You are on page 1of 34


Oil+Air Lubrication Systems

Operating Manual Version 02


Page 1


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

Information Concerning the EC Declaration of Conformity and the Manufacturer´s Declaration ........................2 Notes Concerning this Manual ...................3 Applications..................................................3 Safety Instructions.......................................4 Transport, Delivery, Storage .......................5 Design and Function ....................................5 Principle Function of Oil+Air Lubrication....... 5 Design of the Oil+Air-Lubrication System ..... 5 Components and Operating Elements .......... 6 Compact unit (1) ......................................... 6 Control valve for compressed air (6) .......... 6 Pressure switch for minimum air pressure (8)................................................................. 6 Oil+air dosing unit (9)................................. 8 Function........................................................... 9 Types and Designations ............................... 12 Lubricants...................................................... 13 Compressed Air ............................................ 14 Installation ..................................................14 Setup ............................................................. 14 Electrical Connection.................................... 14 Compact unit ............................................. 14 Pressure switch for minimum air pressure15 Control and Monitoring of the System ......... 15 Systems without controller........................ 15 Systems with controller ............................. 15 Connecting the Lubricant Lines ................... 15 Installation of Nozzles ................................... 16 Compressed Air Connection ........................ 18 First Operation........................................... 19 Filling the lubricant container ........................19 Adjusting the Lubricant Consumption ..........19 Adjusting the Air Consumption .....................19 Setup Operation ............................................20 Operation ................................................... 21 Maintenance .............................................. 21 Failures....................................................... 22 Decommissioning...................................... 24 Temporary Shut-Down ..................................24 Final Decommissioning .................................24 Service........................................................ 24 Specifications ............................................ 25

but does not entail an express assurance of properties. 1967.. and are not approved for application with such.1 to 1. conforms to the regulations set forth in the EC directive 98/37/EC. paragraph 1. (b) The safety instructions in the documentation accompanying the product must be observed.5 bar above the normal atmospheric pressure (1013 mbar) in the admissible application temperature range. They are classified by us to come under article 3 paragraph 3 of the directive. . Therefore. numbers 1. Especially observe the following: VOGEL products must not be used in conjunction with fluids.Information Concerning the EC Declaration of Conformity and the Manufacturer´s Declaration Page 2 US Information Concerning the EC Declaration of Conformity and the Manufacturer´s Declaration For the product designated below: Oil+Air Lubrication Systems Series: OLA xx-xxxxx we herewith certify that it conforms to the pertinent safety requirements set forth in the following Council Directive(s) for the harmonization of the laws of the Member States. Taking into service is not admissible until evidence has been provided that the machine in which this part is installed or to which this part is connected. the products supplied by us will not reach the limit values set forth in article 3. liquefied gases. • Electromagnetic compatibility 89/336/EEC • Electrical equipment designed for use within certain voltage limits (low voltage directive) 73/23/EEC Notes (a) This declaration certifies the conformity with the directives listed. conforms to the regulations and requirements set forth by the applicable directives. vehicle or similar item.Machinery Directive 98/37/EC. Therefore they do not come under the requirements set forth in annex I of that directive. If required. group I (hazardous fluids). according to the definition of article 2 paragraph 2 of the directive 67/548/EC dtd. steams or fluids that will reach a steam pressure of more than 0. VOGEL products must only be used as intended. Use or taking into operation of the products in areas with potentially explosive atmospheres according to the ATEX directive 94/9/EC is not allowed. regardless of whether these entail gaseous atmospheres or dusty atmospheres. Annex II B.. • with reference to the EC directive 97/23/EC concerning apparatus subjected to pressure this product must only be used as intended and according to the notes in the documentation. None of the products manufactured by VOGEL are approved for application in connection with gases. We further declare that the above mentioned product: • is meant for integration into a machine / for connection to other machinery according to the EC . into which the product is integrated. they are not marked with the CE mark concerning the directive 97/23/EC. June 27th. (d) The operation of the products on nonstandard line voltage as well as nonadherence to the installation instructions can affect the EMC properties and electrical safety. gases dissolved under pressure. (c) Taking into operation of the certified products is not allowed until evidence has been provided that the machinery.3 and paragraph 2 of the directive 97/23/EC. you may request the declaration of conformity or manufacturer’s declaration for this product from our central contact address. Provided they are used as intended.

