Centralised lubrication system guide

CENTRALISED LUBRICATION SYSTEMS
An ISO 9001 : 2000 Certified Company
CENTRALISED SINGLE SHOT OIL LUBRICATION SYSTEM

CENLUB Single shot centralised oil lubrication system is an efficient, safe method by which a predetermined amount of oil is delivered to various lubrication points of a machine from one central source. It is a total loss system and does not require any return line for collection of oil ADVANTAGES : 1. 2. 3. 4. 5. PROLONGED LI.E O. MACHINE MORE PRODUCTION MORE RELIABILITY NO HUMAN ERROR OPTIMUM LUBRICANT TO EACH POINT 6. 7. 8. 9. 10. LESS CONSUMPTION O. LUBRICANT LOW NOISE LEVEL LESS POWER CONSUMPTION LESS WEAR & TEAR SA.E. NO NEED TO STOP MACHINE
Can be used on various machines such as Machine Tools, Textile Machines, Die Casting Machines, Sheet Metal Working Machines, Shearing and Press Brakes, Metal .orming Machines, Rubber Mixing Machines, Printing Machines, Injection/Blow Moulding Machines, Presses and Hammers, Packaging Equipment, Pharmaceuticals Machines, .ood Processing Equipment etc.
CENTRALISED SINGLE SHOT OIL LUBRICATION SYSTEM CONSISTS O. .OLLOWING ELEMENTS PUMP METERING CARTRIDGES AUTOMATIC PUMP MOTORISED LUBRICATION UNIT PNEUMATIC PUMP (CAN BE OPERATED HYDRAULICALLY ALSO) TYPICAL SYSTEM LAYOUT MANI.OLDS .ITTINGS & TUBINGS TIME CONTROLLER
HAND PUMP

PLANNING/INSTALLATION O. THE SYSTEM

While planning the system, the following procedures should be adopted : 1. Ascertain lubrication points and find out the areas to be lubricated at corresponding lubrication points of machine. 2. Select dosage of lubrication on each point. .or this purpose, the basic rule is that per shot, a film of min. 25 micron thickness shall be formed over the area to be lubricated for automatic system and 50 micron for hand pumps. This is applicable for frequency of one hour. However, the volume is normally increased considering factors like; shock loading, quality and material of surfaces, service conditions, extra high speeds, heat & dust etc. Pure calculations are not enough and these are to be confirmed by experimental installation. 3. Select metering cartridges according to lubricant dosage for each point. 4. Sum up the dosages of metering cartridges for all the lubrication points. 5. Depending upon machine requirement, finalise the type of pump. While selecting piston type pump (i.e. Hand operated and Pneumatically/Hydraulically operated Pump). Pump output per stroke shall be checked as per the following formula: PUMP OUTPUT = 1.25 x (A) + 1 CC x (B) (b) Main line (normally 6mm OD tube) from the pump should rise upward. (c) If main line is to be taken downward at any place, bifurcate the line such that one line goes upward also at the junction.
(d) Last metering cartridge/cartridges in every branch of lubrication line must be upward. (e) Divide the main line into 2 or 3 branches near the pump, instead of routing one single line around the machine. This will minimise the tube length and give better appearance and ease of maintenance of system. The secondary line (4mm OD tube) joining metering cartridges to lubrication points should be of minimum length. This is to avoid unnecessary time for filling secondary tube by lubrication impulse while commissioning lubrication system.
(f)
(g) Connect outlet of each metering cartridge to one lubrication point only. (h) Use flexible tube (nylon or rubberised hose) for moving parts of the machine. (i) In case of lubrication point situated in the hot zone of the machine (or the zone where hot metal chips are likely to fall such as on the fixture), do not use nylon tube.
(A) = Total Dosage of all metering cartridges used in the system. (B) = Length of primary flexible tubing in meter. In case pump output is less, select bigger size of pump. 6. Select manifolds such that a manifold caters to all the lubrication points existing in the same vicinity. 7. As regards layout of tubings and fittings it shall be so arranged that air which has entered the system may escape through lubrication points. .or this purpose, following points are to be observed: (a) Preferably pump be installed at a place on the machine where oil level can be checked and refilling of oil can be done conveniently.
8. While commissioning centralised lubrication on a machine, loosen the last plug/plugs screwed on the manifolds in each branch of main line. Give few lubrication impulses so that main line gets filled with the oil up to the end and oil starts leaking from the loosened plugs. Tight the plugs. Now give few lubrication impulses, until oil from all the metering cartridges reaches up-to lubrication points on the machine. Once this is achieved, the system becomes ready for use. 9. As regards frequency of lubrication, it may vary from few minutes to few hours depending upon the kind and load of machines.

HAND PUMPS
MODEL : H 170010, H 6006 H 2504 H7
HAND PUMPS
G
These pumps are suitable for Manual Centralised Lubrication System of light duty automatic machines such as Small power presses, Packing machines, Die punching machines, Milling machines, Single spindle automats, Looms, Surface grinders, Pouch filling machines etc. etc. Normally these pumps are suitable for 2-40 lubrication points. These pumps are very simple in construction. The construction is spring return piston type. The piston is operated by pulling a cam handle. The other salient features are strainer at the inlet port, a pressure reducing system which is very important for proper operation of metering cartridges.
Normally outlet is on right hand side of the pump. However pumps with outlet at left hand side and with outlets at both sides are also available. The pump outlet is suitable for direct fitment of 6 mm OD tube without help of any other fitting. The outlet thread size is M 10x1 (.). Relief valve to flow back excess oil is also provided with these pumps. The pumps are provided with oil level gauge for visibility of oil in reservoir. (Model H-7 is without reservoir). Always fill clean oil to get better life and trouble free operation of these pumps. It is not recommended to operate dry pump. Pumps are suitable for oil with viscosity range 40-1000 cst.
MODEL H170010/H6006
Outlet on right hand side unless specified
DIMENSIONS IN MM A MODEL H 1700-10 H 600-6 170 120
B 100 72.5
C 130 100
D 9 7
E 68 68
. 10 7
G 14 11
H 115 90
J 60 50
K 15 15
L 260 215
M 165 140
N 335 275
RESERVOIR CAPACITY IN CC 1700 600
DISCHARGE PER STROKE IN CC 10 6
MODEL H2504
Reservoir Capacity250 cc. Discharge per stroke4 cc. Outlet on right hand side unless specified
MODEL H7
Without Oil Reservoir Discharge per stroke7cc.

AUTOMATIC LUBRICATION UNITS

MODEL : ALU-03/PS/.S, ALU-05/PS/.S, ALU 08/PS/.S, ALU-20/PS/.S, ALU-30/PS/.S, SPLU-03/.S, ELU-2700
MOTORISED LUBRICATION UNITS

Motorised lubrication units are electric motor driven pumps along with reservoir, oil filler, suction stainer, pressure relief valve, bleed valve etc. and are suitable for single shot automatic oil lubrication. These motorised lubrication units are to be run intermittently with metering cartridges for oil distribution. During motor 'ON' period (normally 5 sec) all the metering cartridges eject out required amount of oil at various points of All the units are as per the following hydraulic circuit: If desired these units can be supplied without pressure switch and float switch. Special units as per customers specifications are also manufactured. Units for liquid grease (fluid grease) are also manufactured for use in textile/printing machines. the machine. And during motor O..' period (decided by lubrication frequency min. 1 minute) these metering cartridges get recharged for next lubrication cycle. These units do not require any return line connection as metered amount of oil is lost in normal running of the machine.
MODEL SPLU03/PS/.S
MODEL ALU03/PS/.S
MODEL ALU05/PS/.S
Reservoir Motor Pr. Setting
3 Ltr 120W, 230V 15 Kg/Cm2
Suitable for oils with viscosity range 50150 cst only.

