mist lubricating

-I-

MILANO (ltaly) 20134 viaMassimiano,2S

tel.215725112/3/415

DnoPsfi,

I 91t tetex 157DRoPSA

llffl 0lll IIEHIIIEI1 llB

preface

INDEX

A - PBEFACE History of mist lubrication principles Fondamental Nebol system components

Pago 1 2 3

8 - APPTICATION Basicsteps to &sign Rolling element bearings fitting usage Recommended Vents Oil sumps Plain bearings Becommendedfitting usage Grooversand vents The rules for venting plain bearings Definitionan use of DMP Selection fitting usage Chart values of radicalsfor calculatingCLM Selection of mist geneiator end control system components Dyagramselectionof Nebol gener'ating Nebol system electrical diagram Piping 26 Nebol control unit device 5 7 7 7 8

I 10 10 10 11 12 13 14 15 17 25

PREFACE

history of mist lubrication

high-speed The problem that nurtured this development was the.inability to -satisfactorilylubricate was. too high for spindle bearingson-grindersand similir equipment. The speed of thesg.bearings an exlubricaiion, aid liquio oit generatedioo much heat through fluid friction, necessitating ;;;r; pensiverecirculating system' They prwed Air-lineoilers used to lubricateair powered tools were originallytried for this application. particles produced by unsatisfactory for two reasons. ihe air consumption wls great, and rhe.oil these oilers were too large. and condensedimmediatelyin the piping. Tests.with the oilers showed "ry"tthat only 3% of tne-onoriput, in the form of very small particles,reachedthe bearingsand was development of the. first tedout,,'by the air turbulence between the beiring races, This led to the particles. NEBOLwhich used a small amount of air to prodlce a dense concentration of small oil without condensingin the piping About gTVaof these-particlescould be transmitted to the bearings of regardless the distance of the bearingsfrom the nebulizer. inThe application of mist was xtended to Bvery type.of lubricat6rl surface in a broad spectrum of dustdes.-ln all tn"r" upplications,tte viscosiiv bi ttre oil being atomizdrarely_ex^ceqqd-216.cSt SUS at i,Ooo SUS at l Ooo F.'li was establishedthatwhen the oil viscosrtyexceeded2,O0O 3,OOO mist principle was too low for te-peiature, th clil/airratio obtsinable usingthe tti" pi"""irinl over "*Uient ittrltiu" tudrication on mist applications. Oil reservoir heaters telpeU to stabiliz this output varying ambient temperature. Thermo-Aireair heaters were developedbecauseit was discovered,that by heating the air used to to g"n"6i" rirt, oit" of any viscosity gould be atomized.Applicationsusing oils from 1,OOO 5,OOO subject to extremes in ambient temperature, 5US at lOOo F are now common. Many applications, ,s" fnerrno-Aire to insure a constanl oil/air ratio regardlessof the oil viscosity. In this EngineeringManual all data is expressedln Ct!! of air and CLM of mist at standard conditions. Ai.C1nn jnO misttLM are practicallythe same. Mist CLM contains,in additionto air, atomizedoilin licomparedwith the voluma of air which carries qriO toir. itre votgme of t'he oil pariiclesis negligible, iit"-oir p"nlciis. Since, at som point in designingan mist systm, the air consumption must be known,'using cLM truly cr8tes a single rating system in which rx) conversionsare necessary. Today, the oil mist is still used to lubricatehigh-speedspindlesin grinders.Includedin the increasing to are rang" of mist applications systemsapplied alltypes of other machinetools, web and sheetproequipmentchassis,ferrous and non.ferrousrollequipment,belt and chain conveyors,mobile""siing ihafer screens,vibrators, crushers,centrifuges,kilns, pulverizers,ball mills, dryers, and liing mi[s, quid processingpumps.

PREFACE
FUNDAMENTALPRINCIPLES gas, usuallyair taken lubricationsystem in which the energyof compressed is NEBOL a centralized plant supply, is used to atomize oil which is then conveved by the air in a low pressure from the distribution system to multiplepoints of lubricantapplication. The compressedair is passedthrough a venturi device. Oil, siphonedfrom a reservoirby the air flow, is atomizedinto a fine spray. Bafflesdownstream from the venturi nozzlecausethe largeroil particles to coalesceand return to the reservoir.The remainingair-oil mixture is NEBOL.NEBOLcontaine oil particlesaveragingabout 1-2 microns in diameter,which can be conveyedthrough distributionpiping (mist manifold), at velocities up to 7,5 meters per second, to applicationfittings. At the points of lubricant application,the air-borneoil particlesare "wetted-out" by impingingon a surface at sufficient speed to cause adherence.NEBOLcan be introduced into enclosedhousingsif the lubricatedsurfaces are running within a certain speed range. The speed of the gears, chains and rollingelement bearingswill cause sufficient "wet-out" on these parts to providegood lubrication. For most lubrication points, the applicationfitting must perform the "wetting-out" function. Sufficient pressuredrop through an applicationfitting createsenoughmist velocity {over 3O meters per second to cause turbulent flow. lf the length of the passagein the fitting is much longer than the passagediameter {from 6 diametersrninimumlength for 2Oomrn H2O pressuredrop to 2O diameters minimum length for SOOmmH2O and higher pressuredrop), there is a sufficient turbulent region to causegood "wetting-out". The use of baffles in an applicationfattingincreasesthe "wetting-out" action and almost all of oil particlesare separatedfrom the air and combined into drops of oil. rne total output of NEBOLis a function of the generator.This output is controlledby the size of the nozzleand the appliedair pressure.The applicationfittings meter or proportionthe NEBOLgenerator output, The manifold pressureor pressurein the mist distributionsystem is the pressuredrop across all the applicationfittings that is requiredfor these fittings to fbw the entire output of the generator. from 125mm H2O to lOOOmm H2O NEBOLsystems are designedto maintainmanifoldpressures is dependingon the particularapplication.The DesignManifold Pressure selectedfor each application on the basis of the types of applicationfittings used, the oil viscosity, and the speed of the surfaces being lubricated. vENruRt 1 \-l
AIR INLET

MANIFOLD

OIL LIFTTUBE

HEAVY OIL PARTICLES

OIL RESERVOIR

NEBOLsystem has advantagesuniqueto this method of lubrication.Continuousapplicationof oilcan be matched closely to actual bearingrequirements.This extremely low rate of lubricant application possiblewith NEBOLprovidescontinuouslubricationwithout the necessityof designinga recirculatingsystm. This reducesthe first cost of many designs,and improveshousekeeping reducing by oil consumationparticularlywhere oil seal maintenanceis a probfem. The carrier air used to distribute the oil can provideadditionalbenefits, particularlyin designswhere greaselubrication was previously considered most applicable. The air maintainsthe housingor bearing enclosureunder slight positive pressure,and the outward air-flow preventsthe entranceof contaminants. Becausethere are no moving parts or cyclic mechanisms in the basic NEBOL components, and becausethe system pressureis very low, NEBOLis a reliablelubricationmethod. Properlubrication system operationcan be interlockedwith machineoperationor an alarm system, assuringproper lubrication.

PREFACE
COMPOI{ENTS SYSTEM NEBOT

The barlc ilEBOL tYstcm Gomponcnbinchde: a to filter-waterseparator assure cleanair supplyto the Generator. 1 - An air-line - An air pressure at regulatorto control the pressuro the Gsnerator. 2 - The Generator inJludesa venturi nozzle,oil lift tube, reservoir,and oil fbw adiustmentscngw. 3 fittings. to deviceto conveythe mast th application 4 - The distribution at - Mist,Spray,or Condensing fittingsto meterandconvertthe NEBOL eachlubrication appliiation S point. Accorory ltlEBOLSyrtem Gomponcnr lncludc: valve to start and stop the air supplyto th Generator. 1 - A solenoid 2 - An oil heaterto maintainthe oil in the geneiatorreservoirat the proporviscosityfor good mist genoration. 3 - An air heaterto stabilizsoil/airratio, at varyingambienttemperaturs,of to mist heavlroils which ambienttemperaturewill not atomizeat the prevailing or - An oil level to ribnaf Uraiolttevetin thi raservoir, to control automaticrsssruoirrefill. 4 - A pressure"r'rit"tt to signallow or high manifoldpreesure' switch 5 for gauge{manometer) visualindicationof manifoklpressure. 6 - A pressure in - A mist detectioi unit to signalhigh or low densityof oil Particls the mist. 7 componefitsb ehown lchomatlcaly bebw. The hstaSedbcation of the baslc and acoessoryNEBOT