Note that this operating manual is a part of the system and must be handed to the new owner upon sale of the system. Text marked with this sign alerts to special hazards or work that must be performed with caution. e. steams or fluids that will reach a steam pressure of more than 0. use the table of contents to locate the desired information promptly and successfully. Only media suitable for the system type may be supplied. Unsuitable media can lead to failure of the system and consequential severe property damage and personal injury.5 bar above the normal atmospheric pressure at the maximum admissible temperature. To ensure trouble-free operation and prevent hazards. gases liquefied under pressure. which can lead to injury of operators or other persons or damage to the machine or other property. VOGEL will not warrant for damages resulting from use of lubricants other than those approved by VOGEL. VOGEL will not accept liability for damages resulting from such unintended use. especially materials which are classified as dangerous according to EC directive 67/548/EEC article 2. paragraph 2. bearings of high-speed spindles. . We expressly emphasize that dangerous materials of any type. Applications All products of Willy Vogel AG may be used only as intended and according to the information set forth in the respective operating manual. may be stored and transported and/or distributed with VOGEL products only after consulting Willy Vogel AG and receiving their written consent. Please. we kindly ask you to read the present manual carefully and observe the notes contained in it.Notes Concerning this Manual Page 3 US Notes Concerning this Manual VOGEL oil+air lubrication systems have been made in conformity with the generally recognized rules of technology and the applicable safe working practices and the rules for accident prevention. Other use or use beyond this purpose is considered unintended. Still hazards may be involved in their use. Unless expressly stated for a specific product. products made by VOGEL must nut be used in areas with potentially explosive atmospheres. Further information concerning the lubricants are found in the chapter “Lubricants”. liquefied gases. None of the products manufactured by VOGEL are approved for application in connection with hot gases. g. page 13. The oil+air lubrication system here described is used for controlled lubrication of components subjected to high or highest strain.

refilling with lubricant. substantial property damage or injury of persons may be the consequence.g. Worn-out systems must be made inoperable and disposed of properly. electrical connection and all interventions such as repairs. the supply voltage must be switched off. They are authorised to perform the respective tasks and capable of identifying and avoiding possible hazards. may be carried out only by adequately qualified and instructed personnel. If the system is installed improperly. nor must they be replaced by parts which have not been expressly approved by VOGEL. Before removing the cap of the compact unit. Use the units only in technically perfect condition for their intended use. The safety mechanisms must not be damaged. Be aware of hazards and observe the operating manual. changes. these persons are familiar with the applicable standards. Due to their training and experience. The installation. The system must be disconnected from the compressed air supply and electric voltage and depressurized before undertaking any work on it. repairs etc. cleaning. The oil+air lubrication system may be subjected to pressure. DANGER. component replacement. therefore.Safety Instructions Page 4 US Safety Instructions Please observe the following safety instructions to ensure trouble-free functioning of the unit and prevent damage. instructed and specifically ordered by the owner to perform the work. or in any way made inoperable. The general rules and safety regulations for work with compressed air-operated machines. Unauthorised alteration of the device and use of unapproved spare parts and auxiliaries are not allowed. dismantled. Before extension work. e. The definition of what is a trained specialist and the prohibition of use by unqualified personnel are set forth in DIN VDE 0105 or IEC 364. etc. etc. FATAL INJURY Work on systems which have not been disconnected from power supply can lead to injury of persons. devices and systems must be observed. it must be depressurised. FATAL INJURY Repair work must only be performed after a trained specialist has disconnected the unit from power. . DANGER. accident prevention rules and operating conditions. Qualified personnel has been trained. The electrical installation of the unit must be carried out exclusively by trained specialists. regulations.

Figure 1 shows an oil+air lubrication system in standard version without controller. the lubricating point is continuously supplied with lubricant in the shape of fine drops. the valve set required for relieving and pressure limiting. The finely dosed lubricant is distributed in the form of streaks by air flowing inside a narrow lubricant supply line and is thereby transported to the lubricating point. Storage Page 5 US Transport. Keep the packaging material until any and all problems have been clarified. By means of a nozzle. an oil pressure switch and a float switch for level monitoring. and ensure the package is complete by checking the delivery papers. Storage The oil+air lubrication system is packed according to market standards in conformity with the regulations of the respective country of destination and DIN ISO 9001. Design of the Oil+Air-Lubrication System An oil+air lubrication system is comprised of the following components: • un-controlled or controlled compact unit (1) with gear pump. • air filter. a pressure gauge (4) is installed. resulting in optimum lubrication conditions at the friction points. Observe the respective technical documents supplied. These components. • pressure switch (8) for minimum air pressure. Depending on the application. Upon receiving the package. are optional and not covered by this operating manual. Delivery. Depending on the version. In general. The components are installed on an assembly plate and are supplied as a complete system. • additional pressure switches for lubricant and compressed air supply. however. The oil+air lubrication system is supplied fully assembled on an assembly plate. The storage temperatures can be found in the specifications. air or sea. the product should be stored in a dry and dust-free environment. Delivery. • additional float switches for filling level monitoring inside the compact unit. The lubricant volume required for each lubricating point can be dosed precisely. . further components may be integrated.Transport. There are no limitations for transport by surface. Transport packages must be labeled with the note “Do not throw!”. such as • oil filter (with or without electrical contamination monitoring). lubricant container (2). • control valve (6) for compressed air with pressure gauge. Design and Function Principle Function of Oil+Air Lubrication Oil+air lubrication is a lubrication method featuring minimum volume dosage. please check the items for possible damage. • oi+air dosing unit (9) with integrated piston feeders and mixing valves.