AUTOMATIC LUBRICATION UNITS
MODEL ALU-08/PS/.S MODEL ALU-20/PS/.S MODEL ALU-30/PS/.S

DIMENSIONS ARE IN MM MODEL ALU - 08 ALU - 20 ALU - 30 A 100 120 120 B 50 60 65 C 330 450 525 D 300 425 500 E 200 250 260 . 355 475 550 G 200 210 270 H 375 500 575 K 400 470 480 RESERVOIR CAPACITY 8 Litres 20 Litres 30 Litres
SPECI.ICATIONS
MODEL O. UNIT RESERVOIR CAPACITY DISCHARGE O. PUMP MOTOR - 415 V 3 PHASE 1500 RPM NORMAL RELIE. VALVE SETTING PRESSURE SWITCH SETTING ALU - 03/PS/.S 3 Litres 1.0 LPM 0.12 Kw 15 Kg/Cm2 12 Kg/Cm2 ALU - 05/PS/.S 5 Litres 1.0 LPM 0.12 Kw 20 Kg/Cm2 15 Kg/Cm2 ALU - 08/PS/.S 8 Litres 2.5 LPM 0.18 Kw 25 Kg/Cm2 18 Kg/Cm2 ALU - 20/PS/.S 20 Litres 2.5 LPM 0.18 Kw 25 Kg/Cm2 18 Kg/Cm2 ALU - 30/PS/.S 30 Litres 2.5 LPM 0.18 Kw 25 Kg/Cm2 18 Kg/Cm2
1. 2.
All these units are suitable for oil with viscosity range 50-1000 cst. Units with vertical float switch is also available on customer request.
ELITE LUBRICATION UNIT

MODEL : ELU-2700
Model ELU-2700 ELU-2700/.S ELU-2700/PS/.S ELU-2700-S ELU-2700-S/.S ELU-2700-S/PS/.S
Motor 3 Phase, 0.12 Kw 3 Phase, 0.12 Kw 3 Phase, 0.12 Kw 1 Phase, 0.12 Kw 1 Phase, 0.12 Kw 1 Phase, 0.12 Kw
Pressure switch X
.loat switch
X X
NOTE : 1. Pressure setting of unit with single phase motor is 12 Kg/Cm2 with oil Way lub 68 at 40OC. This unit is suitable for oil in viscocity range 50-150 cst only. 2. Pressure setting of unit with 3 phase motor is 15 Kg/Cm2 with oil Way lub 68 at 40OC. This unit is suitable for oil in viscocity range 50-1000 cst. 3. .loat switch is of vertical reed type and is suitable for max. 24 volts only. 5

PNEUMATIC OIL PUMPS

MODEL : Pn300010/.S, Pn170010/Pn60010 Pn20006/.S
CAM OPERATED OIL PUMPS

MODEL : C15008
PNEUMATIC OIL PUMPS

These are piston type pumps and can be successfully used for automatic lubrication with the help of compressed air power. These pumps are operated intermittently with the help of a direction control valve and by a timer. Min. air pressure required is 4Kg/Cm2. OIL PRESSURE 15 Kg/Cm2. AT AIR INPUT PRESSURE 4 Kg/Cm2 (MINIMUM AIR PRESSURE REQUIRED 4 Kg/Cm2) NOTE : These pumps can be operated hydraulically also. Please consult for such application.
MODEL Pn300010/.S Reservoir Capacity 3000 cc Output per stroke 10 cc
MODEL Pn170010 / Pn60010 Out let on right hand side unless specified
DIMENSIONS ARE IN MM MODEL Pn170010 Pn60010 A 170 120 B 100 72.5 C 70 70 D 75 75 E 14 11 . 9 7 G 130 100 H 115 90 K 305 260 L 15 15 M 9 7
RESERVOIR CAPACITY 1.7 Litres 0.6 Litre
OUTPUT PER STROKE 10 cc 10 cc
MODEL Pn20006 / .S Reservoir Capacity 2000 cc Output per stroke 10 cc System Layout for Pneumatic Pumps

METERING CARTRIDGES
In single shot centralised lubrication system, amount of oil at each lubrication point is controlled by using the element known as METERING CARTRIDGE. .or each lubrication point at least one metering cartridge shall be used. The metering cartridge is a kind of mini-cylinder with a check valve, where stroke of piston determines the amount of ejected oil. It is designed such that every time when pump is operated, SIZE D1
it ejects out predetermined amount of oil. When pressure is released, the cartridge gets recharged. .or proper recharging of metering cartridges there shall be a small time gap in between subsequent operations of pumps (min. 1 minute). Maximum permissible pressure for metering cartridge is 40 Kg/ Cm2. Minimum working pressure is 8 Kg/Cm2 and pressure shall drop to less than 1 Kg/Cm2 in between successive operations. SIZE D2 SIZE D3
DISCHARGE RANGE Size D1 0.01 cc (1/3 drop) 0.03 cc (1 drop) 0.05 cc (2 drops) 0.10 cc (3 drops) 0.16 cc (5 drops) Size D2 Size D3
0.25 cc (8 drops) 1.00 cc (30 drops) 0.40 cc (12 drops) 1.60 cc (50 drops) Outlet of all sizes are suitable for direct connection of 4 mm. OD tube
GUIDE LINES .OR DOSE SELECTION Dose of metering cartridge to a particular points shall be determined as per following procedure. 1) Calculate equivalent area as per below : a) PLAIN BEARINGS : A=DL D = Shaft Diameter L = Length of Bearing b) GEARS : A=DxW D = Pitch Diameter of Gear W = Width of Gear c) LARGE BULL GEARS : A=2DxW D = Pitch Diameter of Pinion W = Width of Pinion Gear d) WORM GEARS : A = (D1 + D2) W D1 = Pitch Diameter of Worm D2 = Pitch Diameter of Worm Gear W = Width of Worm Gear 2) Select Metering Cartridge as per the following table : Area to be Lubricated in Cm2 Upto 4 4 to 12 12 to 20 20 to 40 40 to 65 65 to 100 100 to 150 150 to 400 400 to 650 7 Dose in cc 0.01 0.03 0.05 0.10 0.16 0.25 0.40 1.00 1.60 3) This dose is normally sufficient for every one hour. It is to be noted that following factors may effect the volume required a) b) c) d) Shock Loading Extreme Heat High Speed Dusty Atmosphere
Volume can be increased by selecting metering cartridges of higher dose or increasing the frequency of lubrication. 4) .or metering cartridges of dose other than above mentioned consult us.

MANI.OLDS, .ITTINGS
MANI.OLDS
Manifolds are required for mounting metering cartridges. Manifolds are zinc plated steel blocks with two inline ports, normally suitable for 6 mm OD tubes and no. of side outlets with thread size M8x1 or M10x1.
Model (L) mm 35 55 75 95 115 135 155 175 195 40 65 90 115 140 (M) (A) mm 18 18 18 18 18 18 18 18 18 22 22 22 22 22 Thickness mm 15 15 15 15 15 15 15 15 15 22 22 22 22 22 No. of Mounting Holes 1 1 2 2 2 2 2 2 2 1 1 2 2 2 Centre Distance between mounting Holes C in mm. N.A. N.A. 40 40 40 60 60 100 100 N.A. N.A. 50 50 50
M-1 M-2 M-3 M-4 M-5 M-6 M-7 M-8 M-9 M-1A M-2A M-3A M-4A M-5A
M8x1 M8x1 M8x1 M8x1 M8x1 M8x1 M8x1 M8x1 M8x1 M10x1 M10x1 M10x1 M10x1 M10x1
Type of manifolds is selected depending upon model and no. of metering cartridges to be fitted. A manifold shall cater all the lubrication points lying in the same vicinity.
Sp. manifolds are also available as per specific requirement.
.ITTINGS
STRAIGHT CONNECTORS
Sr. Model No. Suitable for tube with OD in mm 4 4 4 4 4 6 6 6 6 B D L1 L S1 S
01. .-SC-4/M6x1 02. .-SC-4/M8x1 03. .-SC-4/1/8"BSP 04. .-SC-4/M10x1 05. .-SC-4/1/4"BSP 06. .-SC-6/M8x1 07. .-SC-6/1/8"BSP 08. .-SC-6/M10x1 09. .-SC-6/1/4"BSP
6 6 6 6 8 6 6 6 8
M6x1 M8x1 1/8" BSP M10x1 1/4" BSP M8x1 1/8" BSP M10x1 1/4" BSP
17 17 17 17 15 22 22 22 24
25 25 25 25 23 32 32 32 34
11 11 13 13 17 13 13 13 17
9 9 9 9 9 11 11 11 11
STRAIGHT CONNECTORS (TAPER THREADS)

