Operator Manual: #DL3100 Dualine Spray System - Bijur Delimon

Operators Manual
DL3100
Dualine ® Automatic Spray Systems
Installation, Operation, Parts List
DL3100 r#2

Dualine series - AUTOMATIC SPRAY LUBRICATING SYSTEMS
TABLE OF CONTENTS
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Typical system (Pump close to valve panel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
System - Sequence. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Typical System (Pump remote from valve panel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Central Pumping Stations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Valve Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Lance Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
SC400 Controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Air Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
SC1-2 Spray Control Valves - Dimensions & Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
SC1-2 Spray Control Valves - Operation & Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
SC1-2 Spray Control Valves - Conversion For After Blow . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Location For Valve Panels And Spray Lance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Startup And Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
System Diagnosis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
INTRODUCTION
The spray systems described in this bulletin are used to lubricate large gear and pinion sets such as found on ball mills,
rod mills, kilns, etc. Each systems includes an air operated pumping station, a measuring valve panel, a spray nozzle,
electrical controls and a number of optional features.
Gear face widths of 2" to 42" can be lubricated with nozzles and nozzle spacing designed accordingly. Since Bijur
Delimon gear spray systems operate intermittently they can be thought of as film maintaining devices. The
electrical controls provide broad cycling flexibility as well as fault monitoring and after blow to purge the nozzles.
Illustrations and specifications are not binding in detail.
Designs are subject to modification and improvement without notice.
2

Dualine series - AUTOMATIC SPRAY LUBRICATING SYSTEMS
TYPICAL SYSTEM (Pump Close To Valve Panel)
Figure - 1
SEQUENCE OF OPERATION (System Shown in Fig.1)
1. SC400 times out, opening the two solenoid air valves. The pump starts. A measured volume of lubricant
discharges from each of the measuring valves to its spray nozzle. Air flows thru the air manifold to the
spray nozzles, atomizing the lubricant to a penetrating spray.
2. When each measuring valve has discharged once to its spray nozzle, system pressure begins to increase until
at a predetermined point, it shifts the reversing valve; (Factory set @ 1500 psi)
Reversing valve limit switch is operated closing the pump solenoid air valve, but a time delay device in the
SC400 keeps the nozzle solenoid air valve open for a preset time period after lube flow stops. The air
thoroughly cleanses the nozzles.
Lube pressure in the system is relieved to reservoir by the reversing valve and alternate supply line is readied
for pressurizing during next pumping cycle when the foregoing sequence is repeated.
NOTE: For component part numbers, refer to fig's. 2 and 3.
3

Dualine series - AUTOMATIC SPRAY LUBRICATING SYSTEMS
SCHEMATIC - TYPICAL SYSTEM (Pump Remote From Valve Panel)
Figure - 2
SYSTEM DETAILS AND PART NUMBERS
ITEM # PART NUMBER QTY. DESCRIPTION
1 9120 1 120lb Air Operated Barrel Pump
2 DR460A 1 Reversing Valve
3 LD7767CA1 1 Air Control Panel
*4 U623 1 Air Pressure switch
5 200275 1 Lube Supply Hose Kit (72")
6 200277 1 Relief Hose Kit (72")
7 200325 1 Air hose Kit (72")
8 U1929D (OIL ONLY) 2 2-Way Line Checks
9 BY USER 1 Supply Line Pipe or Hose to Panel
*10 F1194G 1 Air Regulator
11 LD12361V6 1 Valve Panel
12 LD9327-XXXXX 1 Spray Lance
13 SC400 1 Timer Control
* Note: Items 4 & 10 sold separately
Refer to Fig. 3 for pumping station details and part numbers. (Page 5)
The spray system layout shown in (Fig.2) provides guidelines for installations where the pump, reversing valve and
controls cannot be located close to the valve panel. To assure good pressure distribution under various operating
temperature conditions, two pipe supply lines are run from the reversing calve to within 30" of the valve panel. Two
36" hose assemblies are used to connect to the valve panel. The size of the piping for the supply lines can be selected
from the table in page 13(Fig. 15).
4