Control valve for compressed air (6) The control valve for compressed air is used to set the air pressure precisely. The pressure is set manually and can be read off at the integrated pressure gauge. Depending on the version. Additionally. the controller outputs a warning signal and switches the machine off (also see technical documentation of the controller). Design of the oi+air lubrication system (schematic representation. This is required because the lubricant can no longer be transported through the lubrication lines to the lubricating points when the air pressure is too low. US Components and Operating Elements Figure 1shows the oil+air lubrication unit. Figure 1. The function and operation of the compact unit and the controller are outlined in the respective operating manuals. since the signals of the oil pressure switch are then processed by the controller. the switch outputs a signal. In some systems the pressure switch for minimum air pressure is connected to the integrated controller. a controller may be integrated. subject to changes) 1 Compact unit 2 Lubricant container 3 Filling connector 4 Pressure gauge for oil pressure (optional) 5 Compressed air connection 6 Control valve for compressed air 7 Pressure gauge for compressed air supply 8 Pressure switch for minimum air pressure 9 Oil+air dosing unit . When the air pressure drops. This is required because the lubricant can only be dosed precisely when the air pressure is maintained at a constant level. Figure 2 and Figure 3 show different oil+air dosing units. the gear pump. an air filter with water separator may be integrated (optional). a float switch for level monitoring in the lubricant container. As soon as the air pressure drops below the set minimum value (see specifications). This signal can be used to trigger an error message and shut off the entire machine. Compact unit (1) The compact unit (1) is comprised of the lubricant container (2). a pressure switch with optional pressure gauge for monitoring of the pressure in the lubricant lines and the valve set required for relieving and pressure limiting. In this case the pressure gauge may be missing.Design and Function Page 6 Pressure switch for minimum air pressure (8) The pressure switch monitors the supply air pressure.

Design and Function Page 7 US .

The valve block of the MV50X type covers the range of small dosing quantities of 2 mm³ and 6 mm³. Pos. 11). the lubricant for each greasing point is charged and is supplied by the air stream over the oil+air greasing pipes to this greasing point. In oil+air units (OLA) the valve blocks of both types can be installed together (see connection overview Figure 5). Oil+air dosing unit MV50X (schematic representation. The dosing of the valve block of MV20X20 type goes from 10 mm³ up to 160 mm³. Figure 3. Pos.Design and Function Oil+air dosing unit (9) The oil+air dosing unit (Figure 2) is comprised of a compactly designed valve block with maximum six (type MV50X. subject to change) 9 Oil+air dosing unit 13 Oil supply connection 10 Air-adjustment screws 14 Compressed air connection 11 Connection for oil+air lubricating lines 16 Pressure control valve . further valve blocks can be connected in series to the oil+air dosing unit. 10). So the dosing range of 2 mm³ up to 160 mm³ can be supplied with one unit. At each greasing point the air current can be regulated by air regulation screws (Pos. 11) or maximum eight outputs (MV20X-20 type. If more outputs are necessary. In the oil+air dosing unit. Page 8 US 11 16 A B A B 14 9 AIR OIL 06 02 06 06 13 10 Figure 2. Figure 2.