Manonreter

Presrtlrc rwhctr

Air zupply

/Filter &\ water speratof Mist dctcqtkrr urit Oil suppV

Mist manifold

Vent littirg

SPRAY FITTTNG

CONDENSING FITTING

MIST FITTTNG

{E

application

APPLICATION

v BASIC STEPSTO DESIGNA NEBOLSYSTEM: CLM requirements. v 1 - ldentify the machineelementsand rate their NEBOL 2 - Determinethe oil Viscosity rating and select the deslgn manifold pressure. v 3 - Select the mist, spray, and condensingfittings, and indicatethe source of venting for each fitting discharge. 4 - Selectthe NEBOLunit and control components. 5 - Determinethe electrical wiring arrangement. 6 - Size and route the mist and air piping. 7 - Indicate initial settings and range of all system adjustments. These seven steps are comprehensively detailedin this manual.The work sheet fomtat below can be used to record systematicallythe data for the first four steps.

r{EBOr 6Y8TEil WOfU(8|{EET TtrI

2 row spherical roller bearing 2 row tapered roller bearing 1 row ctdindrical ro$er bearing Spur gears

ct-t

l24mm shaftdia. (430 rpml 78mm shaft dia. rpml 166O Somrnshaft dia. 166O rym) lOOmm dia.x 178mm 0enghtlphion ( 11 3 Or p m l x 1OO 3O5 drivengear 127mmdia.x 178mm lenght (4OOrpml 1 9 , O 5 1 m mt c h d 2O3mmdia. driv sproc*et(660 rpml

6,77 4,284 2,212 13,4

$pray

8,4 4,452 2,180 4,452

O.nborrd hbyrhth
fitthg

50,4 17,84

Sprey Spray

no rcab

r +ray

r 3,r04
13,458

Semiencloccd

9,80 8,870
Spray

5.708 4,462

Groorre brg. eleeve Smienclcgod

23.472 17,e

Total ryrtam CLM 135,632

+ 70 C Minimum lmbint tsmpgrat$e: Oil viscosity rating: 1O8 cSt (5OO SUS ar lOOo Fl Design manifold pressure IDMPI: SOOmm H2O +7to"460 C Temp. range: Oil type: EP Min. manifold prossurc: 3OO mm H2O

Recommended gsncrator; 120 Ct"ttt rated modubr lgsnerator range 45 to 196 CLMI untt with oil hstr Regufatedair pressure: 3,7 bar 153 pnil lor 135 CLM

NOTESON U$E OF WORK SHEET: 1 - The type of applicationfitting can be selectedwhen the type, size, and speed of the elementare know. 2 - The orifacesize of the application fitting can be selected when the calculated CLM input and design manifold pressureare known. 3 - The NEBOLgeneratingand control componentscan be selected when the total CLM, minimum ambient temperature,and the oil viscosity rating are known. 4 - Where required, the slope of the mist piping can be selected when the minimum ambient and the oil viscosityrating are known. temperature 5 - The size of mist piping can be selectedwhen the total and sectionalDMP CLM values are known,

APPLICATION
INCLUDE: RECOMMENDATIONS THE FOLLOWING - Formulasfor ratinq the mist input for machineelementsin terms of CLM. 1 2 - Methodsof applyiig mist to eich type of machineelement,includinglocationof the application within fitting, methoh'ofvdnting, and locaiibnof groovesor sump to providea lubricantreservoir element. the machine and 3 - Prelubrication machinestart-uprequirements. CALCULATIONFOR CLM mist CLM input for each machine element are based on the design standard Formulasfor rating the_ this for air oif/airratioof 232 mm3 per hour (abilutO,21Ogrammes) ev_ery litre per minute.In practice, per ratiocan be variedfrom 60 mm3 per hour per CLM to 84O mm3 NEBOL hour per CLM. Tle degign standardratio is 232 mm3 becausea generatoropelatingwithout heatersand using a 5OOSUS at mist every hour for lOOo F oil will atomize trom 232 mm3 to 348 mh3of this oil into distributable each CLM of air passedthrough the unit duringnormalplant ambientconditions. These formulas dssume the elements to be fubricatedare properly selected for the intended service and properly assembledand protected from contamination. Where abnormal conditions exist in a is of mechanism, and lubricantcorisumption this-or similarmechanisms much greater(or less)than the formulas call for, the CLM to 84O mm3 NEBOLinstallationshould be designedto provide a technicallysound compromisebetween actualand calculatedrates of lubricantconsumption.The.formulas alsd assume us6 of an oil with the proper rnistingand lubricatingqualitiesfor the intendedapplication. FECOMMENDED FITTINGUSAGE: rules: -pplication fitting selection,usingthese formulas,is basedon thg following.general ai- Use spray fitiings for rolling motion elements such as anti-friction bearings, gears, and chains. slides,w.ayg. for b)-Use cbnd.ensing-fittings slidingmotion elementssuch as plainbearings, operatingin the.proper An exceptionto a.-andb.-isthe use o-fmist fittings for rollingmot:on e-lements speed rdnge under particulartypes of loading.This and other specific exceptionsare noted in the followingdata. Where tEe output of spray fittings flows through the lubricatedelements because of vent location, spray fittings may be installedremotelyfrom the point of lubricantusageif the downstream passages or'sloped downward. To spray diiectly on moving elements, space the spray fitting aie horizon-tal from the movingsurface.To penetrateair barriers within 1 ,2 mm per 25 mm H2O manifoldpressure sprayfittings are installed3 to 6 mm from the movingsurfaceand createdby high speedelemefrts, The inbaEed the velocityof the elementbeingsprayed. is on minimummanifoldpressure established to stalled axis of a spiay fitting should be approximatelyperpendicular the direction of motion of the should sprayedsurface.Fordirectsprayof highspeedelements{overI m/sec},the manifoldpressure mm HeO. be 5OOmm HrO - 2OOO downwards.Horizontalag and Formaximum6fficiency,installc'ondensing sprayfittingsto discharge plications permissible. fitting'flows by gravity directlyto th The oil discharg-e from a condensing are groovessupplying slidingsurface.The fitting locationshouldbe as closeto the groovesas possithe to upwards,the calculatedCLM shouldbe doubled. ble. When spraylittings are-installed discharge Mist fittings can be installedat any attitude in any location,providingthe mist flow envelopesor passesthroughthe elementsto be lubricated. :NTS, GROOVES, AND SUMPS: Fropely sized and positioned vents and grooves in a mist lubricatedelement permit the necessary escapeof the carrierair while preventingthe entranceof contaminants.Additionelly,these psssages are located to optimize oil retention and effectivenesswithin the element. in with rollingmotion elements,are sizedto maintaina very slightpositivepressure Vents. associated Wherethe vent opening thus preventing ingressof contaminants. the an otherwisesealedenclosure, itself is exposedto severecontamination, shielded vents shouldbe used. In a dry-sumpapplication the vent is located to provide drainageof all liquidsfrom the enclosure.ln an oil-sumpapplicationthe vent is located so that liquid oil will not splash or be drainedfrom the reservoirzones of the design. Proximityto oil sensitive materialsshould be consideredwhen locating vents. Grooves.associatedwith sliding motion elements, are located to provide an even spreadof oil, and terminate close to the ends of the slidingelementto permit venting of the carrier air. Groovesshould be locatedin an area which is not under load all or most of the operatingtime. ln flat slidingmotion applicationsor vertical plain bearingapplications,secondarygrooving can be used to provide accessto severalprimarygrooves.ln designswhere the groovesare in a loadedarea or where the carrierair venting provisions required. flow is great, additional are PRELUERICATION AND MACHINE START.UP All machine elements to be lubricated should be prelubricatedwith oil. Grease packed elements should be flushed with keroseneor solvent and then prelubricatedwith oil. This flushing must insure greasewill neitherclog mist inletsor vents nor preventpenetration the oil to the load that residual of bearingareas.When prelubricated elementsare to be storedpriorto use, a preservative shouldbe oil usedin placeof the mist oil. Sumpsshouldbe prefilled applications in usingoilsumps. Heavyservice, slidingmotionapplications which do not have oilsumps,such as largeplainbearings and worm gears, shouldbe run in with bath or circulating lubrication beforeconvertingto mist lubrication. oil