Dualine series - AUTOMATIC SPRAY LUBRICATING SYSTEMS
CENTRAL PUMPING STATION
Figure - 3
ITEM PART NO. DESCRIPTION
1 9120 120 LB Air Operated Barrel Pump
2 DR460A Reversing Valve
3 LD7767CA1 Air Control Panel
4 U623 Air Pressure Switch
5 200275 Lube Supply Hose Kit (72")
6 200277 Relief Hose Kit (72")
7 200325 Air Hose Kit (72")
8 U1929D (OIL ONLY) 2-Way Line Checks
NOTE:
A. The 9120 pump for 120 pound drums is recommended where solvent cut-back lubricants are used. This is to
necessitate frequent drum changes to prevent drying and hardening of the lubricant. The 9400 pump for 400 pound
drums is available if drying and hardening of the lubricant is not a problem.
B. A U623 pressure switch (Item 4) is used to give warning of low pressure and is an optional feature.
C. All Central Pumping Stations are for 120 Volts, 60 Cycle, but other voltages and frequencies are available.
Electrical timing devices are described on page 8.
D. The U1929D two way checks are needed only if the lubricants have fluid characteristics.
5

Dualine series - AUTOMATIC SPRAY LUBRICATING SYSTEMS
VALVE PANELS
18
1/2" NPT
AIR SUPPLY
7
23
19
34.0
.62 32.75
3/4" DIAMETER THRU
8 HOLES
17.88
16
START
20
10
21
14 12
12.88
15.0
15
6.00
1.5
11
2.5 APPROX.
3/8" NPSF
LUBE INLET
24 6
5
24 6
22
9
24
17
6
24
4
13
1/2" NPT
CONDUIT CONNECTION
3
2
FIGURE - 4
VALVE PANEL LD12361V8 PARTS LIST
ITEM # QTY. PART NO. DESCRIPTION
1 4 201222 Hose Assembly with Adapter - 30" long
2 1 201502 Kit - Air Supply Hose - 36" long
3 1 201595 Valve Solenoid 2-way NC 3/4"NPT 50/60Hz
4 8 U1732F Cover Indicator Stem
5 4 DM62100A Dualine Valve
6 4 201223 Hose Assembly with Adapter - 36" long
7 1 F6024MD Filter Air Line 1/2"NPT Auto Drain
8 1 LD9340V8P Plate - Mounting
9 12 U81D3 Sleeve and Nut 3/8" tube x 3/8"NPT
10 1 U101D2 Nipple 1/2"NPT x 1-1/8" long
11 1 U101E1 Nipple 3/4"NPT x 1-3/8" long
12 1 U101E19 Nipple 3/4"NPT x 7" long
13 1 U11354 Elbow Reducing Pipe 3/4" x 1/2"
14 1 U11654 Reducing Coupling
15 4 U119CC Plug 3/8"NPT
16 4 U204C15 Screw Hex Head Cap 3/8"-16 x 5/8" long
17 8 U206K6 Screw Fillet Head Machine 5/16"-18 x 2-1/2" long
18 4 U207G3 Screw Round Head Machine #10-24 x 1/2" long
19 4 U213C Washer Lock #10
20 4 U213G Washer Lock 3/8"
21 2 U2685 Bracket Mounting 3/4"NPT
22 .75' U424E6 Tubing Steel 3/8" O.D.
23 1 LE9629B Pushbutton 'start'
24 8 U1104B Ell Street 1/4"NPT
Shown in Fig. 4 is a typical measuring valve panel(Panel assembly#LD12361V8). This panel has measuring valves to serve
8 nozzles. Panels having from 1 to 8 measuring valves are available as shown in Table 1. All panels have outside dimensions
of 34" X 15". The only variable on each panel is the number of measuring valves(one to eight). DM60 size measuring
valves are standard on the panels, however, smaller capacity measuring valves can be supplied if required.
6
3.94
.25
1.81
3.94
3.94 1.81 3.94 1.81
1.81
7.63
TABLE 1.
AVAILABLE PANELS
PANEL
NUMBER
NUMBER SPRAY NOZZLES
LD12361V1
1
LD12361V2
2
LD12361V3
3
LD12361V4
4
LD12361V5
5
LD12361V6
6
LD12361V7
7
LD12361V8 8