The pipe outlet of the pressure control valve is connected to the feedback of the container (see hydraulic system . The same holds true of the monitoring of the filling level and the lubricant pressure. only one pressure control valve (23 bar) can be mounted at the end of the unit (see hydraulic system. Using the oil+air dosing units of the MV50X type. Figure 5). The pause times are controlled either by the controller integrated into the compact unit or directly by the machine´s control system. Oil+air dosing unit MV20X-20 (schematic representation. Figure 2) with an opening pressure of 23 bar. The lubricant is filled into the lubricant container of the compact unit. 12 15 10 Figure 3. 16. subject to change) 9 Oil+air dosing unit 13 Oil supply connection (either right or left) 10 Air-adjustment screws 14 Compressed air connection 11 Connection for oil+air lubricating lines (either right or left) 12 Pressure measuring connection (M5) 15 Plug screw for installation of dosing units . The gear pump integrated into the compact unit pumps the lubricant to the oil+air dosing unit. that is. 14 AIR Page 9 US 9 11 15 13 13 OIL OIL AIR 14 Function Figure 4 and Figure 5 show the hydraulic system of an oil+air greasing unit in different versions. each lubrication cycle is followed by a pause. Figure 5).Design and Function Valve blocks of type MV50X have a mounted pressure control valve (pos. The ventilation is carried out self-employed for each pump run and provides a bubble-free ventilation of the lubrificant to the dosing unit in MV50X. It provides a self-employed ventilation of the main pipe. The compact unit operates in cycles.

If the compressed air pressure is too low. is processed by the machine´s control system. the machine must be shut off.Design and Function The compressed air is conducted via the pressure control valve to the oil+air dosing unit where it is mixed with the lubricant that has been dosed separately for each lubricating point. which comes either from the pressure switch directly or from the controller of the compact unit. The air flow distributes the lubricant along the lines in streaks and it thereby flows along the lines. because the lubricating points can no longer be supplied with sufficient lubricant. the lubricant is dispensed in the form of fine drops and thereby applied to the lubricating point. The air leaves the lubricating point almost oil-free. At the nozzles. The lubricant dosed is then transported through the lubricant lines to the nozzles at the friction point. Hydraulic diagram of an oil+air lubrication system with oil+air MV20X-20 dosing unit . 4MV204-20 Page 10 US DS2 R x DS1 M P1 P2 x Figure 4. The switch signal. The compressed air supply is monitored by a pressure switch.

Design and Function Page 11 US MV504 4- MV504 4- 4- MV204-20 DS2 23bar R DS1 M P1 P2 x Figure 5. Hydraulic diagram of an oil+air lubrication system with oil+air MV20X-20 and MV50X dosing units .

oil and air filter Filter: Version number: Voltage code 01-99 . Type key Designation OLA 04 2 3 0 01 + 428 US Types and Designations Table 1 explains the type code indicated on the nameplate of the system.without .Design and Function Page 12 Table 1.metal .air filter . System designation Number of oil+air connections Controller Container size Filter Version number Voltage code Controller: Container size: 0 2 0 1 2 0 1 .metal .> 6 litres .6 litres .IG54-20 .IG38-30 .6 litres .below 2 litres .without .oil filter 5 9 3 6 7 8 2 3 .other 3 litres .plastics .2 litres .without .two-digit count number (determined by VOGEL) For details refer to the respective documents and the nameplate of the motor .

In units of type OLA mineral or synthetic as well as rapidly biodegradable oils may be used. it is recommended to attach a note concerning the lubricant to be used to the lubricant container. . Oils with solid substance additives must not be used. Admissible oils Requirement Recommended oil purity class* Recommended ISO VG class* Operating temperature Recommended additives Inadmissable additives Values US Lubricants Only media suitable for the system type may be supplied. storage and processing require that special safety measures be taken... Table 2. because solid substance particles could accumulate in the nozzle bores and choke these. Note that the properties of some lubricants may lie within the limit values indicated. Unsuitable media could lead to failure of the system and possibly severe property damage and personal injury. Keep in mind that oils and greases are generally considered environmentally hazardous and combustible substances and that their transport. Also observe the safety datasheet of the respective lubricant.Design and Function Page 13 VOGEL offers to test lubricants for compatibility with oil+air lubrication systems. Please observe the notes of the machine manufacturer concerning lubricants to be used. 100 °C EP additives Solid substances * Observe the notes of the machine manufacturer. The requirements upon the lubricants to be used are summarised in Table 2. To avoid confusion.. Lubricants with solid substance additives may not be used. since their bearing capacity at higher loads may not be sufficient. Oil of a viscosity lower than indicated in Table 2 should not be used. Do not mix different lubricants. For instance. Avail yourself of the advice of VOGEL employees. 100 related to 40 °C 40 °C . 13/10 (ISO 4406) or class 4 (NAS 1638) 32 . For high-load operations and low speeds oils with EP additives are especially recommended. but these may not be suitable for use with oil+air lubrication systems because of some other properties. since this may lead to damage and may require costly cleaning of the lubrication system. Also bearing play might be critically reduced by attachment of solid particles to bearings.. which in turn may shorten the servicelife of bearings. synthetic lubricants may be incompatible with the material used for seals.