APPLICATION

CLM INPUT CALCULATIONS

ELEMENT BEARINGS: ROLTING CALCULATIONFOR CtM The CLM input for rollingelement (anti-frictionlbearingsis determinedby multiplyingthe shaft diametertimes the numberof rows of rollingelements,and dividingby O,35 for moderateserviceor by O,175 for heavy service.The heavy service factor is used for any of the following conditions: 1 - All constantly thrust loaded bearingswhere the thrust loading is significant in relation to the radial loading. 2 - All preloadedbearings. 3 - All bearings on shafts transmitting more than 4O horsepower. RECOMMENDED F|TNNG USAGE: Spray fittings are recommended for all rolling element bearings. For moderate service bearings having bearing speedsabove 1 m/sec, mist fittings are also recommended. To computeCLM, use the meandiameterof the rolling elements, not th bearing shaft diameter. Spray fittings are installed so their output is close to the rollingelemets. For radiallymounted bearingsdesignedto carrythrust loads,such as angularcontact ball or tapered rollerbearings,spray fittings shouldbe locatedso the flow through the bearing is opposite the direction of thrust from the bearing shaft. This is not necessary an oilsump if or oil bath is maintained. Remoteinstallationis an advantageof mist fittings, and is possiblebecausemost of the dischargefrom a mist fitting will remain air-borneuntil carried into the turbulent region of the bearing.Also, one mist fitting havingthe required combinedCLM dischargecan serve severalbearings. VENTS: For heavy service bearings, the fittings and vents are located so the calculated CLM for each row of rolling elements flows through that row of elements before exhaustingfrom the bearing.For moderateservice bearings the fitting discharge can be used to flow through and lubricatetwo conseeutiverows of elements before being vented. Lubricatingmore than two consecutive rows of elementsis never recommended. The minimum recornmendedvent area is equal to twice the total area of the orifices supplyingflow to that vent. Where fitting dischargeis vented at more than one locataon the vent areas should be chosen to proportion the flow as required. Venting can be accomplishedin small bearingsby notching lip seals or by drilling a hole in the baseof labyrinthseals.In fargebearings,labyrinthscan be used as vents. In large bearings having contact sdals, vents are machinedinto the bearinghousing.
cLM = DR/O,35 CLM = OR/O,IZSI

.UqgJgAILg.EEvrcE r:r_F4yI-LEFv!g
D = shaft diarneterin decimstor R = nurnbergl rows of ehrnonte

MODEFATE SERVICE CLM=O,5x11b.38 = 1,43

ANGULAR COilTACTBALLEEARING

Oirection of thrust
---r-.

HEAVY SERVICE C L M = t x 1 / 0 , 1 7 5 = 5,70 MISTFITTING APPTICATION

Notch seal

MODEflATE SERVICE CLM=O,75xq4,36=4,3O"

FLOW PATH THFOUGH TWO ROWSOF ELEMENTS MODEBATE FOR SEFVICE AP. PLICATION

APPLICATION

An exceptionto the forced tlow principleof inlet and vent location is used advantageouslyon single row, modarate service, ball bearings, on shafts under 1OO mm in diameter, operating-over 1 m/sec. Bearings in this category, mounted in the wall of a machine housingcontaininq i mist atmosphere,can be mist lubricatedif both -of sides the bearingdre freely exposedto the mist. A dlilled hole or undercdt with a miniinum area of 3O mm2 in the outer race support is used to exposethe outboardside of bearingsin blind wall mountingsto the mist in the housing. The *indage created by the rotating parts of the bearing assembly will create sufficient flow of mist through thb rolling elements. Th CLM requirement for all such bearingsis included in the calculated mist input for the housing. OIt SUMFS: A depth of oil sufficient to cover the inside diameter of the bearing cup is rcommendedfor all tapered roller bearings. For other bearingtypes the dpth of oil should be to -rolling element at the bottom of the r-amid-height of the -oearing. For high speed bearings, vents used to control the sump level, should be located toward the directionof shaft rotation from the bottom of the bearing so the churning effect of the rollingelementsdoes not throw sump oil out-of the vent port. Oil sumps, in applicationswhere the bearingsseals are preveritingthe entrance of liquid contaminants, should have drain ports in addition to vent ports. Bearingswith double lip seals require spray inlets and vents located to maintainan oil sump in the area between the contacting lips. The CLM seal requirementis equalto I row of elementson the same shaft in moderate service(CLM = DlO,35l. lf an oilsump is maintainedina moderateserviceapplication,or if the bearingload is very light as in some continuous process machinery, input (CLM : DRIO,TO). Means of sightingsump oil level are recommended. ON VENTS: FOOTNOTE Vent. ar6as equal to twice the application fitting orifice area will produce a back pres$urein the housing equalto 25% of manifold pressure.For contaminationprevention,a ousingpressureof at leasr 5O mm H2Ois recommended.

TO EXCEPTION FORCEDFLOW PRINCIPLE

iIIODERATE SERVICE

OFTIMUMFLOWPATH FORTWO ROWSOF IN ELEMENTS HEAVYSEFVICE

Sprey hlets

APPL'CATION MISTTO BEARING OF WHERE SUMPIS MAINTAINED AND DRAINPI.UGIS ADDED

Ahsmatives for spray inlet -ALTERNATE FLOW PATH FOR TWO ROWS IN HEAVY SERVICE

Vonts ussd to maintain cil level

OPTIMUM FLOW PATHFOFTWO ROWSOF IN ELEMENTS HEAVY SERV]CE

APPLICATION

PTAINBEARINGS FORCLM CALCUI.ATION The CLM input for p!a!n (sleeveo; iournal)bearings.is
with high oil loss.
CALCUI-ATIONS CLM INPUT

j!}ttJl{#,':;i#,svlF, Ht,Fffifl^.trtf$$
Moderate service bearingsare defined as follows; the load 1 - Rotating bearingson horizontalshafts where ' the lower half of the bsaring' ;il-i;-atwavs Tn oil is re2 - Bearingsmounted in Pny position where the bCiring by c6ntact type seals' taineAin the "fric3 - Bearings with potort bushings or synthetic sleeves. tionless" Heavy servicebearingsare defined as follows: 1 - Oscillating bearinls on horizontal shafts -where .the toad zone i" arwivi in'tne ower half of the bearing. Yhere 2 - Unsealedbearings subiected to shock loading. the load .one coirltlntly-shlfts, but boundary lubricapins on trucks. horizontal 3 - Small rotating bearings not mounted on shafts. as: Heavy seryice, high oil loss bearingsare defined
SERVICE MODERATE CLM = OxUO,22 HEAVYSEBVICE C L M= D x U O , l 3 3 HIGHOIL LOSS HEAVYSEBVICE Cl-i/l= DxUO,O65 D - Shaft diamctcr h dcimctcr L = Slcsw |errgthh ddmelor OPSHOWIT'IG FOTATINGBEARING VERTICAL TIMUM GROOVIT.IG

ii;""'i; d"iliJ"[ii'

and rins'pins sprins iuCn'ai

'*f itfnT1g%*#:n',fl - - "l{ln;'i'illi''tgSrjoy#;Y: *1?tt:;/rf3g3lli"i:

where these referredto our technlcal servlce' - Largebearings without seals that are not mounted on 2 horizontalshafts. For bearingsgreaterthan 1.25 mm diameteror 15O.mm uscan be checked. lonq the inputs teJjmrnindgq au-ovq

Jiiniinit- "io iiinrirm ov( bearingsoperate.

or+0, L

.= iXlj"tiiJiii.ura-Lltii": =60 i o x txd/r whele' |total hours for estimateo iiE*"Irti-'driitinl6i'-r o!-thebearing' volume ol iiii'd"i''t'*.n-t oii-inineclearince and ; ;;lG LCtween.one four' depenr llj,IiilV-is-g]ven iing on ine ieverityof the application'
MOUNTED MODEBATE FOR HORTZONTALLY SEFVICE GROOVING = BEARING ROTATINGPLAIN C t - t t- 0 , 8 7 5 x 1 / O , 2 2 3 , 9 8

HEAVYSERVICE 33 CLM = O75xO,75/O,1 = 4,23

FOR HIGH LOADAND CHAMFER GBOOVE LOW SPEED

Condenting

ftting

I I

tI
I I -A lnlets and vents notshown Section A-A

APPLICATION

FITTINGUSAGE: RECOMMENDED Condensingfittings are recommendedfor all plain bearings with complete sleeves. Spray and condensedspray fittings are recommended for all half-sleeve bearings. fittings are installed so the fitting outlet is Cond-ensing abovethe bearinggroovingor other oil reservoirwithin ths bearinghousing. GROOVESAIID VENTS: The following general rules for groove locations in mist lubricatedbearingsare consistent with acceptedgrooving of practice for oil lubricatedplain bearings,regardless the method of oil application: 1 - Groovesshould be located so that 9O% of the surface area of the ungrooved surface (usually the shaft) passes over one oil groove during each cycle of moiion. Tnis rule is best representedby a longitudinal grff)ve extending 9O% of the sleeve tength in a iotating bearing. Following this rule, oscillating bearln ings may requireseverallongitudinalgrooves. small oscillatingbearingsthese primarygroovescan be connected by a circumferentialsecondarygroove with a single condensing fitting supplying all grooves. On large bearingsof this tYpe, a condensingfitting should be used for each longitudinalgroove. 2 - Groovevolumes should be kept to a minimum. With a constant source of lubricant input, large volume grooves, acting as reservoirs,are not required.Large volume grooves can be a disadvantageon machine start-up, if oil has completelydrainedfrom the groove volume during a shutdown period. For this reason' condansingfittings should not be spaced further than 125 mm apart in beadngsover 125 mm long' 3 - All groove edges or housing parting line edgresfacing surface should be rounded or the oncoming slidirXg chamferadto prevent scrapingthe oil from ths shaft. 4 - Grooves should be in the unloaded zone of hydrodynamically lubricatedbearings.On large bearingsof this type the groove should be close to the area where the shaft enters the load zone. Thc rules for venting plsh beadng! 8tt al {ollows: 1 - Groovesare also used to vent plain bearings.For this purpose,longitudinalgrooves shouldextend to within 6 mm from the end of the sleeve in horizontalbearings. Circumferential grooves in vertical sleeves should be in the upper third of ths sleeve and a longitudinal groove extending upward from this groove to the end of the sleeve is preferred for venting and should be opposite the condensing fitting inlet. - Bearingswith very close tolerancesor bearingswith 2 contact seals require a vent passageconnected to the top of the internal grooving. The inlet and vent passagesmay be combined.