Sr. Model No. Suitable for tube with OD in mm 4 4 4 6 6 B D L1 L S1 S
01. .-SC-4T/1/4" UN. 02. .-SC-4T/M8x1 03. .-SC-4T/1/8" BSP 04. .-SC-6T/1/8" BSP 05. .-SC-6T/M10x1
6 7 7 7 7
1/4" UN. M8x1 1/8" BSP 1/8" BSP M10x1
17 17 17 22 22
25 25 25 32 32
11 11 11 13 13
9 9 9 11 11

.ITTINGS
ELBOWS (TAPER THREADS)

Sr. Model No. Suitable for tube with OD in mm 4 4 4 6 6 6 D L1 L H1 H S
01. .-E-4T/1/4" UN. 02. .-E-4T/M8x1 03. .-E-4T/1/8" BSP 04. .-E-6T/M8x1 05. .-E-6T/1/8" BSP 06. .-E-6T/M10x1
1/4" UN. M8x1 1/8" BSP M8x1 1/8" BSP M10x1
22 22 22 22 22 22
30 30 30 32 32 32
11 11 11 14 14 14
21 21 21 24.5 24.5 24.5
9 9 9 11 11 11
BANJO ASSY. 4
Sr. Model No. Suitable for tube with OD in mm 4 4 4 D L1 L H1 H S1 S
01. .-B-4/M8x1 02. .-B-4/1/8" BSP 03. .-B-4/M10x1
M8x1 1/8" BSP M10x1
25 27 27
33 35 35
10 10 10
22 22 22
11 13 13
9 9 9
CONNECTOR BLOCKS
Sr. No. Model Suitable for tube with OD in mm 4 6 H L1 L S
01. 02.
.-C-4 .-C-6
16 18
30 35
45 55
9 11
ELBOW BLOCKS
Sr. No. Model Suitable for tube with OD in mm 4 6 H1 H L S
01. 02.
.-EB-4 .-EB-6
25 25
33 35
33 35
9 11
TEE BLOCKS
Sr. No. Model Suitable for tube with OD in mm 4 6 H1 H L1 L S
01. 02.
.-T-4 .-T-6
27.5 27.5
35.5 37.5
35 35
43 45
9 11

.ITTINGS
CROSS BLOCKS
Sr. No. Model Suitable for tube with OD in mm 4 6 H1 H S
01. 02.
.-CR-4 .-CR-6
35 35
50 55
9 11
BANJO ASSY. 6
Sr. Model No. Suitable for tube with OD in mm 6 6 6 D L1 L H1 H T S1 S
01. .-B-6/M10x1 02. .-B-6/1/8" BSP 03. .-B-6/1/4" BSP
M10x1 1/8" BSP 1/4" BSP
28 28 30
38 38 40
14 14 14
26 26 32
14 14 18
13 13 17
11 11 11
CLAMPS
Sr. No. Model Suitable for tubes with OD in mm/nos. of tube 4/1 no. 4/2 nos. 4/3 nos. 6/1 no. 10/1 no. D L1 L T
01. 02. 03. 04. 05.
C-4-1 C-4-2 C-4-3 C-6-1 C-10-1
5.5 5.5 5.5 5.5 6.5
6 6 6 6 7
20 23 26 20 28
1.5 1.5 1.5 1.5 2
PLUGS
Sr. No. 01. 02. Model M8x1 M10x1 Sealing Washer Cu.W.-8 Cu.W.-10 D M8x1 M10x1 B 5 5 H 10 10 S 11 13
Special fittings (other than above mentioned) are also available. Please check up the availability with us. 10

TUBINGS
.ollowing kinds of tube connections are available for single shot lubrication system :
G
STEEL TUBES NYLON TUBES HOSES
STEEL TUBES : These are copper coated welded steel tubes with thickness of 0.89 mm. a) Steel Tube 6 mm OD : Tube with 6 mm OD is used for primary/mainline. It has smallest bending radius of 22 mm and permissible pressure more than 200 Kg/cm2. Steel Tube 4 mm OD : Tube with 4 mm OD is used for secondary line. It has a smallest bending radius of 8 mm and permissible pressure more than 200 Kg/Cm2.
NYLON TUBES : These are semi transparent flexible tube of material nylon 6. These tubes are easy to work with. These are necessary for points, which have motion. To increase tubes life, these can be protected by suitable size of springs available with us one metre length. Thickness of these tubes is 1 mm. a) Nylon Tube 6 mm OD : This tube has minimum bending radius of 70 mm and maximum permissible operating pressure 45 Kg/Cm2. Nylon Tube 4 mm OD : This tube has minimum bending radius of 50 mm and maximum permissible operating pressure 60 Kg/Cm2.
b)
b)
HOSES : Hoses are used for points where flexibility is a must and also mechanical strength required is more such as sharp edges, area with movement of heavy components, chip falling area in machine tool etc. etc. These hoses are made of synthetics rubber with textile re-inforcement. a) Hose with 6 mm OD steel ends : Hoses are supplied with reuseable type end fittings, with 6 mm OD round ends of 25 mm length. These ends act like steel tubes ends. This hose has ID of 6.3 mm and has a operating pressure of 28 Kg/Cm2.
b)
Hose with 4 mm OD steel ends : Hoses are supplied with reuseable type end fittings with 4 mm OD round ends of 22 mm length. These ends act like steel tubes ends. This hose has ID of 4.8 mm and has a operating pressure of 35 Kg/Cm2.
NOTE : Hoses are available in lengths as per customer's requirement. 11

ON-O.. ELECTRONIC TIMERS

MODEL : ET 11, ET 21 ET 31, ET 41
Power Supply : 220 V AC 10%, 50 Hz Repeat Accuracy : 10% Operating Temperature : 0 to 55O C Maximum Power Consumption : 2.0 VA Control Action : ON/O.. Type Output : 220 V AC Contact Rating : 2 amp Non-inductive at 220 V AC
Start : Automatic 'ON' output when power is turned 'ON'. Application : Provides ON & O.. action of lubricator motor or other element as per requirement. Suitable for direct running of single phase motor of lubrication units SPLU-03, SPLU-03/.S, ELU-2700 S & ELU-2700 S/.S (units without pressure switch). Suitable for units/pumps with 3 phase motor where pressure switch is not used like; ELU-2700, ELU-2700/.S, ALU-03, ALU03/.S, ALU-05, ALU-05/.S, ALU-08, ALU-08/.S etc. etc. However a contractor is to be used in this case. Suitable for solenoid operation of direction control valve with, pneumatically operated oil pumps like; Ph-600-10, Pn-1700-10, Pn-3000-10, Pn-3000-10/.S & Grease Pump PnGP-1500-6 etc.
ON-O.. TIMER MODEL ET-11
50
87
BODY DIMENSIONS O. ON-O.. ELECTRONIC TIMER ET-11/ET-21/ET-31/ET-41
12
83

ON-O.. ELECTRONIC TIMERS

MODEL : ET 11, ET 21 ET 31, ET 41
Model ET-11 ET-21 ET-31 ET-41
On time .ixed 5 sec. Variable 7 values .ixed 5 sec. Variable without step
Off time Variable 7 values Variable 7 values Variable without step Variable without step
Setting of time By slide switch By slide switch Knob Knob
Presence of a switch, Parallel to relay contact for extra lub. shot Yes No Yes No
Normally available timing range. 1. 2. On time fixed .or Model ET-11 & ET-31 (a) On time variable .or Model ET-21 (b) On time variable .or Model ET-41 (a) Off time variable .or Model ET-11 & ET-21 5 seconds 5-300 seconds (5, 15, 30, 60, 120, 180, 300) 5-30 seconds 15-60 seconds 30-120 seconds 1-45 minutes (1, 2, 5, 10, 15, 30, 45) 15-180 minutes (15, 30, 45, 60, 90, 120, 180) 1-5 minutes 5-30 minutes 15-60 minutes 60-180 minutes NOTE : While ordering please mention following : MODEL NO. ON TIME VALUE ANY OTHER SPECIAL INSTRUCTIONS NOTE : Input voltage other than 200 V and potential free output available on request. O.. TIME VALUE
3.
(b) Off time variable .or Model ET-31 & ET-41
Use of Timer with Pneumatic Grease Pump Pn-GP-1500-6
Use of Timer with SPLU-03
Use of Timer with ALU-03/05/08/20/30
Use of Timer with Pneumatic Oil Pump
NOTE : Contactor to be provided by the customer.