Further information concerning the compact unit is found in the operating manual for compact units. Electrical Connection Compact unit The compact unit must be connected electrically by qualified. The system is fastened with the assembly plate to the machine housing. The compact unit is connected electrically by means of a plug to the line socket supplied. The installation dimensions and location of assembly bores are given in the customer specific drawing. Use only the original fuse with the required ampere value. a water separator as offered in VOGEL´s pneumatic component delivery programme with semi-automatic drainage (if at all possible) is sufficient. Requirements upon compressed air Requirement Input pressure Required air volume (pipe with 2. The filling level of the lubricant container and an optional pressure gauge must be clearly visible. Also. If the compact unit is installed improperly. When inductive consumers are connected to the float switch or pressure switch.Installation Page 14 US Installation Compressed Air The air must be dry and filtered. If other fuses are used. Check the fusing of the circuit. recommended oil viscosity range) Values min. The required air volume is stipulated as follows: for use of oils with viscosity higher than indicated in the recommendations. max. a higher air consumption must be expected.1500 l/h With reference to the compressed air quality classified to ISO 8573-1 Particle count Maximum particle size Maximum particle count Dew point under pressure Oil concentration class 3 5 µm 5 mg/m³ class 4 maximum: +3 °C class 3 maximum: 1 mg/m³ . The detailed requirements upon the compressed air are outlined in Table 3. or with higher adhesion. the contacts must be protected by suitable measures. trained specialists that have been authorised by the owner to do so. substantial property damage or injury of persons may be the consequence. The terminal assignment differs from unit to unit with the respective options. Table 3. damage to property or personal injury may be the consequence. The wiring diagrams are printed on a sticker attached to the inside of the cap. For water separation. It is not necessary to open the compact unit to do so.3 1 MPa MPa Setup The oil+air lubrication system should be installed protected from moisture and vibration. 0. If necessary. The supply voltage on site must agree with the information on the nameplate. but easily accessible. sufficient space must be available to refill with lubricant and make settings.3 mm inside diameter. 1000 . control lines must be fed through the cable union and then connected to the terminals on the inside.

Upon shut-off of the compressed air. If the oil pressure is insufficient. Page 15 US Systems with controller In systems with a controller. The minimum runtime of the pump (chapter specifications) and the required pump dwell time must be observed. Monitoring of the minimum supply air pressure and the filling level of the lubricant must be such that error messages are output if the supply pressure fails or drops. The following functions are controlled: • The pause time or the pump run time. The required oil pressure is reached when the oil pressure switch is activated. a spiral (16) is installed. the lubricant distributed inside the spiral will collect at the bottom end of the windings. For monitoring of the oil pressure please note that a few seconds will always pass between start-up of the pump and activation of the oil pressure switch. which serves as lubricant reservoir. The lines may be installed with rising or falling inclination. the system is controlled and monitored by the machine’s control system. Corresponding notes can be extracted from the operating manual of the controller. Approx. The following functions are monitored: • the minimum compressed air pressure. The centre axis of the spiral should always be horizontal. to ensure that an oil pressure error message is only generated after this time has run out.Installation Pressure switch for minimum air pressure The pressure switch for monitoring of the supply air pressure is connected by means of a connector. Control and Monitoring of the System Systems without controller On systems without controller. Detailed information on this is found in the respective technical documentation. • the filling level inside the lubricant container. • the oil pressure or oil pressure build-up. to ensure the dosing chambers of the dosing unit are supplied reliably with lubricant. The pump dwell time is the period during which the pump continues to run after the required oil pressure has been reached. The recommended pump dwell time can be extracted from the specifications. control and monitoring of the operation is taken over by the controller. Connect the lubricant lines as outlined in the diagram in Figure 6. The lubricant lines should be made of transparent plastic tubes to enable visual inspection of the lubricant transport. The requirements upon the lines are outlined in Table 4. thus no wait time is required to ensure that the lubricant is distributed along the entire lubricant line. We recommend to program a fixed monitoring time for pressure build-up. . Recommendations are found in the specifications.5 to 1 m before the nozzle (17). Avoid changes of cross-section from lower to higher cross-section in flow direction. 0. Design changes of cross-section smoothly. Connecting the Lubricant Lines Only original parts made by VOGEL must be used. The pause times or pump run times should be set depending on the amount of lubricant required at the lubricating points (see chapter “First Operation”). depending on the amount of lubricant required at the lubricating points (see chapter “First Operation”) and the requirements upon the operating mode of the pump motor (also refer to the specifications). the system must be shut off to ensure that the lubricant lines are not blown empty. or if the minimum filling level is reached in the lubricant container. Be sure to program a buffer time in the machine’s control system to ensure that possible brief pressure fluctuations in the supply system will not trigger an error message.