Inlets {31 Ventg {3)

Vertictl bearingwith aheftoscillathg l20o HIGHOILLOSS HEAVYSRVICE = CLM = 1xl,25/O,O65 19,2 l\llodoratosoruce

OVER 125 mm INLETAND VENT FOR BEARII{G TYPESEALS LONGwlTH CONTACT Intat y"nt
Vgnt

L-J-

il

UNDER125 mm INLETAND VENT FORBEARINGS WPE SEALS LONGWITF|CONTACT

10

APPLICATION

include: Thefollowing recommendations ManifoldPressurel. and use of DMP (Design a - The definition fitapplicatlon ambienttmpsrature, betweenDMPard oilviscoshy,minimum b - The relationships ting efficiency,and operatingmanifoldprssure. DEFIilmONAltD USEOF DirP: by DMPis the air pressure dropacrossthe application fittingsto supplythe CLM reguired the machine element formulas. MANIFOLD DMPAND OPERATING PRESSURE ln a NEBOL at $ystem,the manifoldpressure the presstffa is differentialbetweentho mist prsssure the pr66curo. DMPand the operatingmanifoldprassura fitting inletsand etmospheric application The are the approximately same when the air pressureto the generatoris the same as ths calculatedair pressure. USEOF DMP Whenthe machineelementinputs have bencalculated,DMPmust be gelected determine to orifice fittings.Thestandard areas the application of for DMPis 5OOmm watsr columnprossure the following reasons: 1 - All types of application fittings operate efficiently. - Directsprayapplications 2 can pnetrateair barriers aroundelementsmovingup to 1O m/secaurface speed. 3 - The effect of oil traps is minimizedwhen compared whh lower manifdd preesures. 4 - Variationof manifoldpressure, to ambienttemprsture influenceon oil viecosiry,is negligibf due untilthe ambientapproaches minimumrecommended the operating temprature the applicaof tion fittings. Wherethese factors are not relevant,lower manifoldprossures equallyeffective. thus: are - Formoderato 1 serviceapplications usingsprayand mist fittings onV, 3OOmm H2ODMPis reco$tmendedwhere close oil output control is used to maintainthe strictest machinecleanliness. 2 - Forlightservice applications usingmist fittingsonly, 13Omm H2ODMPis recommended proto videoptimumoiloutput control. wherethe surface speeds Fordirectsprayapplications, exceed 10OO mm HzO DMPis recommended 1O m/sec.This DMP is alsorecommonded when application fittings are at or slightly below the recommended minimum operating temperature. Whenthe DMPhasbeenselected, orificesizeof the proper the type application fitting is selected by locating fitting sizemeetingor exceeding calculated the the CLM inputat DMP.

/t

APPTICATION
APPLICATION FffNNG SELECTION C+IART
Al+tEANOil TYPE 2 4 6 0,6 1 2 Condenaing 3 4 5 Mist
Condenaed SPRAY Spray fitting

F|TNilG ORIFEE 11,2 11,2 11,2 9,6 9,6 9.6 9,6 9,6 9,8 26 0,50 0,949 1,53 0.55 1 1,35

AIR OR ilTST FLffY - STAT{DAFD CfIT .

PRES8UFE IHOP - mm IYATEF 0,925 1.87 2,8 1,3't 2,68 4 r,08 3.41 5 , 11 o,38 0,86 1,73 2,64 4,',t7 4,98 3,69 0,61 1,O8 1,68 3,3 6,44 5,8 10,04 15 , 4 2 0 , rI 26.e4 29,4 33,88 38,08 42,54 46,79 51,52 55,72 58,8 81,88 2,21 4,5 6,72 0,5 1,17 2,32 3,5 5.76 6,88 2,85 5.46 8,32 0,67 r,54 3,05 4.69 7,58 8,73
6,6

d. rt*, 3,O7 1,2 6,2t r.6 9,35 2 0,81 0,75 1,82 1,1 3,66 1,4 6.46 2 8,91 2,3 10.3 2,4 7,76 2,4

$ray nozzlg

r3
14

1 2 3 5, I 1 2 3 4 5 6 7 8 I 10 tl 12

0,8 1,1 1,4 1 Slot R=0,36 I Sbt R*O,6O 2 Sb$ R=O,50 3 SlotsR-O,6O 5 Sbts R=0,5O 6 Slou R=O,6O 6 Slorc R=O.5O 1.7 0,6 0,9 1,1 1,4 1,7 1,7 1,7 1,7 1,7 1,7 1,7 1,7 1,7 1,7 1,7 1,7 1,7 1,7 1,7

o,192 o,391 o,?82 1,173 1,955 2,346

2,346 2,268

s.8

5.r8
0,81 1,45 2,18 4,5 8.4 7,84 15,56 21,28 27,72 34,10 40,04 46,92 61,52 58,56 61.32 65,8 70,58 74,49 77,84

36 35 35 35 35 35 35 35 35 35 35 36 36 36 36 35 35 35 35

o,281 o,636 o,949 1,53 2,268

2,2e8 4,536 8,8O/r 9,O72 r 1,340 r3.608 16,978 t 8,144 20,412 22,A80 2if,984 27,262 29,620 31,788

0,6 o,84 1,12 2,62 5,O4 3,52 7,84 1 1, 7 4 15,4 19,04 22,68 20.32 29,96 33,88 37,8 41,16 44,8 47,88 60,96

r,12 0,80 0,98 1.84 1,18 1,2 2,66 3,13 1,5 5,54 A,44 2 rO,38 11,76 2,4 9,8 11,2 2,4 18,76 22,12 3,2 27,64 31,92 4 3 5 , 5 4 4 r , 4 4 4,8 43,40 50,4 5 , 2 50,96 68,8 6 67,68 67,2 E , 4 75,01 6,8 64,12 70,28 82,04 7 , 2 76,44 88,76 7 , 6 81,76 95,2 8 t @ . 8 8.4 86,4 106,4 8,8 90 s4,38 110,42 8,8

t{oTEs dt t 8E of APPUCAtXtil FfTTnfC SEtECnq{ CHART 1 - Ban&: Desbn ManifoH PreesLre 5OOmm wator column ic 5 - [vlinimum reggmmendc{ mcnifoHpreaswc condensing for pragurg. fittinss i3 3O0 mm HzO. - Oesign{tianifold ftsscure of 1OOO 2 - ltr{ninwn.recornrnendedyent erea equals twico thc aF 6 mm H2O is rcomplicationfitting orifice area. nreniledfor: rnanifoHpressure mist fittings 3 - Mqlnum recolnrnended lor a. Dkect apray apdbatbns over lO m/sec aurfec is 5O mm HzO. 8peod. 4 - Mininum rec-onrmen{ed manifoU p.eaaurofor rpray fitb. Applicationc whers tho Embism remp. at ths thtingg rhg6 is 2OOmm H2O, it'closa to th6 minimum recommen&d. ST'TUARY OF CALCUTANOilSFORCI.T HT'T8 TO MACICNEEITTtrTTS br.d on ot/*.r& of 4 mmZ d/horr/Gl..t * b+rhgr Sprayad mict finiuc rrc uscd. = DR/O,36 A. D = *pft diamerrh dcclnetsr - DR/O,175 L R = numbgrof rows of elemonts E h brrhef Condensing, condensedepray, and sprsy fittFqs ere used. ' \loderat-eService CLM=LD/O,22 L = beerinqlenoth in dccimotor = LD/0.133 . rleawSorvhe CLM D = sfieft ilismo-tcrin docimotr C. tleavi Servhe,HighLoEs CLM=LD/Q.O5

ffir* o-'

C L M- A / 1 , 8 5 CLM*A/O,92

CondcnCng, srd condonssd spray fitthgr arc used A = maxinum contlc{ ae! ln dcimotsl