Note : Contractor to be provided by the customer.
13

ELECTRONIC CONTROLLERS
MODEL : CSEC-1002, CSEC-1002X CSEC-1002P, CSEC-1002XP
TECHNICAL SPECI.ICATIONS O. ELECTRONIC CONTROLLER

(MODEL : CSEC-1002, CSEC-1002P, CSEC-1002X, CSEC-1002XP) 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Power supply Motor relay On' time Limitation of motor relay On' time Off Time Off Time setting Start Reset Repeat accuracy Operating temperature Maximum power consumption Contact rating : : : : : : : : : : : : 12. 13. Lubshot' facility Monitoring of oil pressure : : 220V/110V, AC 10%, 50 Hz. 5 seconds after actuation of pressure switch 60 seconds (in case of pressure failure) Adjustable 2, 4, 8, 15, 30, 60, 120, 240 minutes By rotary switch Motor relay 'ON' when power is turned 'ON' By Push button "Reset" 10% 0 to 55O C 3 VA (a) Motor relay : One Potential free 'NO' contact 2 amp non-inductive at 220 VAC (b) .ault relay : One Potential free change over 2 amp non-inductive at 220 VAC A 'Lubshot' switch parallel to relay contacts provides extra lubrication as and when required. LED "Lub .ault" flickers & fault relay is actuated in case pressure switch contacts are not open even after 60 sec. of 'ON' time. Caution : NC' contacts of pressure switch is to be used. 14. Monitoring of oil level : LED '.uel Oil' flickers in case float switch contacts are open. Caution : "Top on/Bottom off" type float switch is to be used. OPERATION .LOW CHART Motor Relay ON' Pr. Switch Operates within 60 Seconds Pt. Switch does not operate for 60 Sec. ON' for 5 more Seconds Relay O..' for preset time
Power ON'
Lub. fault indication + .ault relay 'ON'
Attend fault and reset
APPLICATIONS 1. 2. 3. Suitable for units where pressure switch and float switch are provided, like ALU-03/PS/.S, ALU-05/PS/.S, ALU-08/PS/.S, ELU2700/PS/.S, ALU-20/PS/.S, ALU-30/PS/.S. A contactor is to be used by the user for 3 phase motors. May be used for pneumatic pumps PN 3000-10/.S and units with single phase motor SPLU-03/.S, ELL-2700/.S (without any contactor). However to make full use of the controller a pressure switch shall be put in the line. .ault relay contacts can be used for audio/visual commands or for stopping the machine in case of lub. failure as per user's demand. 14

MODEL : CSEC-1002 WIRING DIAGRAM WITH CONTROL VOLTAGE 220V AND CONTACTOR COIL VOLTAGE 220V
DO NOT USE THIS TIRMINAL THIS IS .OR 110 V. CONNECTION
Note : In similar way control voltage 110 V can also be used. Please ask for wiring diagram if required.
MODEL : CSEC-1002P WIRING DIAGRAM WITH CONTROL VOLTAGE 220V AND CONTACTOR COIL VOLTAGE 220V
DO NOT USE THIS TIRMINAL THIS IS .OR 110 V. CONNECTION
Note : In similar way control voltage 110 V can also be used. Please ask for wiring diagram if required. 15

MODEL : CSEC-1002X WIRING DIAGRAM WITH CONTROL VOLTAGE 220V AND CONTACTOR COIL VOLTAGE 220V
Note : In similar way control voltage 110 V can also be used. Please ask for wiring diagram if required.
MODEL : CSEC-1002XP WIRING DIAGRAM WITH CONTROL VOLTAGE 220V AND CONTACTOR COIL VOLTAGE 220V
Note : In similar way control voltage 110 V can also be used. Please ask for wiring diagram if required. 16

ROTARY PUMPS
POSITIVE DISPLACEMENT TYPE
Rotary Pumps (Positive Displacement Type)

These are gerotor type pumps with positive displacement of oil. These are suitable for various purposes which require low discharge, medium pressure oil pumps such as lubrication of gear boxes, headstocks, transfer of oil, low pressure hydraulic power packs, rotary oil filters etc. The pumps are suitable for oils with viscocity range 30-1000 cst/40OC. The pumps are available in seven sizes. Size 1. 2. 3. 4. 5. 6. 7. RP 1 RP 3 RP 4 RP 6 RP10 RP16 RP25 : : : : : : : Oil capacity of 1500 RPM 1 ltr./mt. 3 ltrs./mt. 4 ltrs./mt. 6 ltrs./mt. 10 ltrs./mt. 16 ltrs./mt. 25 ltrs./mt.
Constructionwise these are of two types. 1. 2. 1. .LANGE TYPE INSERT TYPE Non-Reversible : In these pumps shaft can rotate only as per the direction shown by an arrow on the pump. Suction & Pressure port are indicated accordingly. While ordering please specify the direction of rotation of shaft clockwise or anticlockwise while looking from shaft end. 2. Reversible : In these pumps shaft can rotate in either direction. Suction & pressure ports are indicated accordingly. Minimum R.P.M. of shaft required is 500. .irst, Select the type of pump as per the design & space of the machine. Select the size as per the oil capacity required. Check power requirement of drive element taking into consideration size and maximum working pressure. Check direction of rotation of pump shaft and accordingly connect suction port to the suction side and output port to the pressure line. Check suction height is within limits. Suction height shall not be more than 1000 mm at 1500 rpm of shaft with oil viscocity 68 cst. .or higher viscocity this has to be reduced. Also suction tube and suction strainer shall be of proper size to avoid cavitation. Use proper suction strainer. This is very important for pump life. Use relief valve as per requirement to avoid unnecessary loading of pump. 17
.unctionwise pumps are available of two types.
Selection of a Suitable Pump : 1. 2. 3. 4.
5.
6. 7. 8.

ROTARY PUMPS
.LANGE TYPE ROTARY PUMPS (NONREVERSIBLE)
Dimensions in MM
Model RP-1 RP-3 RP-4 RP-6 RP-10 RP-16 RP-25 Discharge at 1500 RPM 1 LPM 3 LPM 4 LPM 6 LPM 10 LPM 16 LPM 25 LPM A 22 22 30 30 30 40 40 B 16 16 18 18 18 25 25 C 3 3 6 6 6 7 7 D 60 60 80 80 80 115 115 d 10 10 12 12 12 14 14 E 2 2 3 3 3 4 4 . 70 75 90 95 105 120 135 G 35 35 45 45 45 65 65 H 7 7 10 10 10 14 14 J 11.5 11.5 14 14 14 16 16 K 3 3 4 4 4 5 5 L 95 100 127 130 140 150 165 M 6.5 6.5 8.5 8.5 8.5 9 9 N 47.5 47.5 65 65 65 95 95 W" in BSP 1 /4" 1 /4" 1 /4" 3 /8" / 1/4"* 1 /2" / 3/8"* 1 /2" 1 /2"
Note : L Brackets for foot mounting are available on request as per requirement.
INSERT TYPE ROTARY PUMPS (NONREVERSIBLE)
Dimensions in MM
Model RP-1 RP-3 RP-4 RP-6 RP-10 RP-16 RP-25 Discharge at 1500 RPM 1 LPM 3 LPM 4 LPM 6 LPM 10 LPM 16 LPM 25 LPM D 60 60 80 80 80 115 115 d 10 10 12 12 12 14 14 G 35 35 45 45 45 65 65 M 6.5 6.5 8.5 8.5 8.5 9 9 N 47.5 47.5 65 65 65 95 95 P 6 6 7 7 7 8 8 Q 48 53 55 65 75 80 95 R 24 24 33 33 33 48 48 S 83 88 103 110 122 140 155 T 10 10 12 12 12 14 14 W" in BSP 1 /4" 1 /4" 1 /4" 3 /8" / 1/4" * 1 /2" / 3/8" * 1 /2" 1 /2"
18