its length depends on the size of the bearing. Key data for installation of lubrication lines Requirement Minimum length up to the spiral Maximum length of the spiral Recommended lines Values 2m 10 m 6x1 mm or 4x0. On single-row bearings the lubricant can be applied to the bearing laterally. g. Alternatively. Assembly diagram for oil+air lubrication lines.85 mm Figure 6. the lubricant must be supplied in this direction. the lubricant should be supplied to the bearing by means of a special nozzle piece.Oil+air dosing unit. On double-row cylindrical roller bearings the lubricant should be sprayed into the bearing from one side on the same level with the outer race track. If the bearings are even bigger. that the lubricant is not supplied into the pressure zone between ball and outer race (Figure 8). angular conical ball bearings). 17 . It will then be distributed almost evenly on both bearing rows (Figure 7). 16 . Ensure. Table 4. the streak sensor allows to monitor the transport of the fine lubricant flow along the lubrication line wall. Consult with VOGEL technicians concerning this or request our descriptive materials. Page 16 US Installation of Nozzles Supply of the lubricant to the bearings depends entirely on the type of bearing and the design features of the bearing´s location. . Figure 7 shows examples of recommended lubricant supply configurations.Installation To monitor the lubricant flow in the lubrication lines.Spiral. however. By no means should the oil+air flow be pointed directly at the ball cage. Installed downstream of the mixing point for air and oil. VOGEL recommends to use a streak sensor GS4011 or GS6011.Nozzle On bearings that entail a pumping action in one direction (e. Further information relating to connections are contained in the specifications. 9 . the lubricant can be supplied directly to the outer race via a supply bore. If possible. install even more nozzles. The nozzle bore should be on one level with the inner race. On antifriction bearings with an outside diameter between 150 and 280 mm it is recommended to install a second nozzle.

If you have further questions concerning installation of the oil+air lubrication system. the lubricant supplied must be drained. please contact your technical consultant at VOGEL. As a guiding value for the diameter of the drain bore take six times the cross-section of the supply opening(s).Installation If the lubricant is supplied through the outer race. Figure 7. it is recommended to provide a drain bore. If a higher air pressure should be required in an individual case. To ensure this. this will not impair the function of the entire system. The air pressure indicated in Table 3 is generally sufficient to penetrate the air turbulences caused by high-speed bearings. but at least 5 mm. a single bore is sufficient for most applications. Recommended lubricant supply for diverse bearing types Page 17 US . To prevent an oil sump from forming at the bottom section of the bearing.

a 3/2 directional valve. an air filter with water separator should be used to ensure that the required compressed air quality is reached. Information concerning the compressed air supply connection are found in chapter “Specifications”. Only original parts made by VOGEL must be used.Installation Page 18 US Compressed Air Connection Ensure that the main air valve is closed before connecting the compressed air line. this helps to ensure that the lubricant supply lines will not be blown empty. to enable shut-off of the compressed air supply in case of failures.g. If required. Please note the requirements upon the compressed air listed in Table 3. Lubricant supply through the outer race . It is recommended to install a controlled valve into the supply line. e. When the compressed air supply is faulty. Figure 8.

Example for a typical configuration: 150 − 200 mm3 h mm3 30 Cycle Cycles h n= n= 5−7 . The dosing volume per cycle (d) depends on the version of the oil+air dosing unit. The minimum runtime for the pump and the pump dwell time must be taken into account (see chapter “Installation”). since this may lead to damage and may require costly cleaning of the lubrication system. The operating pressure must be adjusted so that the required volume can be supplied in all lines. VOil mm3 Cycles mm3 =n ⋅d h h Cycle Cycles n = h VOil mm3 h mm3 d Cycle The number of cycles per hour (n) found is used to determine the pause and pump run times. the adjustment of the pause times is described in the operating manual of the controller. n VOil d number of cycles per hour lubricant consumption at the friction point (Please note that several lubrication points may be present at one friction point or bearing location) dosing volume per cycle Adjusting the Air Consumption The air consumption depends on the amount of lubricant supplied. Generally it is defined in mm³/h. The system must be started only approx. it is recommended to attach a note concerning the lubricant to be used to the lubricant container. Figure 1). The most important criterion is the visual inspection of the continuous and even flow of lubricant through the lines. This volume is subdivided into as many as possible short cycle times with low dosing volumes. To avoid confusion. Adjusting the Lubricant Consumption The lubricant consumption at the friction point must be determined by the machine´s manufacturer. the pressure loss in the line and at the lubricating point must be taken into account. 3. Base the correct adjustment for the air consumption on the information supplied by the machine´s manufacturer or on empiric data. For systems with integrated controller. the number of lubrication lines and the specific properties of the lubricating point. Do not mix different lubricants. 15 min after filling.First Operation Page 19 US First Operation Filling the lubricant container The lubricant container is filled with lubricant through the filling neck (pos. to ensure air bubbles in the lubricant can escape.

