Rotalube Lubrication System

feeding two Rotalube

Applicators - 2 chains
for Stewart Systems Inc-USA
.
Contents

Pages Contents
3 to 5 Safety Instructions

6 to 7 System Backplate and Parts List

8 Typical System layout drawing

9 Pneumatic Layout drawing

10 Electrical connections

11 Rotalube information

12 Rotalube Data sheet

13 Rotalube Mounting Position

14 Rotalube information

15 System operation

16,17 & 18 Testing – Commissioning & Oil Output Adjustment

18 Lubricants

19 Lubricant Consumption

20 Maintenance

21 Trouble Shooting
Safety Instructions For Rotalube Chain Lubrication Systems.
Appropriate Use
Use the RSL Lubrication system only for dispensing lubricants. The System is designed for
intermittent use only.

Misuse. Any use of the Lubrication system that is not expressly mentioned in the Operating
Instructions, for the RSL system , will be regarded as misuse.

NOTE ; If personal injury or material damage occurs as a result of inappropriate operation eg:
if the safety instructions are ignored or resulting in incorrect installation of the system and
applicators , no claims or legal actions can be taken against Rotalube Systems Limited.

Exclusions of Liability:
The manufacturer of the System will not accept any liability for damages
• Caused by lack of lubricant
• Caused by contaminated lubricant
• Caused by lubricants not recemented or tested by Rotalube
• Cause by unauthorised modifications to the system
• Caused by incorrect Installation, electrical connection and programming
• Caused by unapproved parts
• Caused by inappropriate reaction (eg also ignoring ) malfunction signs
•
Regulations for Prevention of Accidents
To prevent accidents, observe all country safety regulations, where the product is to be used.
Avoid operation with
• Unapproved parts
• Insufficient lubricants, contaminated lubricant and unapproved lubricants

General Safety Instructions

Rotalube Lubrication systems

- Are designed specifically for each application
- Are assembled for safe operation
- Incorrect use may result in chain failure caused by lack of lubrication
- Unauthorised modifications or changes to the system are not admissible. Any
modifications must be approved by Rotalube Systems limited.
 Operation & Repair
Attention !
Risk of bursting reservoir if the reservoir is overfilled by auto fill system, do not
over fill over the marked maximum level

Warning !
Before any maintenance or repair of the system switch off the power supply
Do not work on the Rotalube applicators when the conveyor is working, isolate the
conveyor as instructed by the industry site safety Instructions ( usually in
accordance to the RISK basement and method statement.

Caution !
Do not use the pump in explosive areas

Caution !
Never put your hand inside the reservoir and wear safety glasses when operating
the pump to protect from burst pipes.

Must
be re filled on a regular basis
Operates automatically , however regular checks of the systems are require say
every 3 to 4 days to ensure oil levels are changing and lubricant is being correctly
delivered.

Repair
Repairs should be performed by authorised personnel who are familiar with the
repair instructions

Disposal
Dispose of all used and contaminated lubricants as well as the parts that were in
contact with the oil; according to legal regulations pertaining to the environmental
protection. Make sure you observe the safety and data sheets of the lubricants
used.
 Dangers due to Direct current VDC

Caution !
The Lubrication system may be installed and started by an authorised personnel only.
Non- observance of the safety instructions may result in injuries and destroy
connected electrical components.

Installation
Any safety equipment fitted to the machine
Should not be modified or made ineffective
Keep the components of the system away from sources of heat, adhere to the
operating temperatures

Use only Rotalube approved parts

Adhere to the Installation instructions as regards to drilling or welding procedures

IMPORTANT
Route the pies professionally
Firmly bolt together pressurized components

ATTENTION !
Connect t The pump and Solenoid to direct current version in relation to the
operating voltage to DIN 41755.
 System Backplate Picture 1
3 2
AIR IN 7

Bleed Point for commissioning

5
Item Part Description / Details

1 Oil Fill point See page 15

2 Pressure gauge In Line pressure gauges x 4
3 Air Regulator Regulate air pressure to Rotalubes R1 ,R2,R3 &
R4
4 Junction Box See page 10
5 Oil Injectors Adjustable Oil Injectors (see page )
6 Pump Pump with 6 Ltr reservoir and low level switch
7 24V DC Solenoid Solenoid Valve N/C 24V DC ( Min 5 Bar)
Typical System Layout.

Rotalube Air/Oil System 4 outlet

7
Typical System Layout
Pneumatics.

Rotalube Air/Oil System 4 outlet 9

Electrical Junction Box Terminal Drawing.