F|rr dr*r, po$r trrtlnltthg Slbnt cfi.h

cLM=pDn\4iltootsloJz

cuvr=wo!4mffiE:;
CLM={3DW+O,1LW,/1 ,12 '

Convoyot cholr

sd"t: ff9.ffii#*T',3Y,T,:*ti3"""1fr*", W = width oi Ctralnin O-ecimiter

L = lengnh of chein in decimercr Spray, and condcnsd $pray fittirrg8 ars uscd F = face width of cah in decimetcr D = maximum diarneter of canr h d$imter Spray. and mirt fittings are usod D = t*tch darnetei of nut, h decimster R = ttumber of rows of elemsfits

Spray, P = 6 = R = W = S =

condensod sprEy, ond mist finhog are usad pitch of chah ol sDrockct in dec-irnetor iritch dia of snall iorocket h docimoter 'cheh nunfier of rows of rollerc width of chair in dccinrcter rpm of srnrlf sprockst

Camr Frclcd|thc rc*rc.brn nt rutr (.n+frHon fl rrutd

CLM=FilO,g = CLM lDf3o+DR/3ootxl r,7 1

'rS[#o*-BiFihrui''frffi HrH"+6"rf[P#ffi ;SbMft?K$GB(x]vES;'AGErFoRDw.

12

APPLICATION

VATUES RADICATS OF FORCALGU]ANNGCLM il{ruT TO SItEilT CHAIN,AND ROLLER CHAII\I, FOWER TRAI'ISMITTF{G n = rpm of rmal ryrccket

(,i*J
28 29 30 32 33 34 35 36 38 39 40 4? 43 44 46 47 48 50 51 52 54 55 57 58 60 6? 63 & 66 67 69 70 72 73 75 76

/n Y

n 1825 1850 1875 1900 1925 1950 1975 2000 ?p,25 2050 2075 2100 2125 21 50 2175 22W 2225 2254 2?75 2300 2325 2350 2378 24AO 2425 2450 2475 2500 2525 2550 2575 2600 2625 2650 2675 270A 78 80 81 83 84 86 88 8K) 91 93 95 96 98 r00 101 103 105 r 07 109 r10 1t2 114 116 118 119 121 123 125 127 12e 131 133 r 35 r36 138 lrto

"Jm
2725 2750 2775 ?800 2825 2850 ?475 2900 ?g.25 2950 2975 3000 3025 3050 3075 3100 3125 31s0 3r75 3200 3225 3250 3275 3300 3325 3i150 3375 3400 3p.25 3450 3/.75 3500 3525 3550 3575 3600
142 144 146 1/18 150 t52 154 156

25 50 75 r00 125 150 175 200 225 250 275 300 325 3s0 373 400 425 450 475 500 525 550 575

6m
625 650 675 700 725 750 775 800 825 850 875 900

0,3 0,4 0,5 1.0 1.4 1.8 2.3 2.8 3.4 4.0 4.6 5.2 5.9 6.6 7.3 8.0 8.8 9.6 10.4 11.2 12.0 12.9 13.8 147 15.6 16.6 17.5 18.5 19.5 20.6 21.6 22.6 23.7 24.8 25.8 27.O

925 950 975 f000 1025 1050 1475 t 100 1125 11 5 0 11 7 5 1200 1225 r 250 1275 1300 1325 1350 1375 1400 1425 1450 1475 1500 't525 1550 r 575 1600 1625

r58
160 162 lAt 166 168 171 173 175

r77
179 181 183 185 187 190 192 194 196 r98 201 203 205 287 2W 212 214 216

r650
1675

r 700
1725 1750 1775 1800

tt

APPLICATION
apply to: The following recommandations a - Selecting generator with best range of mist - output need for oil and air heaters. b - Determining c - Determiningreservoirrefill intervals. and adjustingoil and air outputs. d - Controlling e - Oil selection.

CLM OUTPUT: NEBOLGEIIERATOR Generatorair consumption is equal to the total CLM passing through the applicationfittings. The Generatorselectedfor any applicationmust providethe total applicationfitting CLM, as calculatedat DMP when operating with a proper regulated elir pressure. Minimum and maximum regulated air pressuresare listed for each model in the "NEBOL List". The air pressure necessaryto have the generator CLM equal to the system CLM at DMP can be located on.the air flow vs. regulatedair pressurecurve of the mist generatingnozzle. Where severalnozzlescan supply the CLM requiredat DMP, the nozzlethat will operate closest to rated regulatedair pressureis recommendedbecausethe range of adjustment from DMP output is greatest. USEOF OIL AND AIR HEATERS: At the temoerature at which atomization is occurring, oil viscosities between 324 and 54O cSt into (15OOanO25OOSUS)arethe heaviest efficientatomization, and the amountof oil converted for At distributablemist per litre of air decreasesrapidly with decreasein tempe-rature. some viscosity per ratioof 4 cubic millimetes hour designstandard betweenthesevalles the oillairratiowillequalthei per CLM. The exact oil viscosity at which this occurs dependsprimarilyon the mixture of molecular structuresin the oil and its additives. I ines of constant operatingconditionsgraphedon coordinatesof oilviscosity in cSt, SUS at lOOo F --.rd minimum ambient temperaturein centrigradedegrees,are shown on page 1 5. Th lines pertaining to NEBOLgenerators indicate approximate limits for producing design standard oil/air ratio using oils with minimum acceptablemisting properties.The lines pertainingto applicationfittings indicate the approximatelimits for obtainingthe CLM flow of these fittings shown on the CLM output charts and graphs. The limits for mist fhtings and spray fittings with orifices smallerthan 1,7 diameterare approximatelymidway between the two applicationfitting lines shown. The minimum ambient temperatureand oilviscosity rating for any applicationis plotted as a point on this chart. The location of the point indicatesthe extent to which oil and air heating is required.This chart assumes: 1 - Oil heaterthermostatsare set between 32 and 38" C. 2 - Generators equippedwith oil heatersbut not air heatersare enclosedin a cabinet when operating below 5o C. 3 - The temperature of the air entering generators without Thermo-Aire is the same as ambient temperature. 4 - Oil heaters are used in conjunction with air heaterswhere Thenno-Aireis required. RESERVOIR REFILLINTERVALS: The maximum hours operation before refill for Generatorsoperating at design standard oil/air ratio output is the usablereiervoir capacity in liters dividsd by the system CLM times 4OOO.For systems without Thermo-Airethe recommendedrefill scheduleis 112 maximum operating hours. /here specificationsrequire reservoirrefill periodsexceed a certain number of hours {usually2OO) the requiredreservoircapacity should be calculatedas: O,2SxhxCLM Reservoir capacity Q =

1000

This reservoircapacity is the liters. Where installationof large reservoirsis inconvenient,or where a largenumberof NEBOL systemsare operating, manualorautomaticrefillsystemsare recommended. SYSTEMCONTROLAND A&'USTMENT: All mist system controls are providedto: the CLM output of ths Generator. 1 - Maintainmanifoldpressure controlling by nozzle. the oil viscosityand oil flow rate to the generating 2 - Maintainoil/airratio by controlling pressureor All adjustments made to change the performanceof systems affect either manifold adiustments, with devicespermittingall possible oil/airratio.Somemodelgenerators equipped are others are limited to a sihgle adjustment (changeof regulatedair pressurel.The type of adjustment and rangeof adjustmentrecommended each type are listed below. for HEATER 1 . CHANGEAIR TEMPERATURE SETTINGOF THERMO.AIRE This changesthe oil/air ratio without changingmanifold pressure.This change is most effective and almost linear when the viscosity of the oil at the temperatureof the heated air is between 108 and Referto NEBOL of 432 cSt (50O and 2000 SUS).Adjustmentincrements 5Oo C are recommended, Ust for adjustment rang of individual models. Thermo-Aire temperatures that produce oil temperatures temperaturesin the oil reservoirabove 54 - 65o C are not recommended.Thermo-Aire will approximatelyl Oo C higherthan the minimum recomrnended usuallysuffice to obtain maximum oil/airratio.

Itl

{il

APPLICATION
OF SELECTION I{EBOLGEI{EBANNG COMFOilENTS TO OBTAIT{ OIUAIB RANO OF 4 CUBIC MILUII'IETER CtM OF The minimumambienttemperature the oil viscosityfor any intendedapplication usedto locate and is a point on this chart. The locationof this point providesinformationused to determinethe NEBOL requirements the intendedapplication. equipment for

CSt SUS 38 0C 100 0F 1300 1060 860 650 453 320 214 r60 107 86 65 6000 5000 4000 3oo0 20(X) 1500 1000 750 500 400 300
ermo-Aire
mended operating tempcratura fq 1,7 D

200 r50
Gcncre or.t opcrating t r.Frdcr. lino do not rd rftb qrro ngttrs

roo
90 80 7A 60 55
Temp3F Temp.'C -30 -20 -10 0 10 n s 40 50 60 70 go 90 100110120130140
rt3 49 54 60 66
Oil haterg gro r6corn. mendcd for gencratorr opruting bohrvgonthgao

-34,5 -29 -23 -179 -122 47

-1tr 4fr tO 15,6

f6!