Especially watch for formation of an uninterrupted oil streak inside the lubrication lines. The air consumption of the individual lubrication lines is set using the corresponding airadjustment screw (pos.3 . 6 in Figure 1). 9 in Figure 1). • Let the compact unit cycle until a continuous lubricant film has formed in the lubrication lines and fine lubricant drops escape from the nozzles. 9 in Figure 1). It should be set between 0. 10 in Figure 2 and Figure 3) at the oil+air dosing unit (pos. 10 in Figure 2 and Figure 3) or the compressed air control valve (pos.1 MPa or 3 . • Remove the plug screws of the compressed air measuring connection (pos. Changing the air consumption of a lubrication line will always influence the air consumption of the remaining lubrication lines.10 bar). the oil+air lubrication system and the machine must be shut off. a minimum supply volume will always remain. When the compressed air pressure build-up is failing.3 and 1 MPa (3 to 10 bar). Note: It is not possible to shut off a lubrication output entirely using the air-adjustment screw. to prevent insufficient lubricant supply to the lubricating points. Page 20 US Setup Operation • Close the compressed air control valve (pos. • Reinstall the plug screw. • Switch the line voltage on and let the compact unit cycle until the lubricant drools bubble-free from the opening of the compressed air measuring connection. • Watch the oil+air lubrication system and set the air consumption with the aid of the airadjustment screws (pos. • Open the compressed air control valve (pos. 6 in Figure 1). . 12 in Figure 3) at the oil+air dosing unit (pos.First Operation Set the operating pressure at the compressed air-adjustment valve (pos. 6 in Figure 1). 6 in Figure 1) and adjust the operating pressure (0.

Also regularly check the lubricant level in the lubricant container and refill lubricant if required. If an unsuitable or dirty lubricant has been used. leave hoses and cables connected while cleaning and close any openings to prevent cleaning agents from entering the interior. in order to ensure faultless functioning and to prevent dangers from arising. Please contact us if this situation arises. Note: On oil+air lubrication systems with controllers. the lubricant supply along the lubrication lines should regularly be checked visually and the air supply should be readjusted if required. as outlined in chapter “First Operation”. However. check all connections regularly. If necessary. If possible. this would invalidate any warranty claims. material-safe (non-alkaline. The lubricant container must not be disassembled.Operation Page 21 US Operation The oil+air lubrication system operates automatically. the compact unit can be cleaned with mild. . WILLY VOGEL AG assumes no liability for damages which accrue from improper installation work on the minimum-quantity lubrication system. Interior cleaning is not necessary in normal operation and if compatible lubricants are used. to ensure continuous lubricant supply. Maintenance VOGEL oil+air lubrication systems require little maintenance. a pre-lubrication cycle is started upon each power-up. Nonetheless. no soap) cleaning agents. the interior of the lubricant container must be cleaned. If the system is switched on and off frequently. this may result in excessive lubrication. For safety reasons we recommend to separate the system from the compressed air supply and electric power supply before cleaning.

replace defective push-button Motor too hot. Failures and their remedy Problem Pump motor does not start running when the operating voltage is switched on or when the DK button is pressed. turn motor manually. the supply voltage must be switched off. the thermal protection has been triggered Pressure switch for minimum air pressure tripped Correct on-time of motor (max. turn it manually. Motor runs hard at too low speed. Replace lubricant in the entire system. Increase temperature. Use only original VOGEL spare parts.Failures Page 22 Table 5. replace if required. FATAL INJURY Work on systems which have not been disconnected from power supply can lead to injury of persons. Clean pump or return system for repair. DANGER. Check pressure relief valve. if it runs hard. Before removing the cap of the compact unit. pressure relief valve jammed or defective Pump or motor jammed Ambient temperature too low . Missing or too low air pressure Before any other work switch off power supply to the unit! Pump blocked Remove pump. Have an electrician do the following: • • • • • check supply connection check power plug or power cable and correctly connect it check operating voltage at the motor check fuse check push-button. FATAL INJURY Repair work must only be performed after a trained specialist has disconnected the system from power. if it runs hard. on-time see Specifications). Remove old lubricant entirely before and dispose of it properly. DANGER. replace the motor. Possible cause No operating voltage applied to motor Remedy US Failures Table 5 provides an overview of possible failures and their causes. You should contact us if the problem can not be rectified by taking the measures described here. replace the pump. Wrong lubricant (see Specifications) Pressure too high.