Junction Box , Item number 4 on page 6

Component

Pump Motor 24V DC 2.4 Amp

Air Solenoid Valve N/C 24V DC 10W 429mA

Internal Pump connections

Rotalube Air/Oil System 4 outlet

10
Rotalube Mounting Example.

Rotalube Air/Oil System 4 outlet 11

Rotalube Mounting Example.

SureFire 4 outlet 12
Rotalube Orientation
 Rotalube mounting Position
Rotalube Part Number 2819-500

Fig A Fig B

Directional indicator marked The arrows Indicate where the

Both sides of the Rotalube. Lubricant is dispensed. If you
Important make sure the RED Ensure that the RED dot is in the
Indicator dot is facing the chain Correct position , the lubricant
Will only be dispensed from the
Holes adjacent to the chain

The Rotalube Inlet is tapped 1/8” BSP Female both sides

The Inlets can be fitted with a push In fitting or a standard
compression fittings.
Fixing threads are both sides of the applicator and when mounting
the Rotalube , the Rotalube should have a gap between the sprocket
and the chain roller. ( see page 12 for details).
 System Operation .

System control.

The Lubrication system is controlled by the customers PLC or by a separate control panel.
The PLC/controller would operate the pump at pre determined intervals which should be fully
adjustable, so that the lubricant output can be increased or decreased to achieve optimum
lubrication without under or over lubricating.
On operation of the conveyor, the PLC will accumulate the operation time and operate the
lubrication system at pre-set times for example one complete cycle of the conveyor chain +5% to
ensure the whole chain is lubricated correctly. To operate the system the PLC would have to
power the pump and air solenoid valve at the same time

After the operation time has been completed the power to the pump and air solenoid would be
switched off for a pre set time by the PLC/Controller . This time will be called the dwell time. In
the PLC there should be an a memory backup that would accumulate the conveyor operation
time. For example if the chain operates for one hour and then stops , the PLC/controller will carry
on counting from the one hour when the chain restarts.
The system is to be set to only operate if the chains are operating, this to avoid oil lubricating the
same part of the chain as the chain is not moving.

For operation times , these times will all be individually set as each chain requirements are
different. Consult the Lubricant manufacturer for recommendation of oil dosage rate.

Pump Cycle Time

The pump cycle time would also be set to cycle on and off , during the lubrication system run
time (ON)
The pump cycle times will determine how many times the oil injectors (PDI`s) operate and hence
the amount of lubricant be delivered . PDI`s can be seen on page 15 and on the main system
picture on page 7.

Pneumatics (Air)
The oil dispensed by the PDI`s are delivered into a manifold , the manifold is connected to a
regulated air supply (item 4 on page 7). The air pressure can be regulated manually so that the oil
delivered to the Rotalube is not over pressurised. Most applications run at 10 to 30 PSI only, this
depends on the oil viscosity and the distance of the Rotalube from the pump.
Caution : To over pressurise will mean the lubricant may overspray and contaminate
Underpressurised will mean that the lubricant may not spit correctly onto the chain link

SureFire 4 outlet 15
 Test Pump and Injectors .

Fill the pump reservoir with the recommended oil

at the filler breather to the MAX fill line marked
on the plastic reservoir

Bleed The System.

Make sure that there is no Air in the feed from the
pump to the (PDI`s) Injectors.
Run the pump and loosen the plug as shown until you
See oil leak from the plug. Tighten the plug and seal
And the Injectors will deliver oil on each cycle of the
pump

Once the reservoir has been filled with the

recommended oil and the system Bled.
Pull out the 4mm pipes located on the push in
fittings on mixing manifold , as shown.
Turn power onto the pump and the pump will cycle.
Pressurise then de-pressurise . The injectors will
start to deliver oil on each cycle, keep the pipes
open until you see oil . Oil should flow out of the
pipe indicating that the system is functioning within
a minute or so.

Rotalube Air/Oil System 4 outlet 16

 Testing and Commissioning .

Connect the Feed Pipes to the Rotalube and turn open the air
solenoid valve open , adjust the air pressure to between 10 to
30 PSI depending on application .
Connect both Rotalubes to the two feed outlets R1 & R2 and
mount one of the Rotalubes on the test bracket or simply hold
in position by hand , ensuring the red marker is indicating that
the oil will be delivered onto the card. Hold the applicator onto
a flat surface on some card. Operate the pump and solenoid
and index the Rotalube applicator with your hand. Slowly turn
the applicator and increase or decrease the air pressure until
we see a good spray pattern.
Note: The oil output is controlled and will be very fine, the
system works on the principle of “little oil but often”.

A very light spray pattern should be observed as detailed, the air

pressure may have to be adjusted to give you the best pattern .
This pressure can alter depending on operating conditions and
length of feed line pipe. Once successfully tested repeat the test
with the second feed line and the second applicator.

