed valve with a manual override. The manual override simpliﬁ es system testing, line ﬁ lling, and line bleeding by allowing the operator to control when the pump dispenses lubricant. When the solenoid receives a 115 VAC signal from its controller, it actuates the valve to allow air ﬂ ow to the pump. While the solenoid is energized, the pump strokes forward sending lubricant through the system. When the solenoid is de-energized, the pump piston returns. An FR unit (FRL with high pressure pumps) must be used upstream of the air valve to remove harmful dirt and water from the air supply. Air pressure should be a maximum of 100 psi (7 bar) for the high-pressure pump or 150 psi (10 bar) for standard pumps.

MOUNTING

Sturdy bracket, with four mounting holes, holds pump with solenoid and reservoir. Assembly should be mounted in a protected, centralized, and readily accessible location. Pump must be mounted in a vertical position only, with reservoir up. Use four 5/16 inch or M8 machine screws at the mounting holes to ensure secure placement.

FEATURES / BENEFITS

Proven dependable performance. Many pumps now in use have logged over 5 years of trouble-free operation. Pump features include:

OPERATION

Figure 3 portrays the air-operated pumps in the “at-rest” position. The ﬁ gure represents both standard and high-pressure pumps. The description of operation applies to both. At this point, air is not present and spring (8) pressure has moved piston (7) to the down position. When the piston is down, ﬂ apper valve (1) opens and lubricant from reservoir ﬁ lls lube chamber (9) above the piston. Spring pressure on check valve (4) prevents lubricant from ﬂ owing through the outlet port. This condition also allows residual pressure in the lube lines to raise ball (3), pass through screen (2) and return to the reservoir. This venting of the output lines allows injectors to prime themselves.

When air at 40 to 100 psi (3 to 7 bar) is applied to air inlet port (6), pressurized air ﬁ lls air chamber cavity (12), forcing piston (7) upward, pressurizing lubricant in lube chamber (9). The pressurized lubricant closes ﬂ apper valve (1) (preventing the discharge lubricant from being fed back to the reservoir) and forces check valve (4) open, allowing lubricant to ﬂ ow through lube outlet port (5) to the injectors. When air pressure is removed, spring (8) returns piston (7) to the down position to repeat the cycle. On the standard pump a diaphragm (10) is used to seal the air chamber cavity (12), on the high-pressure pump, this is accomplished by a lip seal (11).

OPTIONS

Low-Level Switches

Several assemblies are available to provide a signal when the lubricant level is low. Low-level switch assemblies used on oil reservoirs depend on ﬂ oats that fall with the depletion of lubricant and actuate contacts on the switch. Switch assemblies used on grease reservoirs are actuated when a cable attached to the grease follower is pulled away from the switch as the follower reaches the low position. Limit switch assemblies used on grease reservoirs are rated at 15 amps. Oil reservoirs use 10-watt reedtype switches.

• Simple design—few moving parts results in less wear and downtime.

• Compact modular construction allows you to customize the pump/reservoir design to ﬁ t your application.

• Lube supply status at a glance.

• Rugged aluminum construction to provide lightweight features with heavy-duty capabilities.

Page 5

The low-level assemblies with a 15 amp rating are often used to activate a warning device such as light or alarm. The 10-watt assemblies are used to provide input to controllers which may be programmed to use the input signal as desired.

Solid-State Timer

This solid-state timer can be used to initiate pump cycles on a time basis at intervals from 1/2 minute to 32 hours. A built-in memory retains the cycle time for 1-1/2 hours during power failure or machine shutdown to resume from the point where it was suspended. For details, see Literature No. 14521. Sophisticated multi-function controllers are also available for use in systems using pressure switches. Refer to literature No. 14540 (LC-1000) and 14750 (WMP III).

L12100

RESERVOIR

HIGH-PRESSURE

1. FLAPPER VALVE

2. SCREEN

3. BALL

4. CHECK VALVE

5. LUBE OUTLET PORT

6. AIR INLET OUTLET PORT

Figure 3. Air-Operated Pump Operation

SPECIFICATION

Pumps:

Air Inlet Pressure

Stadard 40 to 150 psi (3 to 10 bar)

High-Pressure 40 to 100 psi (3 to 7 bar)

Lube Outlet Pressure

Standard (9:1) 360 to 1350 psi (25 to 93 bar)

High-Pressure (24:1) 960 to 2400 psi (66 to 165 bar)

Pump Output per Stroke

Standard 1.5 cu.in. (24.59 cm

High-Pressure 1.4 cu.in. (22.95 cm3)

Air Inlet Port 1/4-18 NPSF

Lube Outlet Port 1-4/18 NPSF

Operating Temperatures (w/NLGI #1) 40ºF to 135ºF (4ºC to 50ºC)

Lubricant Oil or Grease (NLGI #1 or lighter)

Type

Low-Level Switches:

Grease or Oil Reservoir 15 amp Switch

115 VAC 15 amp

Air-actuated positive displacement

)

STANDARD

7. PISTON

8. SPRING

9. LUBE CHAMBER

10. DIAPHRAGM

11. LIP SEAL

12. AIR CHAMBER CAVITY

125 VDC 0.5 amp

250 VDC 0.25 amp

Type Single-pole, double-throw

Oid Reservoir Only - 10 Watt

115 VAC 10 Watt

Single-pole, single-throw reed

Type

Solid-State Timer:

Electrical 115 VAC, 50/60 Hz, 3 amp (max)

Temperature range - Operating Storage

Enclosure High Impact Plastic

Component Technology Solid-State CMOS

Cycle Frequency, Adjustable

Range 1 1/2 min to 30 mins

Range 2 1/2 hour to 32 hours

“On” Time 0.2 min to 13 mins

Standard; LED Indicator, Manual Run Buttom; Vibrations

type switch, normally-open or normally closed

0ºF to 131ºF (-18ºC to 55ºC)

-67ºF to 185ºF (-55ºc to 85ºC)

5g’s, 50 Hz

Page 6

DIMENSIONS

Figure 4 presents layouts of the standard and high-pressure pumps along with common options.

L12100

NOTE

DIMENSIONS SHOWN ARE IN INCHES

STANDARD 9:1 PUMP

0.50

(12.7)

3.563

(90.50)

3.25

(82.6)

1.75

(44.5)

6.87 DIA. (175)

(MILLIMETERS)

5.063 (129)

MNTG. HOLES

0.75 (19.05)

“A”

4.56

(116)

0.343 DIA. (8.71)

TYP.

PLASTIC GREASE

RESERVOIR

1.00

(25.4)

3.69

(93.7)

RESERVOIR SIZE 61220

A DIMENSION 12.72 (323) 17.22 (437) 24.22 (615)

OPTIONS

2.85

(72.9)

15 AMP GREASE LOW-

LEVEL

3.03

(76.9)

1/2-14 NPSM COND. CONN.

15 AMP OIL LOW-LEVEL

1/2-14 NPSF COND. CONN.

1/2-14 NPSM COND. CONN.

3.75

(96.3)

HIGH-PRESSURE 24:1 PUMP

ALL DIMENSIONS ARE

IDENTICAL TO 9:1

PUMPS

EXCEPT THOSE

SHOWN.

5.38

(137)

Figure 4. Air-Operated Pumps - Dimensions

2.62

(66.68)

3.0

(76.2)

0.875 HEX (22.23)

SOLENOID

10 WATT OIL

LOW-LEVEL

1.50

(38.1)

2.19

(55.6)

VALVE

1/2 COND. CONN.

MANUAL OVERRIDE

1/4 NPSF

Page 7

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