ROTARY PUMPS
.LANGE TYPE ROTARY PUMPS (REVERSIBLE TYPE)
Dimensions in MM
Model RP-1 RP-3 RP-4 RP-6 RP-10 RP-16 RP-25 Discharge at 1500 RPM 1 LPM 3 LPM 4 LPM 6 LPM 10 LPM 16 LPM 25 LPM A 22 22 30 30 30 40 40 B 16 16 18 18 18 25 25 C 3 3 6 6 6 7 7 D 70 70 92 92 92 135 135 d 10 10 12 12 12 14 14 E 2 2 3 3 3 4 4 . 70 75 90 95 105 120 135 G 35 35 45 45 45 65 65 H 7 7 10 10 10 14 14 J 11.5 11.5 14 14 14 16 16 K 3 3 4 4 4 5 5 L 95 100 127 130 140 150 165 M 6.5 6.5 8.5 8.5 8.5 9 9 N 47.5 47.5 65 65 65 95 95 W" in BSP 1 /4" 1 /4" 1 /4" 3 /8 / 1/4"* 1 /2 / 3/4"* 1 /2" 1 /2"
Note : L Brackets for foot mounting are available on request as per requirement.
INSERT TYPE ROTARY PUMPS (REVERSIBLE TYPE)
Dimensions in MM
Model RP-1 RP-3 RP-4 RP-6 RP-10 RP-16 RP-25 Discharge at 1500 RPM 1 LPM 3 LPM 4 LPM 6 LPM 10 LPM 16 LPM 25 LPM D 70 70 92 92 92 135 135 d 10 10 12 12 12 14 14 G 35 35 45 45 45 65 65 M 6.5 6.5 8.5 8.5 8.5 9 9 N 47.5 47.5 65 65 65 95 95 P 6 6 7 7 7 8 8 Q 48 53 55 65 75 80 95 R 24 24 33 33 33 48 48 S 83 88 103 110 122 140 155 T 10 10 12 12 12 14 14 W" in BSP 1 /4" 1 /4" 1 /4" 3 /8 / 1/4" * 1 /2" / 3/8" * 1 /2" 1 /2"
* Will be supplied only when specified in orders.
19

MOTOR PUMP ASSEMBLIES
MOTOR PUMP ASSEMBLY WITH L BRACKETMPAL
Motor Rating in H.P. (1500 RPM 415 V) MPAL-1-63 (.25) 0.25 MPAL-3-63 (.25) 0.25 MPAL-4-63 (.25) 0.25 MPAL-6-63 (.25) 0.25 MPAL-6-71 (0.50) 0.5 MPAL-10-71 (0.50) 0.5 MPAL-10-80 (1.0) 1 MPAL-16-80 (1.0) 1 MPAL-16-80 (1.5) 1.5 MPAL-25-80 (1.0) 1 MPAL-25-80 (1.5) 1.5
Model
Pump Model
Pump Capacity in LPM
Maximum Pressure in Kgs/ Cm2 15 15 10 5 15 10 15 10 15 5 10
Dimensional Details in mm D d d1 A L L1 . H H1 M T a b c e W" in BSP /4" /4" 1 /4" 3 /8"/1/4"* 3 /8"/1/4"* 1 /2"/3/8"* 1 /2"/3/8"* 1 /2" 1 /2" 1 /2" 1 /2"
1 1
RP-1 RP-3 RP-4 RP-6 RP-6 RP-10 RP-10 RP-16 RP-16 RP-25 RP-25
1 3 4 6 6 10 10 16 15 25 25
60 60 80 80 80 80 80 115 115 115 115
95 95 95 95 95 95 95 115 115 115 115
140 140 140 140 160 160 200 200 200 200 200
130 130 130 130 130 130 160 160 160 160 160
335 340 370 375 405 420 420 465 485 480 500
132 144 169 174 174 174 193 208 228 223 243
70 75 90 95 95 105 105 120 120 135 135
160 160 160 160 190 190 225 225 225 225 225
90 90 90 90 100 100 125 125 125 125 125
8.5 8.5 8.5 8.5 8.5 8.5 10.5 10.5 10.5 10.5 10.5
8 8 8 8 8 8 10 10 10 10 10
60 60 60 60 75 75 80 80 80 80 80
20 20 20 20 20 20 25 25 25 25 25
100 100 100 100 120 120 160 160 160 160 160
140 140 140 140 160 160 200 200 200 200 200
Note : These assemblies are available without L Bracket also (i.e. flange type)
* Will be supplied only when specified in order
TECHNICAL CHARACTERISTICS
1.5
5 -2 RP
25
RP-2 5
-16 RP
DISCHARGE IN Ltr PER Mt.
1.0
DRIVE POWER IN K.W.
20
RP-16
10 RP-
16
0.5
RP-6
10
RP-10 RP-6
0.25
RP-3 RP-1
6 4 3 1 10 15 0 5 10
RP-4 RP-1 RP-3
15
20
25
PRESSURE IN Kg/Cm2
PRESSURE IN Kg/Cm2
We also supply pumps with special mountings and sizes. 20

MANUAL GREASE PUMPS

MODEL : MGP-1500-4 MGP-600-2
MANUAL GREASE PUMP

G
This Pump meant for feeding grease to bearings and other moving parts of machines such as Calendaring machines, Mixing machines, Rolling mills, Bending machines, .urnaces and other likely machines having 1-20 lubrication points. (Model MGP-600-2 for 1-6 points and Model MGP-1500-6 for 1-20 points). The pump consists of various parts as shown in the diagram. When the handle is pulled, grease is sucked through the suction port. While pushing handle this grease come out under pressure through a check valve and is supplied to the grease pipelines.
The pump has reservoir, which can be either of acrylic or Mild Steel (as per the customer's choice). A tell tale rod indicates the level of grease and a follower plate assembly helps in providing positive suction of the grease. Grease filling in the reservoir can be done manually as per the procedure given below. .or those who want to fill grease by another pump, a 1/4" BSP port is provided on right hand side of the pump. This port is normally plugged. Pump has got outlet ports of 1/4" BSP on both sides (Right hand side and Left hand side). Normally left hand side is plugged and check valve is fitted on right hand side. However, if required, this plug and check valve can be interchanged.
DIMENSIONS IN MM MGP-1500-4* MGP-600-2
A 55 42
B 116 80
C 12.5 9
D 70 42
E 140 96
. 136 94
G 165 111
H 400 290
J 18 32
K 51 32
L 420 300
M 525 430
TECHNICAL SPECI.ICATIONS
SPECI.ICATION RESERVOIR CAPACITY DISCHARGE PER STROKE MAXIMUM PRESSURE RESERVOIR MATERIAL OUTLET SIZE MODEL MGP-1500-4 1500 CC 4 CC 100 Kg/Cm2 M.S./ACRYLIC 1/4" BSP MGP-600-2 600 CC 1.5 CC 60 Kg/Cm2 ACRYLIC 1/4" BSP G G
AIR REMOVING .or air removing unscrew the bleed plug, pull the handle maximum out and press the grease pusher by knob till grease comes out of the bleed port. Plug the bleed port. The pump is ready for operations. Press the handle. DISTRIBUTION SYSTEM Grease from pump is further distributed either with the help of progressive blocks for positive distribution or with the help of manifold blocks. With manifold blocks grease distribution is as per pipe resistance. IMPORTANT
G G
HOW TO .ILL GREASE MANUALLY ? 1. 2. 3. 4. 5. 6. 7. .or grease filling first of all unscrew bleed plug. Pull the handle maximum out. Remove grease pusher alongwith top cover by unscrewing 3 nuts of top cover. .ill the grease from top of the reservoir. .it grease pusher, tighten 3 nut of top cover and press the pusher by knob till grease comes out of the bleed port. Plug the bleed port. The pump is ready for operations. press the handle.
G
Handle grease with utmost care for cleanliness. Use pipes of maximum possible I.D. for smooth operation of pump. Avoid sharp bends in piping. With lengthy pipes of small diameter and sharp bends pipe resistance may increase to the level that pump may not operate at all. In such case use bigger dia pipes.
* Our earlier model was MGP-1500-6 which has been discontinued. The model MGP-1500-4 is similar to MGP-1500-6 except for output per stroke. 21