Dualine series - AUTOMATIC SPRAY LUBRICATING SYSTEMS
SPRAY LANCE - MODEL LD-9327
Model LD-9327 spray lances described below include spray nozzles in which air under pressure atomizes lubricant from
the valve panels and sprays it onto the gear face. Note that guard width must be exactly 3" wider than gear face width.
Contact factory for special applications.
A
A
U1078
1-1/2"
PIPE CAP
B6519
"B"
"B"
"B"
"A"
U922C U1104B U101B1
"B"
1-1/2" STEEL PIPE
1.5" FORGED STEEL SLIP ON FLANGE
(NOT FURNISHED BY BDI)
U424C6
GEAR GUARD
3/8"OD TUBING
Group 1 - Assembly Numbers and Dimensions
ASSEMBLY
PART #
LD93271020S
LD93271030S
LD93271040S
LD93271050S
LD93271060S
LD93272070S
LD93272080S
LD93272090S
LD93272100S
LD93272110S
LD93273120S
LD93273130S
LD93273140S
LD93273150S
LD93273160S
LD93274170S
LD93274180S
LD93274190S
LD93274200S
LD93274210S
LD93275220S
LD93275230S
LD93275240S
LD93275250S
LD93276260S
LD93276270S
LD93276280S
LD93276290S
LD93276300S
LD93276310S
LD93277320S
LD93277330S
LD93277340S
LD93277350S
LD93277360S
LD93277370S
LD93278380S
LD93278390S
LD93278400S
LD93278410S
LD93278420S
GEAR
FACE
WIDTH
2"
3"
4"
5"
6"
7"
8"
9"
10"
11"
12"
13"
14"
15"
16"
17"
18"
19"
20"
21"
22"
23"
24"
25"
26"
27"
28"
29"
30"
31"
32"
33"
34"
35"
36"
37"
38"
39"
40"
41"
42"
GUARD
WIDTH
4.5"
5.5"
6.5"
7.5"
8.5"
9.5"
10.5"
11.5"
12.5"
13.5"
14.5"
15.5"
16.5"
17.5"
18.5"
19.5"
20.5"
21.5"
22.5"
23.5"
24.5"
25.5"
26.6"
27.5"
28.5"
29.5"
30.5"
31.5"
32.5"
33.5"
34.5"
35.5"
36.5"
37.5"
38.5"
39.5"
40.5"
41.5"
42.5"
43.5"
44.5"
NO. OF
SPRAY
NOZZLES
1
1
1
1
1
2
2
2
2
2
3
3
3
3
3
4
4
4
4
4
5
5
5
5
6
6
6
6
6
6
7
7
7
7
7
7
8
8
8
8
8
DIMENSIONS
B C
A +/- +/-
1/16" 1/16"
8" - 2.25
10" - 2.75
11" - 3.25
12" - 3.75
13" - 4.50
14" 4.00 2.25
15" 4.50 3.00
16" 4.50 3.50
17" 5.00 3.75
18" 5.25 4.13
19" 4.38 2.87
20" 4.38 3.37
21" 4.68 3.57
22" 5.00 3.75
23" 5.25 4.00
24" 4.50 3.00
25" 4.50 3.50
26" 4.75 3.75
27" 5.00 4.00
28" 5.25 3.88
29" 4.50 3.25
30" 4.75 3.50
31" 5.00 3.75
32" 5.25 4.00
33" 4.38 3.30
34" 4.38 3.80
35" 4.68 3.55
36" 4.68 4.05
37" 5.00 3.75
38" 5.25 3.63
39" 4.38 4.11
40" 4.68 3.71
41" 5.00 3.25
42" 5.00 3.75
43" 5.25 3.50
44" 5.25 4.00
45" 4.68 3.87
46" 4.80 3.95
47" 5.00 3.75
48" 5.10 3.90
49" 5.25 3.88
7
"B"
8.0" 6.7"
5.75"
1.75"
"B"
B6514
GEAR GUARD
1.67"
3.0"
1.22"
"C"
9.0"
7.75"
1.0"
4.75"
VIEW A-A
U1103B
1/2”NPT
AIR INLET
1/4”NPT
LUBE INLET
LUBE HOSE - REF.
60° 6.75"
4.25"
.625"
Ø.75"(X4)
NOTE:
"S" series spray lances are shipped with
round spray nozzles installed. Flat spray
nozzle set is also included with each spray
lance.