See failure “Motor runs hard”. dosing valve(s) do(es) not shift. return pump or unit for repair. Problem No pressure is built up in the main line. US No pressure build-up in the lubrication line. Repair the line. Replace the relief valve.Failures Table 6 continued. Relief valve jammed (contaminated) . Page 23 Failures and their remedy Possible cause Air in the main line Line broken Relief valve does not close Insufficient filling level Pump or pump motor defective Motor does not run or runs hard Remedy Vent the line. Filling with lubricant Replace. Clean or replace the relief valve. Final Decommissioning If you should terminally decommission the oil+air lubrication system. The system can also be taken back by VOGEL for disposal. For long-term shut-down we recommend to pump empty the lubricant container. please observe the legal regulations for disposal of oil-contaminated equipment. provided the costs are covered.Decommissioning Page 24 US Decommissioning Temporary Shut-Down For temporary shut-down of the oil+air-lubrication system separate the entire system from compressed air supply and electric power supply. please contact our technical sales and service centre or our representations. Service If you encounter problems or have questions. . You can find a list with current addresses on the Internet at: • www.

. the minimum pause time is 1 min) Operating voltage. 24 (inquire for > 24) Unit Values V min-1 W 230 V 50/60 Hz or 115 V 50/60 Hz (inquire for others) Standard version: installed 2700/3300 105/125 ...Specifications Page 25 US Specifications Table 6.. Specifications Designation Entire system Dimensions W x H x D with assembly plate Weight (filled) Number of oil+air outputs Compact unit Container volume..25 min cycle time.25 min) l l/min MPa (bar) °C MPa (bar) 3 or 6 (inquire for special sizes) 0. 6 Standard version: S3. 100 3 (30) IP 54 mm kg depending on version (see customer drawing) depending on version (see customer drawing) 1 . +60 oil on mineral oil or synthetic basis... the run time is 15 s...25. for 1... nominal Flow volume Operating pressure Operating temperature Supplied medium Recommended ISO VG class Opening pressure of pressure relief valve Enclosure type Motor Operating mode (to VDE0530) (e. 20 % (1.g.2 (inquire for special flow volumes) 3 (30) +10 . standard Thermal switch Rated speed at 50/60 Hz Power consumption at 50/60 Hz Oil+air dosing unit Number of oil+air connections per oil+air dosing unit Type MV20X-20 Type MV50X pcs pcs 1 . 8 1 . compatible with NBR and Viton 32 ..

. adjusted: 0..100) Compressed air connection Control system Recommended pump dwell time Recommended monitoring time for oil pressure build-up s s 5 30 MPa (bar) Nl/h 0.3 ... adjusted: 3) resistive: 6 A at 24 VDC and 0.5 A at 220 VDC inductive: 6 A at 24 VAC and 3 A at 220 VAC V AC A VA opens when filling level is too low 48 0. 10) 1000 . 1500 M10x1.... oil to ISOVG 32. countersunk for pipe ∅6 M8x1.Specifications Table 6. 10..5 30 2 (20) Unit Values Page 26 US ....3 mm. Specifications Designation Oil pressure switch (part of compact unit) Contact type Maximum switching voltage Maximum switching current Maximum contact load Switching pressure Float switch (part of compact unit) Function Maximum switching voltage Maximum switching current Maximum contact load Pressure switch for minimum air pressure Switching pressure Switching capacity Connection of oil+air lubrication lines Oil+air output Compressed air connection Operating pressure Air consumption (for pipes with internal diameter of 2.1 .7 50 V AC A VA MPa (bar) normally open contact 42 2. cont. 1..3 (1 . countersunk for double conical ring pipe union for pipe ∅4 MPa (bar) 0. 1 (3 .

Notes US .

Notes US .

Notes US .

Notes US .


skf. 2007 .Willy Vogel Aktiengesellschaft A company of the SKF group Motzener Strasse 35/37 • 12277 Berlin • Germany PF 970444 • 12704 Berlin Phone: +49 30 72002-0 • Fax: +49 30 72002--111 • 951-130-178 • www.