MANUAL RADIAL GREASE LUBRICATORS

MODEL : HRGP-02-2-*
MANUAL RADIAL GREASE LUBRICATORS

HRGP-02-2-10
SPECI.ICATIONS : 2 Ltrs. G As per Customer requirement (max. 10). G Maximum Pressure 150 Kg/cm2 G Grease Output Adjustable Max. 0.25 cc/ unit/two rev. G Output suitable for 6mm O.D. tube/4mm O.D. tube (on requirement). * Specifies No. of Pumping Units to be used.
G
Reservoir Capacity No. of Pumping Units
.RONT VIEW
SIDE VIEW
PLAN VIEW
MANUALLY OPERATED GREASE PUMP

G
These pumps are hand driven. The number of rotation of cam is half of handle rotations. Maximum operating pressure for this pump is 100 kg./cm.sq. Pump is suitable for applications where grease requirements is low. The force required on the handle is not much and pump is very light in operation. By using 6 mm OD tubes, grease can be supplied easily as far as 10 metre long distances. The main element of this pump is pumping unit one for each point. Plunger of each pumping unit is given a reciprocating motion with the help of a cam. The pumps are provided with a stirrer to provide positive suction of grease and minimize air trapping. Pumping units are of output capacity - 0.05-025cc for every rotation of cam. 22
Reservoir of aluminium and has a volume capacity of 2 Ltrs. The pump can accommodate maximum 10 Nos. pumping units. In case, less units are required a unit can be removed and a plug with thread size M22x1.5 with sealing ring is to be used. Do not plug output of any pumping unit. If not required, remove it and plug it. While using this pump it is very important to use clean good quality greases of viscosity up to grade NLG-2, Spurious grease, impurities and foreign elements as chips etc. may damage the pumps.

MULTIPOINT LUBRICATORS
.OR OIL LUBRICATORS

MODEL : MMPOL Maximum output per point per minute 0.25 x 1500 = ____________ 50 C.C.
MODEL : MMPOL Maximum output per point per minute n' is input shaft RPM. PUMPING UNIT It is actually a small plunger pump which gives metered output of lubricant for every stroke. The stroke of the plunger is always same. However internal construction is such that by rotating adjusting screw clockwise, output is reduced and by anti-clockwise rotation output is increased. If and when required an individual pumping unit can be changed, removed or added. TECHNICAL SPECI.ICATIONS 1) Output 2) Delivery Pressure : : Maximum 0.25 cc per stroke (adjustable) More than 300 Kg/Cm2 for Grease. More than 200 Kg/Cm2 for oil By rotating adjusting screw a. Clockwise for less output b. Anti-clockwise for more output. 0.25 x n = ____________ 50 C.C.
APPLICATION MULTIPOINT LUBRICATORS are used for Centralised Lubrication of machines like : Rolling Mills, Calendering Machines, Sugar machines. Cement Machines, Hydro Turbines, Stone Crushers, .orging Hammers etc. They are very simple in design and require little maintenance. These typeof lubricators are fitted on a machine suitably and are connected to the lubrication points by means of welded/seamless steel tubes, rubber hoses and compression type fittings & clamps. Details of various Multipoint Lubricators available with us are shown on following pages. CONSTRUCTION The main element of various Multipoint Lubricators is pumping unitsone for each point. Plunger of each pumping unit is given a reciprocating motion with the help of a cam. The cam itself rotates at suitable RPM by any machine shaft or with the help of an electric motor and a gear box. .or grease lubricators a deflector/ stirrer also rotates with cam. The helps in creating positive suction of great and minimises air trapping. Lubricators driven by electric motors are normally run intermittently. .or this purpose cycle timers are used which are available as per requirement. Pumping units output is adjustable with maximum capacity of 0.25cc per stroke. Lubricant output from each point of multipoint lubricators can be calculated as per the following formula :
3) Output Adjustment
.OR GREASE/OIL LUBRICATORS

MODEL : MMPGL Maximum output per point per minute 0.25 x 1500 = ____________ 50 MODEL : MPGL 0.25 x n = ____________ 50 1. C.C. 2. C.C. 23
CAUTION Do not plug output of any pumping unit. If not required, remove it and plug it (Ask for plug M-22x1.5 with sealing ring). Cleanliness of lubricant is of utmost importance. Spurious Grease or contaminated oil may damage the lubricator.
Maximum output per point per minute

MULTIPOINT GREASE/ OIL LUBRICATORS
MMPGL-01-04- *
MMPGL-02-09- *
MMPGL-03-15- *
* Oil filter-cum-breather & oil window are fitted in case the lubricator is being used for oil. Please mention in the order whether lubricator is required for oil or grease application. MPGL-01-04- * MPGL-02-09- * MPGL-03-15- *
Model Reservoir Capacity No. of Pumping Units Motor Capacity 3 Phase (415V, 1500 RPM) Model Reservoir Capacity No. of Pumping Units Permissible RPM of input shaft
MMPGL-01-04-* 4 Ltrs Max. 10 0.25 HP MPGL-01-02-* 2 Ltrs Max. 4 50 - 1500
MMPGL-02-09-* 9 Ltrs Max. 12 0.5 HP MPGL-02-09-* 9 Ltrs Max. 12 50 - 1500
MMPGL-03-15-* 15 Ltrs Max. 24 0.5 - 1.0 HP MPGL-03-15-* 15 Ltrs Max. 18 50 - 1500
* It indicates the actual no. of pumping units in the pump. Note : The lubricators can be fitted with minimum level switch at extra cost on request. 24

MULTIPOINT OIL LUBRICATORS
MMPOL-01-05- *
MPOL-01-05- *
MMPOL-02-10- *
MPOL-02-10- *
MMPOL-03-15- *
MPOL-03-15- *
Model Reservoir Capacity No. of Pumping Units Motor Capacity 3 Phase, 415 V, 1500 RPM Permissible RPM of Input shaft
MMPOL-01-05-* 5 Ltrs. Max. 8 0.25 HP N.A.
MPOL-01-05-* 5 Ltrs. Max. 8 N.A. 1-100
MPOL-02-10-* 10 Ltrs. Max. 16 N.A. 1-100
MPOL-03-15-* 15 Ltrs. Max. 24 N.A. 1-100
* It indicates the actual no. of pumping units in the pump. Note : The lubricators can be fitted with minimum level switch at extra cost on request. 25

PNEUMATIC GREASE PUMPS
This pump is meant for Automatic feeding of grease to bearings and other moving parts of machines such as Calendering machines. Mixing machines, Rolling mills, Bending machines, .urnaces and other likely machines having 2-20 lubrication points. More points can also be incorporated in consultation with us. The pump consists of various parts as shown in the drawing. When compressed air is applied at port 'A' of Pneumatic Cylinder grease is sucked through the suction port. With the help of a Direction Control Valve and a timer compressed air is applied at port 'B'. With regular intervals grease comes
out under pressure through a Check valve. This grease is supplied to the grease pipe-lines.
G
The pump has a reservoir, which can be either of acrylic or M.S. (as per the customer's choice). A tell-tale rod indicates the level of grease and a follower plate assembly helps in providing positive suction of the grease. Grease filling in the reservoir can be done manually as per the procedure given below. .or those who want to fill grease by another pump, a 1/4" BSP port is provided on front side of the pump. This port is normally plugged.
Model Pn-GP-1500-6 Pn-GP-1500-6/DV Pn-GP-1500-6/DV/T Pn-GP-1500-6/Adj Pn-GP-1500-6/DV/Adj Pn-GP-1500-6/DV/T/Adj Pn-GP-3000-10 Pn-GP-3000-10/DV Pn-GP-4000-10 Pn-GP-4000-10-DV
Reservoir capacity 1500 cc 1500 cc 1500 cc 1500 cc 1500 cc 1500 cc 3000 cc 3000 cc 4000 cc 4000 cc
Discharge per stroke (cc) 6 6 6 0-6 0-6 0-6 10 10 10 10
Direction control valve No Yes Yes No Yes Yes No Yes No Yes
Timer No No Yes No No Yes No No No No
IMPORTANT
G
HOW TO .ILL GREASE MANUALLY?