Dualine series - AUTOMATIC SPRAY LUBRICATING SYSTEMS
SC400 MULTI-FUNCTION CONTROLLER/MONITOR
General
The SC400 Controller is a full featured lubrication control, offering “two plus one”
functionality. The controller has the ability to operate a single pump and two zone valves
(e.g. frequent/infrequent lubrication cycles) or two separate pumps (e.g. one oil pump &
one grease pump). For single zone systems, the SC400 Controller also offers two intervals
(e.g. weekday /weekend). The controller can activate a fi ll pump as needed to maintain
proper fl uid levels in the oil or grease reservoir.
Features
+ 2 zone operation (for Progressive, Injector and Dualine Hydraulic systems).
+ IP56 enclosure, constructed of molded polyester fi berglass.
+ CE approved.
+ Four supported languages (English, French, Spanish, German).
+ Pump output may be powered externally or via control power.
+ Valve A, Valve B and Fill pump may be powered exrternally or via controller.
+ Critical Inputs accept PNP, NPN or mechanical switches.
+ 500 mA of 24 VDC is available to power customer's accessories.
+ Primary alarm inputs may be programmed for N.O. or N.C. functionality.
+ Machine watchdog and cycle monitoring.
+ Pause (standby), jog (manual operation).
+ Accepts all BDI electric reversing valves and cycle/pressure/"end-of-line" switches. Refer to the following documents for more info:
Technical Data
Input Voltage 85 to 265 VAC, 50/60 Hz
Output Rating (Line A & B) 8 amp (90 to 250 VAC)
Enclosure Rating IP-56
Idle Time Range 1 second to 100 days
Machine Cycle Counts 1 to 999,999 Counts (30 counts/second at 50% duty cycle)
Watchdog Timer 1 second to 60 minutes
Monitor Time 1 second to 24 hours
Cycle Counts On 1 to 999 counts
Over Counts 0 to 9
Net Weight 5 lb
Length x Width x Height 12.3” x 9.2” x 5”
Fault Relay Contacts 5 amp
8
+ Datasheet #35980: SC400 Controller

Dualine series - AUTOMATIC SPRAY LUBRICATING SYSTEMS
SYSTEM AIR REQUIREMENTS
A free air volume of V a cubic feet, calculated by the equation
below, should be provided for each lube cycle. This is twice
the theoretical air volume needed to operate both pump and
nozzle. A lube cycle is defined on page 3.
V a = 2V 1 (T 1 +T 2 )+2V 2 (T 1 +T 2 +T 3 )
Where:
V 1 = Free air volume used by the pump*.
assume = 5.0 cfm.
V 2 = Free air volume used by the nozzles in cu.ft. per minute
see Fig. 9.
T 1 = Time in minutes to compress lube in distribution lines.
see Fig. 10.
T 2 = Time in minutes required by a pump to discharge lube
from the nozzles during one count. See Fig. 9.
T 3 = Time in minutes for air to clean lube from nozzles after
discharge. Allow 0.50 minutes.
Example: Find the free air volume needed by the spray system shown in Fig.2. (Page
4) The lance has six U922C nozzles. The valve panel has six valves - DM62 valve
blocks. Distribution lines consist of 100' of 1" pipe. The system is to be operated
four times an hour.
V a = 2 x 5 (.18 + 0.09) + 2 x 81 (.18 + 0.09 + .5) = 127cu.ft. per lube cycle
Volume of free air required for one hour is: 4 x 127 = 508 cu.ft.
9
NO. OF
NOZZLES
T2
FOR DD5X FOR DM6X
V2 (cfm)
1 .005 .015 13.5
2 .010 .030 27.0
3 .015 .045 40.5
4 .020 .060 54.0
5 .025 .075 67.5
6 .030 .090 81.0
7 .035 .105 94.5
8 .040 .120 108.0
Fig. 9 - Values for T2 and V2 .
LUBE COMPRESSION TIME “T2” IN MINUTES
.80
.70
.60
.50
.40
.30
.20
.10
1-1/2” PIPE
1-1/4” PIPE
1” PIPE
3/4” PIPE
1/2” PIPE
0
0 50 100 150 200
LENGTH OF DISTRIBUTION LINES IN FEET
Fig. 10 - Lube compession time “T1”
(based on 1% compressibility of lubricant).
*The pump is assumed to be operating with air pressure regulator set between 80 and 100 psi and a line back pressure
of 1000 psi (the line back pressure is usually much lower). Lube volume discharged by the pump is assumed to be 40
cubic inches per minute.

