Instructions for Lubrication Oil StationXYZ-100GDesigner:Inspector:Administrator:China Luoyang Wanli Metallurgical&Machinery Co., LtdMarch, 2013 CatalagueⅠ. Brief IntroductionⅡ. Main SpecificationsⅢ. Work Theory& Structural FeatureⅣ. Installation-Adjustment& Test RunningⅤ. Maintain & Safety SkillsⅠ. Brief IntroductionThe station is mainly applied in the field of Cement, metallurgy, Rolling, Mining, Energy, Light Industry, Communication& Transportation, Petrol-chemical and electrical fields. Through Circulating Thin Oil System, the stations supply lubricant to friction sections as gears and bearings of host gearboxes for mechanic equipment which can reduce the attrition and cool equipments so that the equipments can function properly and continuously.The station use N220-N320 medium-workload industrial gear oil or other mechanical lubricant oil as its work media.This device consists of a lubrication oil station, a panel and an electronic control box. The oil supply pressure≤0.4MPa; Oil Supply Temperature: 40±3℃; Filter Accuracy: 0.08-0.12mm; Temperature of Cooling Water≤30℃; Pressure of Cooling Water: 0.2～0.3MPa; Oil supply temperature of Heat Exchanger is about 50℃; Temperature Drop≤8℃.Ⅱ. Main SpecificationsNominal Flow Rate 100L Nominal Pressure 0.4Mpa Oil Tank Capicity 1400L Oil Supply Temperature 37～43℃Oil Pump Type BB-B100 Electric Motor Type Y112M-4 Electric Motor Power 4kW Filter Type SPL-40 Filter Accuracy 0.12mm Cooler Type GLC3-6/0.6 Cooler Area 6m2 Heater Power 12kW Oil Supply Pipe 40mm Oil Return Pipe 80mm Lubricant Oil N220～N320 medium-workload industrial gear oilⅢ. Work Theory& Structural FeatureWork TheoryDuring operation, the gear-wheel pump absorbs the oil from the tank, then the oil will be supplied directly to lubricating point through the one-way valve, the center valve and pipe of the duplex filter and tubular- type oil cooler,.The maximum operating pressure of the lubrication oil station is0.4MPa. According to the requirement of lubricating point, safety valve should be adjusted to choose the work pressure, when the pump pressure exceeds the setting pressure, the safety valve will be opened automatically, and oil will return to the tank.Normally, one pump works, the other for spare. The spare pump will automatically supply the lubricant when the system pressure falls to the setting pressure due to some reasons. The spare pump will stop working until the pressure is normal; however, when the pressure continues to reduce to the other setting pressure, the warning signal will indicate alarm and stops the mainframe. So as oil filter, one for work, the other is spare. Also, there is a pressure-difference controller installed on the input and output gate. When the pressure-difference is over 0.1MPa, the spare filter will work by manual work, then taking out and cleaning or changing filtering element.There are two pressure-type temperature controllers installed to maximum and minimum two boundaries according to oil supply temperature. That is, under low temperature circumstance, the signal light shines, operate manually the heater to heat; when the oil temperature reaches the maximum point, cut off the heater automatically and stop heating; when the oil outlet temperature is high, the signal turns light, alarm bell rings and turn on the cooler；There places a bypass straight pipe beside the cooler. When there is no need for cooler or it need inspecting, the valve can be closed and the bypass should be opened so that the oil flows out directly through the straight pipe and repair the cooler, which will not affect the normal work of oil lubrication station.The oil lubrication station is an integral structure which adopts electrical heating and all parts are installed on the oil tank.Structural Feature1.Installing Spare PumpThere has two oil pumps for the station, one pump works, the other for spare. Normally, one pump works, the spare pump start when the system pressure falls to the setting pressure in order to supply lubricant oil continuously.2.Adopting duplex oil filter.There two filter element in the duplex oil filter, one for work and the other one for spare. It doesn’t need to stop the mainframe when change the element by using the switch valve to take out the original filter element and start the spare one. The filter without bypass has a compact structure, which can be connected and exchanged easily.It can improve the filtering ability by placing the filter in front of coolers; lubricant with higher viscosity can also get through.3.Adopting GLC tubular- type oil cooler.Copper-heater exchanger- tube has fine cooling effects with a small volume and light weight, and has much less resistance than plate heater exchangers, so it is relatively adoptable to use in the Lubrication Oil System which has no intense pressure.4.Installing magnetic filter in the gate of oil returning.This may keep the oil clean by adsorbing and filtering small ferromagnetic substances.5.Installing bypass valveOpen the bypass valve when heating, so that oil can keep flowing and even heating, also to avoid aging of the oil for the too high temperature partially.9. Installing dashboard and electric cabinet, by the device running parameter can be viewed easily, also for automatic controlling and emergency warning.Ⅳ. Installation-Adjustment& Test RunningThis integral lubrication oil station doesn’t need to be fixed by foot screw but just placed on a flat ground or the hole beside the mainframe. It can be carried when hang the four lifting lug on the oil tank.The station has been passed performance test before out of our factory, so it can work well after connecting with oil supplying pipe, oil returning pipe, water pipe, electric cabinet and after trial running.Pipes should be pickled to remove rusts or phosphate treated, neutralized by lime water, rinsed by clean water and dried by compressed air before connecting with equipments.Operation Manuel1.Set the pressure controller and temperature according to the system pressure andoil temperature, then turn on the oil, water and pressure of the station;2.Set the duplex to the operating place of one filter and check whether theconnection of the cooler is tight or not, and fasten if necessary;3.Turn on the electric heater to heat the oilaccording to the oil temperature required ,and the oil should be kept flowing when being heated;4.Start the oil pump before the mainframe works, only the system temperature isachieved can the mainframes begin to work. When stop the machine, mainframe should be stopped firstly and then the pump.5.During the operating of the lubrication oil station, there will be signal lightslighting and alarm sound if the oil pressure/ temperature/ level on the irregular place, then turn off the alarm and remove the failure according to the signal light.6.It should move the change valve immediately when the pressure difference is over0.1MPa, then start the spare filter and take out the filtering element from theoriginal (the work one) and clean or exchange the filter.7.When the supplying oil temperature is over 45℃, the cooler could turned on, atthe same time it should open the water valve, the oil valve and close the bypass valve of the cooler. Otherwise, the water valve and the oil valve should be closedand the bypass valve should be opened if not use the cooler long-term.Ⅴ. Maintain & Safety Skills1.The seal gasket of the gear- wheel should be checked frequently, any leakage ordamage should be replaced in time;2.According to the water quality, coolers should be inspected and cleaned every5-10 months;3.The duplex filter should be cleaned to remove the dirt deposited inside every 3months, and replaced according to the sealing condition;4.The Magnetic Filter should be cleaned every 3 months;5.Pay attention to the oil level, once there is water, it should be discharged by loosethe two oil screws;Lubricant oil in oil box should be sampled and tested every month to decide whether to be exchanged according to the oil quality。