G G G
Maximum Pressure (Air pressure at 6 Kg/Cm 2 .) 80 Kg/Cm2. Handle grease with utmost care for cleanliness. Use pipes of maximum possible I.D. for smooth operation of pump. Avoid sharp bends in piping. With lengthy pipes of small diameter and sharp bends pipe resistance may increase to the level that pump may not operate at all. In such case use bigger dia pipes. AIR REMOVING
.or grease filling first of all unscrew bleed plug. Apply compressed air at port 'A'. Remove grease pusher alongwith top cover by unscrewing 3 nuts of top cover. .ill the grease from top of the reservoir. Assemble grease pusher, tighten 3 nuts of top cover and press the pusher by knob till grease comes out of the bleed port. Plug the bleed port. The pump is ready for operations. Apply compressed air at port B'.
G G
G G
G G G
.or air removing unscrew the bleed plug, apply compressed air at port 'A' and press the grease pusher by knob till grease comes out of the bleed port. Plug the bleed port and pump is ready for operation. DISTRIBUTION SYSTEM
Note : 1) 2) 3) 4) 26 Please ask us for details of model selected by you. Special Pumps are also available as per customer requirement. Solenoid Valve, Timer & distribution accessories are not supplied with pump unless specified. Min. Grease level switch can also be provided on request.
Grease from pump is further distributed either with the help of Progressive Block for positive distribution or with the help of Manifold blocks. With manifold blocks grease distribution is as per pipe resistance.

PROGRESSIVE DISTRIBUTOR BLOCKS

MODEL : PB-4555, PB-6080

MODEL : PB-4555/PB-6080 INTRODUCTION Cenlub Systems progressive distributor blocks of PB-4555/ PB-6080 series are meant for distribution of lubricant delivered by a pump to various lubrication points in sequence-one after another. If any of the lubrication point is blocked the progressive block will stop functioning. With suitable monitoring device, this blockage is sensed and suitable warning is given to avoid running the machine without proper lubrication system. Secondary blocks can be connected to output of a progressive block for further distribution of the lubricant. These blocks can be used for following kind of Centralised Lubrication Systems : 1. 2. 3. Intermittent Grease Systems Intermittent Oil Systems Recirculating Oil Systems
27


MODEL : PB-4555, PB-6080
CONSTRUCTION
1. Progressive blocks are assembled with three types of element blocks: (a) Starting block A', (b) Middle Block M' and (c) End Block E'. Each middle block 'M' has two outlet connections. Minimum three middle blocks are required for operation of a progressive block. Smallest progressive block has 6 outlets (3 middle blocks) that can be reduced to two outlets by their connections. There can be any number of middle blocks. The number marked on the middle block divided by one hundred indicates volume of lubricant in Cm3 cc that will be delivered from the corresponding outlets of next middle block. (Please refer example of Block No. 1 PB-6080-4-8) Sealing of element block is by O-rings.
MONITORING O. BLOCK .UNCTIONING

In case any point is blocked in the system, the same can be immediately sensed by any of the following methods : 1. By sensing rise in pressure 2. By observing to and fro motion of indicating pin 3. By monitoring function of proximity switch. While ordering please specify the kind of monitoring desired. If block is to be used with a hand pump, non functioning of system can easily be felt by the back pressure on the handle.
2. 3. 4. 5. 6.
HOW TO ORDER
Please specify in order the following : PBSNXIPPS Stands for progressive block Indicates size : 4555 or 6080 No. of middle block; Minimum - 3, Maximum - 10 (At present) Note : If known mention block designation also. 4. X No. of outlets; Minimum - 2, Maximum - 2 x N (i.e. if there are 5 middle block, max 10 outlets are possible) Note : Qty. of oil at each outlet per cycle is to be mentioned as per table shown in the examples. 5. *IP Indicates that indicator pin is to be provided. It is required for visual monitoring of block. Standard position is 1L/mention specifically for any other position) 6. *PS Indicates that proximity switch is to be provided. It is required for automatic monitoring. Standard position is 1L/mention specifically for any other position. * There are optional elements. 1. 2. 3. PB S N
7.
SPECIAL .EATURES
.ollowing are the design features of these progressive block : 1. Middle blocks can have different spool sizes to have different deliveries from different outlets in same cycle. But both outlets of a block will give same dose to the corresponding outlets of next block. (Refer table in progressive blocks drawing). Output of outlets of middle blocks can be joined together by removing a separate screw and a washer shown in figure and plugging one of the outlet. This will double the volume in the other remaining outlet.
2.
IMPORTANT
.ollowing is to be observed while using these progressive blocks : 1. The progressive blocks shall be mounted only on the machined surface. If machined surface is not available, it is necessary to use packing washers between blocks and mounting surface. 2. While commissioning the system, sometimes it is required to bleed the block. Bleed the system by loosing one by one the piston butt screws of first middle block by one turn. After bleeding tighten the screw. 3. As far as possible connect secondary lines with the lubrication points only after lubricant reaches end points at all the tubes. (A must for grease system). 4. Always use clean lubricants. This is very very essential. 5. In case at any stage no. of middle element blocks is to be changed or outlet configuration is to be changed, it shall be done at our works or only by experts who understand thoroughly the working of these blocks. 28
3.
Adjacent outlets of different middle blocks can be connected externally by means of special connecting banjos.


MODEL : PB-4555, PB-6080
EXAMPLE : HOW TO ORDER PROGRESSIVE BLOCKS

MODEL : PB-4555 & PB-6080 BLOCK NO. 1 PB-6080-4-8 Input Lubricant NOTE : 1. Spool displacement of middle block 2 (M55-0.55cc) is delivered through outlets of middle block 1(1L, 1R). 2. Spool displacement of middle block 3 (M35-0.35cc) is delivered through outlets of middle block 2(2L, 2R). 3. Spool displacement of middle block 4 (M35-0.35cc) is delivered through outlets of middle block 3(3L, 3R). 4. Spool displacement of middle block 1 (M75-0.75cc) is delivered through outlets of middle block 4(4L, 4R).
Outlets Dose in cc per cycle
1R 0.55
2R 0.35
3R 0.35
4R 0.75
1L 0.55
2L 0.35
3L 0.35
4L 0.75
BLOCK NO. 2 PB-6080-4-6-IP
NOTE : 1 I.P. at standard position
NOTE : 1. Output at 1R is from middle block 2 (M550.55cc) & from middle block 3 (M35-0.35cc) joint together by joining banjo as shown. Total output 0.55cc + 0.35cc = 0.90cc 2. There is no outlets at 2R as joining banjo is used here. 3. Output at 3R is from middle block 4 (M350.35ccx2=0.70cc) it is multiplied by two, because separating screw of middle block 3 has been removed and outlet 3L is plugged. 4. Output at 4R is from middle block 1 i.e. 0.75cc. 5. Output at 1L is from middle block 2 i.e. 0.55cc. 6. Output at 2L is from middle block 3 i.e. 0.35cc. 7. Output at 3L is plugged. 8. Output at 4L is from middle block 1 i.e. 0.75cc.
BLOCK NO. 3 PB-6080-4-6-PS
NOTE : 1 P.S. at standard position
* Block 2 & block 3 are similar except that proximity switch has been added in block No. 3.
Outlets Dose in cc per cycle 1R 0.90 2R X 3R 0.70 4R 0.75 1L 0.55 2L 0.35 3L X 4L 0.75 Outlets Dose in cc per cycle 1R 0.90 2R X 3R 0.70 4R 0.75 1L 0.55 2L 0.35 3L X 4L 0.75
BLOCK NO. 4 PB-6080-8-6-IP-PS
NOTE : 1. IP at location 7L 2. PS at location 8R

Outlets Dose in cc per cycle Outlets Dose in cc per cycle 1R
PB IP PS SSR
1.0+1.0+1.0 = 3.0 cc Output 1R, 1L, 2L Joined together 3L 1.0+1.0+1.0 = 3.0cc Output 2R, 3R, 3L Joined together
Progressive Block Indicator Pin Proximity Switch Separating Screw Removed