Dualine series - AUTOMATIC SPRAY LUBRICATING SYSTEMS
BDI SPRAY CONTROL VALVE & NOZZLE ASSEMBLIES
APPLICATION: SC1-2 spray control valves are used on manually operated spray systems, automatic gear spray systems
on shovels and drag lines, and on older gear spray panels.
COMPONENT ASSEMBLIES
1. SC1 Series spray control valve
1-3/32”
21/64”(X2)
(identical for all assemblies)
1-3/8”
1-3/8”
1/2”
1”
2
1
3/8”
1” 1”
2”
1/2”
1-3/4”
1/2”
2-3/4”
3-27/32”
11/16” TO CENTERLINE
OF 1/4”NPTF LUBE UNIT
HOW TO ORDER EXAMPLES:
A. Spray nozzle setup if known: One SC1-2 spray control valve with spray nozzle setup.
(Specify correct spray nozzle setup, whether U943A, C or F.)
B. SC1-2 w/After Blow: Order P.N. SPR13241B (Order U943 separately)
C. Spray nozzle setup:
1. U943A - for light oil.
2. U943C - for oil or grease - recommended for most spray applications.
3. U943F - used when flat spray pattern is desired such as spraying wire rope.
SC1-2 SPRAY CONTROL VALVE WITH
U943 SPRAY NOZZLE SET-UP
ITEM # PART NO. DESCRIPTION
*1 N/A Valve Body
*2 N/A Piston
3 SC110061 Spring-Piston Stop
4 SC110072 Air Check Valve Assy.
**5
Check Valve Body
**6
N/A
Lock Nut
**7 Spring
**8 Quad Ring
9 U204B6 5/16-18 x 1-3/4 Cap Scr.
10 U213F 5/16 Lockwasher
11 U219B 5/16-18 Hex Nut
12 U230D 5/16" Check Ball
19
13 U943 Spray Nozzle Set Up
20
14 U1204D 7/16-20 Dr. Ret. Scr.
13
15 U1305G 7/16" Copper Washer
18
16 U1522D Closure Plug
21
17 U1526 Ball Retainer
*Items 1 & 2 shown for reference only - not for resale.
**Items must be purchased in item#4.
U-943 SPRAY NOZZLE SET-UP
10
2. U943 spray nozzle setup
(model selected depends on lubricant
and application)
NOTE:
SC1-2 spray control valve and U943 spray
nozzles are sold separately. Must purchase
individually.
ITEM
U943A
PART NO.
U943C U943F
NAME
18 UX943A1 UX943C1 UX943C1 Fluid Nozzle
19 UX943A2 UX943C2 UX943F2 Air Nozzle
20 UX943A3 UX943A3 UX943A3 Hex Retainer
21 UX943A4 UX943A4 UX943A4 Gasket
5
14
7
6 4
17
12
8
3
2
1
15
16

Dualine series - AUTOMATIC SPRAY LUBRICATING SYSTEMS
BDI SPRAY CONTROL VALVE & NOZZLE ASSEMBLY
HOW TO ADJUST MODEL SC1 SPRAY CONTROL VALVES
SC1 valves are factory adjusted to function properly with NLGI #0 consistency lubricant. If other lubricants are used,
the following adjustment may be needed to improve atomization or to eliminate nozzle burping at the start and end of
the lube cycle.
1. Pump to 1000 psi on the pressure gauge. Relieve system with the pump solenoid valve and then loosen locknut
(item 6, page 10) at the air inlet and turn check valve body (5) clockwise until air slows thru spray nozzle (13).
Finally turn check valve body counterclockwise until no air escapes.
2. Repeat "1" several times if needed for good atomization. Then tighten locknut. Caution: To prevent a change in
setting, hold check body firmly while tightening locknut.
HOW SPRAY CONTROL VALVE & NOZZLE ASSEMBLIES OPERATE
1. Lube under pressure fl ows thru port A into chamber
B causing piston D to move toward ball E. this both
unseats the ball and opens a port from chamber B to
passage G.
2. Air fl ows past ball E thru passage F and lube fl ows
thru passage G. They meet in air nozzle H and produce
a spray. Removal of the air nozzle will only produce a
more concentrated spray.
11
H
ASSEMBLY NOTES
F
G
C
E
1/8” DIA.
STEM
THIS END
When assembling an SC1 valve, install large (1/8" dia.) end of piston D toward ball as shown in figure.
SCI PERFORMANCE DIAGNOSIS - (Valve fails to operate properly)
Cause Repair
1. Insuffi cient air supply. 1. Check pressure - should be 80psi minimum
(not less than 60 psi during spray cycle)
2. Incorrect setting of air control valve. 2. Re-adjust - see above for details.
3. Clogged spray nozzle. 3. Wash with solvent and reassemble.
4. Clogged spray control. 4. Remove pilot piston and clean it and the piston bore
with solvent. Reassemble.
D
B
A