15

APPLICATION

AIR 2. CHANGEREGULATED PRESSURE fliq -niJcnanges the generatorCLM output which changesthe manifold.pressure. adjustmentwill applicationfitting efficiency is providea li-near or inc-rease decreaseih Ootnair ancioil output provicieci range is: hot affected. Recommended 50 - 2OOOmm HrO - Systemswith mist fittings only. 2O0 - 2OOOmm HrO - Systemswith spray fittings included' fittings included. 3OO- 2OOOmm HiO - Sistems with condensing 5OO- 2OOOmm HiO - Directsprayon elementsmovingover I m/sec surfacespeedalsosystems temp. recornmended fittings operatingclose to minamum with application also mm HeO - Direct'ipray on elements movlhg over 1O m/sec surface speed^ 1OOO 2OOO systems with applicationfittings operatingat or slightly below manlmum recommendedtemp. to the temperaturg,. oil tend.s form When applicationfittings operate close to minimum recommended a neavilioating in theboris or the passagesof applicationfittings. The manifold pressure.increases conditions so thbt theie is no bbrrelationbetween calculatedand actual manifold iaoidlv'underth--ese piEsirlri. Since the total mist output is controlledby the generatorand not the fittings, this.manifold bressureincreaseis the only wai the system can bompensatefor the restriction caused by the oil under boatins.As long as the DMP is high enough,good sysiem balanceand output is maintained these Eonditioni, but the usefulnedsof manifold presbureindicatorsis greatly reduced.On Thermoiire installations this effect can be reducedby usirighigherthan normalair temperaturesand installing .e generatorclose to the fittings to raise ihelr operatingtemperature.Pipe laggingand high-low Tfrerino-Rireoperationcan be used to further improve fitting operatingtemperature. The above manifold pressurerangesare possibleto the extent the generatorcan providemist without mm pressurelimits. a DMP or manifoldpressure adiustmentabove2OOO For regulated'air exceeding H2O consultour technicalservice. SCREW SETNNG 3 - CHANGE OIL AT}JUSTMET{T ftris changsi the ffow rate of oilto the venturi device, which changegthe oil/air ratio without affectinq ma;if-oldpressure.This adiustment is not linear.An incremeniof adjustment at large initialsetiin6s chJnqes ttte flow slishtly'while an increment of adjustrnentat low-initial settings changesthe on of The rans:o adiustment is from 1/2 turn opn. to 2 to 4 turns open,-dpending floil aoore6iably. type oi'generatbr. Maximum opening is recommendedas initial setting for all applications. 4. abcdeOF OTHERIT'IETHODS CHANGI]IG OUTPUT INCLUDE: Changeoil heater temperaturesetting. Changeoil to different viscosity or typ. Add air by-pas use intermittent or high-low system operation. Changetype or size of individualapplicationfittings.

OIt SELECTION: ^il Type: Applicationsnot requiringEPoils application. Use turbinequalitymineraloils for industrial Use motor oils for automotive applications. Applications requiring EP oils Industdalmist oils prefened. Automotive and industrialqear lubes are also suitable. use 108 - l SQ c$t {!qq - ZO0 SUS at lOOo F), appticatlons Oil Viscoshy: Majorityof industrial ' 43 Wl"iere bold ambientsirb encountered - 108 cSt (2OO- 5OOSUS at 1000 Fl are usuallyused. applicationsuse 7,4 - 65 Extremeiycold ambients or very high speed rolling-element (5O - 3OOSUS at lOOo F). cSt Heavy Serviceapplications use 1 50 - 21 6 cSt (7OO- l OOOSUS at 1OO" Fl. 2350 SUS at lOOo F). in Large'elements heavy serviceuse 324 - 5OB cst (15OO_gear sets irse 650 - 1 3OOcSt (30O0 - 6000 SUS at l OOo F). Large,sfow, semi-enclosed include: Many additivescommonly used in lubricatingoils do not affect system operation.Exceptions such as graphiteand MoS2, shouldnot be used without our aF a - Oils with solids in suspension, procedures proval.Additionalmaintenance may be required. b - Oils compoundedwith most rust and oxidation inhibitors,detergents,and dispersantscan be used. Oils containing viscosity index improvers can be misted, but these additives might considerablyaffect the mist output. c - Oils compoundedwith paratac or soap fillers are not recommended.

16

APPLICATION
DIAGRATTI IT{TERCOI{1{ECTIOI{ $YSTEMELECTRICAL BASICTTIEBOL
I

8je

to

ll

t2 /3 t 4 ts t6 t 7 t8 t9
7

-{F
ceF
TS-l

1sff
/
I

rs-e
---1

t6:rffi#

soL a 3^4

t--i."
^
5I-

on * ots
lt

rtg"f

- * Lps

*-F-lt

HPS ,2 1. 6 ' G^ -7

l" I

o:
-/3

l&Tom*ral |r-"tirrf

8 b not cot|nccr.d to t .mfud .ttlp. 16H wtc r'tsrdr to t mlh.l box, but b rct codt ciad lo arnhd

rrb-

TABLEOF COMFONENTS Codo SOLA AH OH TS-1 TS-2 TS-3 OCAP LFS HPlS
Cqnponent Air valve solnoid Air heater element Oil heater lement Air heater thennostat Air heatsr thermostat Low air tamperatureswitch Capacitor Mist manifold low Pressureswhch Mist manifold high pressure switch Reservoir low level switch Reservoiroil level switch High LevelSwitch 5 - 15H Low LevelSwitch 5 - 15. switch can be modified (by user) to open when oil level is low.

t"Ls oLs

oNot on all models,

NOTES: allttp but diagramfor all generators, most modelsdo not incorporate 1 - This is the interconnection componsnts. slectrical for are boxeshavingthe sameterminalstrip numbering recomm$rded ModularDeefin 2 - Terminat Generators. elementarydiagramsfor all units, ov6n - Theseterminalnumbersare used in the recommended 3 all most modelsdo not incorporate the electricalcomponnt8. though of in diagrams this ssction are intendedto be represerrtativ the elementary 4 - The recommonded hookuPs. of maiority desired likeliahernatives shown. are Wherefeasible, - Availabilityof modelsor componentswith different vokage and/or frequencyratir3 must b S List. by determined consultingthe NEBOL List' powsr consumption riodels and components also listed in NEBOL is of

17

APPLICATION
RECOMIIIEIUDED ELEMENTARY WIRING DlAcRAItts FOR NEBOL sysTEMS WfTHOUT otl HEATERS These wiringdiagrams recommended systems_integral a singlemachine. relay can are for with CR {5} be usedto interlock machine start andstop wiih NEBoL sfstem operation. DS-l (1) can be omittedif machine equipped is with a power disconnect.

(t) (2)

os-t

Main ewitch

p)
(4)

p8-d

Motor starl relay

(s)
(6)

SEOUET{CE OPERANON OF ruPPER DIAGRAM}: 1 - Manuallyclosing^P:1- {1.}energizes air solenoidSoL A the {41, allowingair to flow to gnerator. Closing DS-l alsoenelgizes red tight {6} and CRisf; tr,ii"rore, CRcontact the the {2} is oFD, and machine cannotbe started. 2 - Whensufficientmanifold prassure attained, is LPS(51opens, ' de-energizing andthe red light. CB The machina can now be startedby closingpB_l. FUilCNOil OF CR COHTACTS: 1 - With cR contactsin location1, machine cannotbestartedwithoutmist,andwillshut downwhen thereis low oil level,row manifold prssure, highmanifoldpr"""ui". or 2'With cR contact^s locstion2, machinecannotbe startedwithout in mist, but is started,failureof the mist will energize light, but will not shut down tho once machine red machine. siouetce oF opERATtoN{LowER DIAGRAMI: 1 - Manually cfosing Ds-1 (1) start the.mistsystemsimultaneousry the machine, failure with and of the mist willonly energize red light (Si. the

(r) (4 H (4
6)
Motor start ralay

18

APPLICATION
RECOMMET{DED ELEMENTARYWIRIilG DIAGRAN,ISFOR SYSTEMS WITH OIt HEATERS AT{D SIGNALS Thesewiring diagrams recommended systemsintegralwith a singlemachine.CR relay(3) can are for be used to interlock machine start and stop with systems operation.An alternate relay CR-2 (71can be wired in serieswith DS-3, and CR omitted. Where DS-1 (1) is operatedjust prior to machinestart, the oil heatershouldbe wired upstreamof DS-1. DS-1 can be omitted if machineis equipped with a power disconnect.
-*Stpply