4R 7R 0.75+0.75 = 1.5 cc Output 7R, 7L Joined together 8L 0.75+0.75 = 1.5cc Output 8R, 8L Joined together
1.0+1.0+1.0 = 3.0 cc Output 4R, 4L, 5L Joined together 6L 1.0+1.0+1.0 = 3.0cc Output 5R, 6R, 6L Joined together
29

PROGRESSIVE BLOCKS
MODEL : PB-4555, PB-6080
PROGRESSIVE BLOCK
MODEL : PB-4555
PROGRESSIVE BLOCK
MODEL : PB-6080
Max. delivery volume of the CS/4555 Progressive Block with oil circulation is 0.5 lits/min. This delivery volume is independent of the number of outlets. Intermediate Element M' IMPORTANT THIS VOLUME O. OIL WILL BE DELIVERED .ROM THE CORRESPONDING OUTLETS O. NEXT MIDDLE BLOCK SPECI.ICATION O. PROXIMITY SWITCH NORMALLY USED
l l l l l l
Max. delivery volume of the CS/6080 Progressive Block with oil circulation is 2 lits/min. This delivery volume is independent of the number of outlets. Intermediate Element M'
Element Designation M15 M20 M25 M30 M40 l
Delivery per Outlet 0.15 cm2 0.2 cm2 0.25 cm2 0.3 cm2 0.4 cm2
Piston 6 7 8 9 10
Element Designation M35 M55 M75 M100 l
Delivery per Outlet 0.35 cm2 0.55 cm2 0.75 cm2 1.0 cm2
Piston 8 10 12 14
The element with Indicator Pin or element with Proximity Switch can be fitted in any desired position.
Detail of Element with Indicator Pin.
OUTPUT POLARITY : POSITIVE SENSING DISTANCE : 2mm CABLE LENGTH OPERATING VOLTAGE THREAD M12X1 WITH LED
CONNECTION DIAGRAM
The element with Indicator Pin or element with Proximity Switch can be fitted in any desired position.
Detail of Element with Indicator Pin.
: 200mm : 24 VDC
Detail of Element with Proximity Switch.
Detail of Element with Proximity Switch.
PLEASE CONSULT US .OR ANY OTHER SWITCH 30

DUAL LINE LUBRICATION SYSTEM
DUAL LINE LUBRICATION SYSTEM

(END O. LINE SYSTEM) This type of system basically consists of a reservoir with in-built reciprocating plunger pump, reversing valve, dose feeders, end pressure relay and pipings. In this system, there are two main supply lines which are laid parallel to the equipment to be lubricated. Inlet to dose feeders are connected to these two lines and the outlets from the feeders are connected to points of lubrication. The pump feeds grease alternately into the two main lines through the reversing valve. The end pressure relay is located at the farthest point from the pump which trips the pump motor and changes position of the reversing valve as soon as a pre-set pressure is achieved in the line being pressurized. This completes the cycle. The next cycle is started through an adjustable timer. A dual line system generally have a working pressure of 100 300 Kg/cm 2 and can feed metered grease to hundreds of lubrication points through a pipe line.
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
Pump with lubricant reservoir Pressure line Pressure relief valve .ilter Reversing valve Main line Dose feeder (metering device) End pressure relay .eed line Lubrication point Relief line
Pump can be manually operated, pneumatically operated & motorised. Please ask us for details mentioning No. of points on the system and grease qty. to be supplied to all these points per cycle. End pressure relay is not required in manual system and small' in length' systems. It is basically required for big systems to ensure positively pressure building at the end of line. Control panels for automatic operation are also available. Please ask for details.
31
DOSE .EEDER
MODEL CSD.-11
DOSE .EEDER
MODEL CSD.-21
Note : 1. 2. 3. 4. Discharge capacity per point per half - cycle 0.5 to 2.5 cc (adjustable) total 5cc/cycle. Maximum working pressure-250 Kg/Cm2. Any outlet can be plugged also it does not effect working of other outlets. Suitable for grease/oil.
32
DOSE .EEDER
MODEL CSD.-31
DOSE .EEDER
MODEL CSD.-41
DOSE .EEDERS
MODEL : CSD.-11, CSD.-31, CSD.-21, CSD.-41

Centralised lubrication system guide

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Centralised lubrication system guide

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CENTRALISED LUBRICATION SYSTEMS

An ISO 9001 : 2000 Certified Company

CENTRALISED SINGLE SHOT OIL LUBRICATION SYSTEM

CENTRALISED SINGLE SHOT OIL LUBRICATION SYSTEM

CENTRALISED LUBRICATION SYSTEMS

CENTRALISED SINGLE SHOT OIL LUBRICATION SYSTEM

PLANNING/INSTALLATION O. THE SYSTEM

CENTRALISED LUBRICATION SYSTEMS

Outlet on right hand side unless specified

DIMENSIONS IN MM A MODEL H 1700-10 H 600-6 170 120

RESERVOIR CAPACITY IN CC 1700 600

DISCHARGE PER STROKE IN CC 10 6

Without Oil Reservoir Discharge per stroke7cc.

CENTRALISED LUBRICATION SYSTEMS

AUTOMATIC LUBRICATION UNITS

MOTORISED LUBRICATION UNITS

Reservoir Motor Pr. Setting

3 Ltr 120W, 230V 15 Kg/Cm2

Suitable for oils with viscosity range 50150 cst only.

CENTRALISED LUBRICATION SYSTEMS

AUTOMATIC LUBRICATION UNITS

MODEL ALU-08/PS/.S MODEL ALU-20/PS/.S MODEL ALU-30/PS/.S

ELITE LUBRICATION UNIT

Model ELU-2700 ELU-2700/.S ELU-2700/PS/.S ELU-2700-S ELU-2700-S/.S ELU-2700-S/PS/.S

CENTRALISED LUBRICATION SYSTEMS

PNEUMATIC OIL PUMPS

CAM OPERATED OIL PUMPS

PNEUMATIC OIL PUMPS

MODEL Pn300010/.S Reservoir Capacity 3000 cc Output per stroke 10 cc

RESERVOIR CAPACITY 1.7 Litres 0.6 Litre

OUTPUT PER STROKE 10 cc 10 cc

CENTRALISED LUBRICATION SYSTEMS

CENTRALISED LUBRICATION SYSTEMS

Sp. manifolds are also available as per specific requirement.

STRAIGHT CONNECTORS (TAPER THREADS)

1/4" UN. M8x1 1/8" BSP 1/8" BSP M10x1

CENTRALISED LUBRICATION SYSTEMS

ELBOWS (TAPER THREADS)

1/4" UN. M8x1 1/8" BSP M8x1 1/8" BSP M10x1

21 21 21 24.5 24.5 24.5

01. .-B-4/M8x1 02. .-B-4/1/8" BSP 03. .-B-4/M10x1

M8x1 1/8" BSP M10x1

CENTRALISED LUBRICATION SYSTEMS

01. .-B-6/M10x1 02. .-B-6/1/8" BSP 03. .-B-6/1/4" BSP

M10x1 1/8" BSP 1/4" BSP

01. 02. 03. 04. 05.

C-4-1 C-4-2 C-4-3 C-6-1 C-10-1

5.5 5.5 5.5 5.5 6.5

1.5 1.5 1.5 1.5 2

CENTRALISED LUBRICATION SYSTEMS

STEEL TUBES NYLON TUBES HOSES

NOTE : Hoses are available in lengths as per customer's requirement. 11

CENTRALISED LUBRICATION SYSTEMS

ON-O.. ELECTRONIC TIMERS

ON-O.. TIMER MODEL ET-11

ON-O.. TIMER MODEL ET-21

ON-O.. TIMER MODEL ET-31

ON-O.. TIMER MODEL ET-41

BODY DIMENSIONS O. ON-O.. ELECTRONIC TIMER ET-11/ET-21/ET-31/ET-41

CENTRALISED LUBRICATION SYSTEMS

ON-O.. ELECTRONIC TIMERS

Model ET-11 ET-21 ET-31 ET-41