Dualine series - AUTOMATIC SPRAY LUBRICATING SYSTEMS
SCI CONVERSION - TO PROVIDE AFTER BLOW
(FOR EXISTING SPRAY PANELS EQUIPPED WITH SC1 VALVES)
STAINLESS
STEEL BODY
LUBRICANT
SOCKET SET SCREW
5/16”-18 X 5/16” LG.
(LOCTITE THREADS)
.257” DRILL
5/16”-18 TAP
AIR
LUBE CROSSPORT
TO NOZZLE
FIGURE - 14
12
FLUID
NOZZLE
HEX
RETAINER
AIR NOZZLE
(MUST ORDER
SEPARATELY)
AIR RELEASE
VALVE BODY
AIR ENTRY PORT
TO NOZZLE
JAMB
NUT
NOTES
Existing spray panels equipped with SC1-2 spray control valves can be upgraded to incorporate after blow by employing
the following procedure:
1. Remove items (shown on page 10) numbers 2, 3, 8, 12, 17, 7 and 14.
2. Drill piston bore .257" then tap 5/16"-18.
3. Insert 5/16"-18 x 5/16" long set screw coated with Loctite thread locker.
4. Insert solenoid air shut-off valve in air line to nozzles and wire in parallel with air operated barrel pump.
5. Install time delay relay in control circuit to provide approximately 60 seconds after blow.
CAN ORDER SC1-2 WITH AFTER BLOW FROM BDI. PART # SPR13241B. MUST ORDER AIR NOZZLE SEPARATELY(SEE PG 10)

Dualine series - AUTOMATIC SPRAY LUBRICATING SYSTEMS
INSTALLATION INSTRUCTIONS
INSTALLATION
1. Pump Close To Valve Panel (See Page 3): In most installations of this type, hoses are used to make all air and
lubricant connections. Hose lengths must be adequate to allow movement of the pump during lubricant drum
changes.
Clean inside of hoses thoroughly before installing to remove foreign material. Tighten all hose connections
securely using a thread lubricant and sealant.
2. Pump Remote From Valve Panel (See Page 4): Hoses are used to connect the air line to the pump and the pump
to the reversing valve. Pipe is run from the reversing valve to within 30" of the valve panel with the final
connection to the valve panel made with hose assemblies.
Pipe size selection is important, as it will affect the operating pressure of the system. For guidance in selecting
proper pipe size, see pipe sizing table in Figure 15.
Pipe Sizing Table - Fig. 15
(Pump Remote From Valve Panel)
PIPE SIZE
50° - 90°
OPERATING TEMPERATURE (°F)
32° - 50° 0° - 32°
1/2 60 FT. 40 FT. 20 FT.
3/4 - 60 FT. 30 FT.
1 - - 40 FT.
NOTE: Longer lengths and larger diameter pipe is not recommended due to the fact that the compressed volume
of lubricant, within a pipe, causes the valve manifold to cycle after the pump shuts down. This can result in
excessive consumption of lubricant and/or cause the SC400 control to fault.
Clean pip thorougly before installation to remove all scale, chips, dirt and burrs. Install pipe in protected
locations and firmly clamp in place. Pipe threads should be cut clean and free of burrs. Use a good thread
lubricant and sealant. Use 3000 pound forged steel fittings and schedule 80 pipe. Pull all connections tight.
3. For valve panel and spray lance locations - see page 14.
4. The Lubricant: High quality open gear lubricants are readily available that can be pumped and sprayed at low
temperatures without requiring heat. Be sure that the lubricant selected will remain pumpable at the minimum
operating temperature that will be encountered.
13

Dualine series - AUTOMATIC SPRAY LUBRICATING SYSTEMS
INSTALLATION & LAYOUT
INSTALLATION
LOCATION FOR VALVE PANEL LD12361 AND SPRAY LANCES LD9327 AS SHOWN IN FIGS. 16 & 17.
GEAR
1-7/32”
ANGLE OF
SPRAY
30° +/- 10°
SPRAY LANCE LD9327
8” +/- 1/2”
SPRAY LANCE LD9327
GEAR GUARD
GEAR PITCH CIRCLE
30° +/- 10°
SPRAY
PATTERN
CENTERLINE
FIGURE - 17
14
SPRAY LANCE LD9327
FIGURE - 16
PITCH CIRCLE - GEAR
GEAR TOOTH
CENTERLINE
PITCH CIRCLE - PINION
GEAR GUARD
GEAR GUARD
30° +/- 10°
8” +/- 1/2”
8” +/- 1/2”
CENTERLINE
SPRAY
PATTERN
GEAR GUARD
1-7/32”