(t I (2) G) (1)

c.s- /

Mainswitch

F
6

(s)
@ (7) (8) soL /, 3^a

SEAUEilCE OF OPERANOil {UPPEFDIAGRAMI: 1 - ManuallyclosingDS-1 (1) energizes oilheater OH {2} and the red light {b} indicatiqgpowsr the on, 2 - Manually cfosing DS-2 {8} energizesthe air solenois SOL A, alfowing air to flow to generator. 3 ' When sufficient manifold pressurais attained, LPSt4! de-energizesthe red light, a6d energizesthe gren light (4! and optional relay coil CR (31. 4 ' lf CR is used, machinecan now be started. Afso, DS-3 {6} may now be closedto lock in howter H for annuciationof system fault and optionaf relay coil CR-2 (il. SEOUEIICEOF OPERATIONILOWER D|AGRAMI: 1 - In the diagram Slow, WS Light Signalunit 1640650 - 1640660 is used in place of the indivldual red and greenlights shown above. in case of a malfunction,tho red light and'rc*f"t n, it usiC, witl remain-e-nergized untif reset. Sequence of operation is the same, [xcepi there is no indication when DS-3 can be closed without energizingthe red light and howler. Also, there is no indicationof power on when-DS-1is cbled to energizethe oil heater;instead, the green light indicatesthe air solenoidis energized.

supph
(t)

Main rwhch

e)
B) (11
{51 6) 0) (e)

@
I

!1"-:--

ws

19

APPLICATION
RECOMMENDED ELEMENTARYWIBING DIAGRAMS FOR SYSTEMS WIT}| AIR AND OIL HEATEBS AIUDSIGI{ALS Thes.e. wiring diagrams are recommended where system is lubricating a machine segment of a multiple-machine operation. Malfunction of the system energizesthe warning signals,but does not stop the machine. WS alarm signal units are interchngeable either circuit irra'irgement. in Upper circuit shows air heater on same power inpuias control circuits, and includes low oil level switch. Lower circuit shows.airheateron soparatepower input, and includestow-highoil level switches, with only the low oil level swhch connected Uppercircuit can include 2CR relay {4} for interlockingmachinestart with proper mist system opra_ tion. when 2cF is used, 2cR contacts in start circuii are normally open.
Supply
(t)

7S-e

(2] (r/ (41

(sl t6t
(7)

ff-:;t

,o" nz-Ji4

(8L
(e)

(UPPER SEOUENCE OPERATION OF DTAGMMI: - Poweracross inputlinesenergizes oil heater (1). 1 the the OH - Manually (21startsthe lubrication 2 closingDS-l system. S - Wltql _sysJem stabilized, is DS-2{6,8} is closed lock in WS atarm,{LightSignal164O65O to and 1640660, H soundsignal1638430 and 1640670 andoptionat 2cR-relay.(LOWER SEQUE]TCE OPERATION OF DIAGRAMI: WS LightSignal unit, or equivalent. shownin placeof the alarmcircuitshownabove,and DS-2is is not required. 2CRrelaycannotbe usedin circuitbelow,unless WS afarmsystemshownin upperdiagram used. the is 1 - Manually closing DS-1{1,5} startsthe NEBOL system. 2 - Whenthe NEBOL systemis stabilizsd, waminglightsare de-energized. all
Supply Main switch

(t )

4g-7

k) (3)

(41 (5) (6)

7s-2

6.s-7

Malrowitch

(zl (8t (e) (to)

20

o.

APPLICATION

RECOMMENDED WIRINGIXAGRAMSFORNEBOL SYSTEI'IS WITH OILAI{D AIB HEATERS AND tt{DIVIDUAL SIGNALS This.wiring diagramis recommended where mist is lubricatinga machineBsgmant of a multiplemachineopration,aM neon pitot tights are used to indicatetfu eauseof malTunction. Malfunctionof the mist $ystomenergizes waming signals,but doee not stop the machine. the The circuit shows air heater on a separatepower input, and includesnormafly-gpen low-o11evsl switchLLS{8). lf no air heateris used,a normeily-clo8ed low-oil{evelswitch can be usedin placeof TS-3 (1 l l inthe circuitshown. The circuit can include4 CRrelay (1S) for interfockirgrnachine srart with proprmist systemopra, tion. when 4 cR is used,4 cR contactsin the start circuitare normally-open.

( r)
(2)

(3) (4) 6)
r OS-/ Mator switch
AOL A

rcl
(7) @) ( E)

(e)
(to) (t t) (tz) ('3) (t1)

el3ir+
/aCR

--*-'<}r-i i r
ecR* llr t

I I

rrp
?(
x-4

IH

(r3)

!r

tts)

t1

APPLICATION
THE FOLLOWIHGRECOMMENDATION APPLY TO: - Air Piping, including all piping, tubing, hose, devices, and connections used to supply air to the 1 genefator. - An piping,tubing, hose devices, and connectionsused to distributethe air-borneoil particlesfrom 2 the gene.rator.to mist, spfay, and condensingfittings, or passages the simulatingfittings. This piping is referredto as mist piping or manifold. All air and mist piping should be free of dirt, scale,or other contaminatingmaterial.lntarnaldiameters shouldbe of sufficient size to avoid excessivepressuredrop. Materialss-hould compatiblewith inbe ternal fluids, and resistant to extemal abuse, ihemical attick, and ambient temperatllre. AIR PIPING: Galvanized cgppej pipe,.copperor anodizedaluminumtubing,.and rubber hoqe_or or synthet_ic tubing are recommended.Table A gives pressuredrop, at various air flows, through 30 meiers of pipe. Sincecompressedair usu_ally contains condensate,e water saparatorshould be used in the air piping supplyingthe generator.Since most supply piping contains scile or rust, a 25 or 40 microns aii fitte-r should be installedupstreamof the watei separat-or. air filter may be either an integralpart of the The watr separator,or a separate unit. The plant main supply.ptpemist be largerthan the^branchsupplyingthe genrator.The plant supply pipe pressure,at the inlet to the branch,must be at leagtequaito ihe sum of tne regulatedair presbure and the pressuredrop througt the branch and the air acc6ssories,such as air solenoidvalvb, water se.parator, and air regulator..lf the strainers in the water separator and the air regulator become clogrg*;d, tlre pressuredrop will increase.

TABLEA-AIRPIPING
AIB FLOW CLM rt 7 brt rt 25o C 56 t12 196 420 560 980 12 0 0 2800 PRE$8URE DSOPPER3o.rnrtcrr Of PIPE. brr PIPESIZE- nrHmotfrr 7,.D.

9 t.D.

12 r.0.

16 t.D.

2l t.D.

0,14 o,36 t,:,

o,oz
o,2t o,91 t,:t

o,21 o,35 o,98

oiz

tft

: o,o7 0,14 o,28 o,49 2,31

o,l4 o,58

o,o7

MIST PIPING: Any manifoldmaterialmeetingthe generalrequirements above can be used. Hack pipe and olainsteel tubing can be used if protect-ed from extemdl corrosionby paint. The bore of btiik pioe'shouldbe coated with preservativo oil to prevent corrosion prior to the introduction of oil miit. Mist oioino should.permitmis.tflow with minimum condensation of oil, and provide for drainageof the condbnset 'il withow creating obstructions to the mist flow. Since thd mist systom ofrrates at verv low -Trelltlur,the use gf pipe dopa or other thread-eealingcompounds is n6t neces'saryand not ricommended..lmproperly used, these compounds can cbntaminate th mist pipinq.'Flushino of ttre manafold recommended is during installationto eliminatescale and dirt which brin p-lug sm-all the bores of the applicationfittings.

srzlt{G illsT PrPritG: oF

The maximum recommended velocity of mist in the distribution manifold is 5 m/sec (meters Der second). .Highervelocities will create rixcessivecondensation,and may cause a rapU fluctualion-ot manifold pressuredue to the "water hammer" effect of the liquid oil'in the manifbld. The distsnce that mist can be canied in the manifold in any direction from the goneratoris primarily determined. by.the allowabfe Fresgure_ drop.in the manifold-. Excessivepressure-orop cJni5use rmproPrlubrication, by increasilg !h6 flow through applicationfittings nbar the geneiator, at the xpenseot flow through remoto fittings. lt is assumedin Table B that a 2O% drop [n manifoldpressure, btween tfi6 genorator and the most remote application fitting in the sysiem, is the rhaximum allovable.Pressuredifferentlalsthie great are rare in actual instalfations,bobaus'it is impraitical to size all the manifold so that the misfvelochy is always at the maximum. The service radius is Table B refers to the distance between the generator and the most rsmote application fitting. This distance is obtained by adding the footase-ot ati manitotOsizej ilirvi"l miit from the generatorto the fitting. Application6requirlig a longer-service radiusare feasible,Uirtitroutci be referreclto the factory for piping recommendation-s.

