1.Progressive lubrication system description

Progressive lubrication system comprises a feed pump and progressive distributors, whereby, the distributor is equipped with a circulation control . In addition there are the necessary pipelines, threaded pipe fittings and fastening components. Pressure indicator in the inlet of the respective progressive distributor, are additionally helpful for function control. The lubrication pump should be assembled on an easily accessible position of the machine, so that uncomplicated refilling of the container is possible. The progressive distributor should be assembled as close to the lubrication points as possible.

The line system must be designed such that it can take maximum pump pressure. Preferably steel pipes are laid. If mobile lubrication points are to be lubricated, high pressure hoses of appropriate dimension must be used. The length of the high pressure hoses should be kept as short as possible, as these expand under pressure and can intake appropriate lubricant quantity.

Timely secure feeding of the lubricant is thus no longer guaranteed. Moreover, like for air inclusions, a quick pressure suppression, which may affect the lubricant adversely, is prevented.

Only lubrication lines, i.e. lines directly leading from the distributor to the lubrication point, can be laid in polyamide pipe, if it is ensured that the permissible operating pressure of the pipe shall not be exceeded.

It is recommended to select the cross sections of the pipeline according to the length of the pipes so that only little operating pressure (less than 80 bar) is required. Slow action pumps are beneficial. Higher pressure changes the lubricants adversely. Hence, possibly low operating pressure must be selected in the pneumatic pumps. The pumping pressure can also be reduced through a throttle in the air line.

2. Mode of action:

The lubricant is pumped into the main line by actuating the pump and fed to the connected progressive distributor. The lubricant is distributed over the number of outlets of the distributor and then delivered to the lubrication points or fed to another downstream progressive distributor, divided there and dispensed to the connected lubrication points. Dosing is done as per the selection of the dosing elements with different flow rates.A circulation control detects every circulation of the system. If a progressive distributor cannot deliver its lubricant or if a piston is blocked e.g. due to contamination, the system reports fault i.e. the circulation control has not reported within the monitoring time.

Particularly for large systems, which are operated with grease, it is essential to start the system step-wise from the lubrication point to the pump i.e. lubrication points, lines and progressive distributor must be pre-filled individually. The pressure requirement of individual segments of the system can thus be checked directly. Pay attention that the lubricant is refilled on time, for preventing air bubbles in the system. Else the complete system must be re-ventilated.

3. Start-up:

Before start-up, the pump must be filled with clean grease without any air bubbles. It is important that the pump is filled using a filling or barrel pump. The barrel pumps mustbe equipped with follow piston. Clean and air-bubble-free filling can thus be ensured. A cartridge pump with pre-filled cartridges may also be used for small consumption quantities.

Then the pump and subsequently the progressive distributor must be ventilated. Pumping follows till bubble-free lubricant appears first on the pump and then on all the outlets of the main distributor and subsequently on the downstream progressive distributors.

Particularly for large systems, which are operated with grease, it is essential to start the system step-wise from the lubrication point to the pump i.e. lubrication points, lines and progressive distributor must be pre-filled individually. The pressure requirement of individual segments of the system can thus be checked directly. Pay attention that the lubricant is refilled on time, for preventing air bubbles in the system. Else the complete system must be re-ventilated.

4.Assembly:

The fastening surface of the progressive distributor must be plane, so that the housing is not

braced while screwing. If required, washers may be required for alignment.Outlet bore of the progressive distributor must be closed. Cleanliness must be observed. Pumps, progressive distributor and particularly the pipelines and fittings must be cleaned thoroughly prior to the assembly.

5. Lubricant:

Generally, grease can be dispensed based on mineral oil that shows a walk penetration more than 265 (1/10 mm), NLGI-Klasse 000 - 2 in the bielomatik progressive lubrication system.Greases must not be mixed. In exceptional case.

6.Maintenance:

Impermeability of the system and the container fill level must be checked at regular intervals. A fault occurs if the circulation control has not responded within the monitoring time.

Reasons:

a) Container or barrel empty.

b) Pump not ventilated or defective.

c) System blocks at high pump pressure.

● Lubrication line closed

● Lubrication point or its channel closed

● Outlet on the progressive distributor closed

unauthorised

● Piston in the progressive distributor fits tightly (bracing, contamination)

● Channel within the progressive distributor closed due to contamination.

● All pistons of a progressive distributor are at centre position.

In case the system is blocked, fault may occur at any location in the system. There is overpressure at the blocked location, which is signalled to the relevant pressure indicator by a protruding pin. Source of fault can thus be localised on a secondary distributor.