Dualine series - AUTOMATIC SPRAY LUBRICATING SYSTEMS
START UP AND MAINTENANCE
START UP PROCEDURE
1. Program the SC400 controller in accordance with instructions given.
2. Fill air line lubricator with light oil (SAE #10).
3. Adjust pump air regulator to obtain 1800 psi pump line pressure.
4. The DR4 reversing valve is set to reverse at 1500 psi at the factory.
5. Set the air regulator for the spray nozzles to 60 - 80 psi. Re-adjust for best spray.
6. To fi ll the two main supply lines to the measuring valves:
a) Remove the pipe plugs from the last measuring valve.
b) Start pump by pressing SC400 manual/reset button.
c) Bleed (1) pint of lubrication from line 1 at the last measuring valve.
d) Stop pump by pressing SC400 manual/reset button again.
e) Insert pipe plug in last measuring valve (line that was purged).
f) Start the pump again. Pressure will build up to operate the reversing valve.
g) Follow steps c, d, and e for purging supply line 2.
7. After purging both suply lines, the system is ready to operate. Cycle the system manually until the spray
nozzles are operating properly and the gear face is being completly covered with lubricant.
8. Coat the entire gear face (all teeth) with lubricant before starting up the mill.
MAINTENANCE
A. Too much water in the air fi lter drain bowl on the air control panel will make the fi lter ineffective and water will
enter the pump. Empty it regularly, a drain cock is provided. If moisture in the air supply line requires frequent
draining of the air fi lter we suggest installing automatic drain assembly.
B. Be sure lube container has plenty of lubricant. Pumping from an empty drum may force air into system, causing
diffi culty in building pressure.
C. Use clean lubricant. Foreign matter might clog valve manifold.
D. Keep line stainers clean. These are usually installed in the line leading to the valve manifold. Establish regular
intervals for this service.
E. Inspect entire system regularly including hose (replace if damaged), connections (they should be tight), and
the gear (see that the teeth are being properly lubricated). Check spray pattern frequently by inserting a
piece of cardboard in front of the spray nozzles while the system is operating. Complete coverage of the gear
face is important.
F. Completely clean the system with a fl ushing solvent every year or two to extend its life.
15

Dualine series - AUTOMATIC SPRAY LUBRICATING SYSTEMS
TROUBLE SHOOTING
A. Pump doesn't operate*
SYSTEM DIAGNOSIS
CONDITION CAUSE REMEDY
B. Pump operates but doesn't build
pressure.
C. Manifold valve indicator doesn't
operate.
1. Insuffi cient air supply. 1. Adjust air pressure to 40/50 psi.
2. Timer control failing to operate
solenoid shut-off.
3. Lubricant has hardened in drum.
16
2. Check wiring of system timer according
to instructions and SC400
controller. Also check timer for
proper programming.
3. Use smaller sized drums - diluent
in some lubricants tends to evaporate
causing lubricant to harden.
1. Reservoir empty.
1. Check and renew lubricant supply.
Purge air from lines.
2. Broken line. 2. Repair or replace as necessary.
3. Air in system.
3. Bleed lines and valves as described
on page 15.
1. Lack of pressure. 1. Repair - see condition B.
2. Incorrect operation of reversing
valve..
3. Dirt in Dualine measuring valve.
2. Check valve condition by "shortcircuiting"
it with two 3/8" pipe plugs
installed in reversing valve discharge
ports. Start air-operated barrel
pump, and reversing valve will oscillate
if properly adjusted for type of
system. Clean any strainer in lines
every six months.
3. Remove inlet bore plugs and piston.
Clean bore by pouring solvent through
it. Clean piston and re-assemble.
4. Locate obstruction, remove line
4. Plugged discharge line.
and blow clean, or replace faulty section.
*For more information on the air operated barrel pump, see Data Sheet # 35993.

Dualine series - AUTOMATIC SPRAY LUBRICATING SYSTEMS
Notes
17

Dualine series - AUTOMATIC SPRAY LUBRICATING SYSTEMS
Notes
18

Dualine series - AUTOMATIC SPRAY LUBRICATING SYSTEMS
Notes
19

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