22

APPLICATION
TABTEB. MIST PIPING
I.D. PIPC lmml 3 4,6 7 8 I 11 12,5 15,5 21 27 35 41 63 63 78 FIOW AREA
hq rilill

ilAX M|ST FLOWlCLill One applicationfitting - 5,6 Two or more flttlngs - 3.08 One applicationfitting - 14 Two or more fittings - 7 16 20,5 29 40,5 53,5 85 150 244 420 675 940 1342 2080

IIAX IEIIGTH OF illsT Llltl lmcterrl . = --miL A P ICLMI A P (CLMI ---frs6 7,5 11 15 18 23 30.5 38 49 61 73 73 73

7,06 15,9 38,5 50.2 53.6 95 122,7 194,7 346 572 962 1320 2202 3t 17 4778

TABLE B NOTES: 1 - Table B appliesto system designedto operate at manifold pressuresabove 4OO mm H2O. For systems designedto operatabetwean 4OOmm ard 150 mm H2O,divide either the serviceradius or the air flow by 2. For straight mist systems de$ignedto operate below 150 mm H2O, divide both the servica radiusand the air flow by 2. 2 - Table B assumesthe minimum use of elbows, tees, and other connectors,and assumesmaximum use of straight runs of pipe or tubing. Changesin the directionof mist flow in the manifoldproduce additional condensation and a p.essure drop eguivalent to many meters of straight run. In particular, globe valves, angle valves, and solenoidvalvss are not recommendEdunless the valve orifice is twice the manifold flow area shown in Table B. 3 - The manifold from the generator to any application fitting should preferably consist of no more than three different pipe diameters{shouldnot be reduced mor than twice}' - In Thermo-Airesystems, which use heated air to stabilizeoil output under varying extsrnal am4 fittings are not bient conditions,Table B appliesif temperaturedifferentialsamong the apPlication by increasing the excessive. Great temperature differentials can result in improper lubrication, flow through hot fittings st the expense of flow through cold fittings. Table B thus appliesto Thermo-Airesystems operatingunder onc or more of the following conditions: al Heatedair temperatureneverexceedsambientby more than 38o C. b) All applicationfittings are about the same distance from the generator. c) All application fittings located farther from the generator than distance L in the following formula: empirical 6 = pipe intemaldiameter{mm} (oCl L = Txd/45O where T = trnFrature L = lenght {metersl d) lf the Thermo-Airesystem cannot be designedto setisfy al or bl or cl, allthe manifold should be heated to maintain the same tempratureat all appficationfittings. INTERNAL DIAMETER: MAfTIIFOLD formula is used to calculatethe minimum manifold lD when the mist flow is known: The following d = 1 ,7\ffi where d = manifoldinsidediameter,millimeters

23

APPLICATION
SLOPEOF MIST PIPING: The proper slope of horizontalmanifold is as important as proper manifold diameter. The main manifoldshould be slopedtoward the generatorwhereverpossible.lt is especiallyimportant to slopethe first 3OOdiametersof the main manifoldtoward the generator,since most of the oilcondensationoccurs within that distance.Branchmanifold,if slopedtoward the main manifold,shouldbe connectedto the top or sides of the manifold, to avoid liquid oil traps. TableC indicatesthe recommendedslopeof manifoldfor properdrainageof condensedoil back to the NEBOLgeneratoror other oil collector. TABLE C . SLOPEOF MIST MANIFOLD TOWARD GENERATOR MhIIilT'M AMBIEIIT OR MA'IIFOID TET#ERA'TURE o|Lvlscoslw
cst 20,5 38,5 64,5 108 173 324 540 1080 t S U S . rl o o o F l 100 180 300 500 800 1500 2500 5000 -17,80 C 5,3 8,8 10,5 '12,2 18,O oo c 3,7 s,4 6,1 7,2 8,5 1l , o 15,O loo c 3,0 4,1 4,6 5,5 6,5 8,8 10,4 14,4
Percont slope of meni{old 2% slope equals 50 mm H2O drop every 2,5 ml. of manifold

25o C 2,4 3,O 3,7 4,4 5,1 6,1 7,1 9,O

38o c 2,1 2,5 2,9 3,5 4,0 4.9 5,4 6,7

TABLEC NOTES: I - TaHe C is for rnanifold where condensad oilflow is opposite the mbt flow. 2 - Wherc drainage provisions a[ow tho condensed oil and mlst to flow in the same drectbn, horizontal runs do not reqtdre any slope. Hodrontal runs wHch an not sbped shor.ffi have &alnage Xrinte mt farther apafi than 3OO tknes tho manlfold l.D. The dralnage may be to pointc of fubrlcation, or to a sta@ipo or sump having provicirn for perlorfic dumping of condsnsod oil. 3 - Tabh G is for Installati6ns h continuous ofratbn. For $ystems oporating ono or two shifta daily, dvide dwc in TaHo C by 2. OIL TRAPS: possible.Small oiltraps do not stop the flow of mist, but quid -6auseoil traps should be avoided wherever loss of manifold pressureequal to the pressurehead of oil in the trap. The loss of manifold pressure the decreases flow of mist to machineelementsservedby the trappedline. When the height of oil in the trap is about equal to manifold pressurein millimeterswater, the flow of mist will stop. exceeds2OOmm Oil traps will not form in branchlinesunder4,5 mm 1.D.,if the manifoldpressure

Hzo.

To avoid traps, the manifold should have drainageprovisionsat all low points. a Where oil traps are unavoidable,and oil drippingis permissible, 12 mm diameterhole at the lowest point of the trap will drain the condensedoil. Where oil traps are unavoidableand oil drippingis not permissible, condensatelines must be installedbelow the manifold, with connectionsto the bottom of the manifold. Where oil condensatelines are installed,the condensatetank should be vented with a 1,2 mm diameter hole. The venting prevents back pressurein condensatelines, and allows the {low of mist through th condensatelines, thus aidingthe flow of the condensedoil to the tank. The venting permits the use of small3,75 mm l,D. condensate linesfor mist systems,and 6,25 mm l.D. condensate linesfor Thermo-Aire linesshouldbe at least9,5 mm systems.Without the venting,the condensate LD.

24

APPLICATION

TYPICATMIST SYSTEilIPIPII{GSCI{EtrIATIC

NAtrOTD PnEs8r.E8WrCH
R(I,'TE OVEROSSTHJSNOilETO AV()|D TFAFE mount hlwryr ndtdr o h.Yr r+ wrrd routrd mlrt mdto|d com.cdonl

}IAITFOTD BLOCTS

MST EX}TilJ3T TJil8 lur whrr urit tr Eo.N. !o oF lcnrllvr nnrr*l

LIOUID OIL RETURTI IITES m ol ltr rdrr drhplnf l. Pff' drdrl

r---l. )
lK.
t\

: I I I I

o(ilTROt

PArEr I
t

ST

OI'TLET

I I
I

mAn HAilFOLD lno omrcdonr SLOPED m$o|d prilrtltbd h tt* rrctbtl

to bottqn of

t,r

ArRUilE OON{TnOL8
AIR IIS.ET

RETIRtrtOil. COLLECTfi |do na rauar ln rnlrt lrmrrOd

Itrt5ll TAP?trlO Ef,AIrCH lJ{E @f$ XECTORS DIRECTTY IilTO trATIFOtD PIPE COTT{ECTOR fiREAD 8HOIJ].D rcT MTN.IX IITO PfE

_.L____
q,TLETAUIOTATIC WATERSPARATOR

fG\

25

APPLICATION

UNIT DEVICE NEBOLCONTROL controlandcheckingof oil UNITdevicepermitan immediate CONTROL The completeNEBOL pressurizedat real time, mist into the manifold parts: It is composed two principal in - one detectordevice - one digitalunit.

- -'lOL detector The mist detector is an electronic device that produce an electricoutput in functionof the opticalsignalfrom analogic density of mist in the manifold' The density of mist is continuouslyin accordingto electric output from the device.

Digital unit conveilor that The digitalunit is an electronicanalog-digital permit to visualize the quantity of NEBOLin the manifold. of The visualization NEBOLis direct and in real time with numbers on the digit proportionateto quanti{ of oil in percentage the mist. at The electricconnectionbetween detectorto control unit is feasible with a little screenedcable. Appropriate potentiometersallow to define the scale of valuesindicatedon the digit.

26

APPLICATION

assembled unit devicefor explosion*proof In the picturebelow there is a particularyNEBOL completewith a NEBOLcontrol device.