Install the Rotalubes onto the pre-fabricated bracket. Ensure that the applicator teeth of the sprocket are
central and not touching the sides of the chain . Operate the line slowly and observe that the Rotalube is
running smoothly, stop and re adjust the applicators needed, if operation is not smooth.
The system operation times are now ready to be set
Operation Times.
To be determined on a case by case basis , some applications need very little oil due to the application
and the chain may be in a Food factory or the chain may be close to product.
Some applications may need larger volumes of oil due to the conditions or the chain may be large or in a
very dirty environment. ( please consult the machine manufacturer and lubricant supplier to determine
the oil requirement)

Rotalube Air/Oil System 4 outlet

17
 Lubricant Adjustable Output Injectors (PDI).

The PDI injectors are designed to displace an

accurate amount of lubricant as and when they
are cycled ( pressurised and de pressurised)

The volume of oil delivered per cycle can be

adjusted manually by taking the push in fitting
off the end of the injector and then locating a
flathead screw inside the injector.

By turning the screw:

Clockwise, this will decrease the oil flow.
Anti clockwise will increase the oil flow.

If the oil flow was to stop functioning this may

mean the screw has been fully tightened letting
no oil out.
Or the system may be airlocked below (Bleeding
the system)

Be aware that the PDI injectors are pre set to

displace 0.25cc per shot
The maximum output from an Injector is 0.5cc
per shot

The cycle time of the injector can be can be

adjusted see page 12.

18
Rotalube Air/Oil System 4 outlet
Recommended Lubricants

For best results the applicator operates with oil viscosities of 68 to 120 Cst.
Consult Rotalube Limited if the oil you are planning to use contains Esters,
Anti-Misting, Anti-Foaming, Dispersants or Tacky additives. These additives can
have a negative effect on a systems performance. Oils with solid additives such
as PTFE / Teflon, Chlorinated Paraffin’s, Graphite, Molybdenum Compounds
should not be used.
 Maintenance and up keep .

Action Period Instructions

Re – fill the reservoir Weekly Re- fill the reservoir with recommended oils at the fill
point detailed on page 15 of document
Use recommended lubricants only see
page 18.
Monitor Oil Consumption Weekly Check the oil consumption to ensure that the oil being
applied to the chain is consistent with the machines
running times.
Clean the oil filler Yearly Remove the pump filler on top of the pump reservoir
breather/strainer and clean with solvent. Dry and install back in the
same position.
Rotalube Check Monthly Check the cleanliness of the Rotalube and that the
Rotalube nozzles / outlets are not restricted by the
build up of dirt. If so remove and clean.
Check that the applicators are running smoothly in the
chain and not catching the side plates. ( Rotating Free)
Use the test bracket and test the operation of the
Rotalube before re mounting. Use the installation
gauge when re mounting the Rotalube on the line.

Rotalube Check Yearly Remove the Rotalubes and disassemble, check for
contamination internally and externally and clean
using solvent. Dry the applicators and re seal using the
repair kits.
Alternatively replace the Rotalubes with the stock
units and send the applicators to Rotalube or official
Rotalube distributor for a full re- furbish
Use the test bracket and test the operation of the
Rotalube before re mounting. Use the installation
gauge when re mounting the Rotalube on the line.
 Trouble shooting .

Problem Cause Solution

Pump does not 1. No Power Check power to the pump
work 2. Fuse Blown Check Fuse and replace
3. Loose electrical connections Check all wires and connections
4. Defective PLC Re program
5. Defective Motor Replace the motor

Chain Appears Dry 1. Empty Reservoir Re- fill the reservoir

2. Inoperative pump (see above)
3. Inoperative pump element (see above)
4. Time between lubrication cycles Adjust the time cycle
are too long
5. Reservoir filled with incorrect Re-fill with recommended oil
lubricant
6. Main feed line damage Repair pipes and fittings
7. Solenoid failure Replace the solenoid valve
8. Blocked Rotalube Inspect the Rotalube

Pump working but 1. Empty Reservoir Re- fill the reservoir with correct oil
no lubrication 2. Inoperative pump (see above)
3. Reservoir filled with incorrect Re-fill with recommended oil
lubricant
4. Main feed line damage Repair pipes and fittings
5. Solenoid failure Replace the solenoid valve
6. Blocked Rotalube Inspect the Rotalube

Over Lubrication 1. Too much oil on the chain and Adjust the time settings
chain guides
Rotalube not 1. Contamination externally Remove and clean
functioning 2. Contamination internally Remove and clean or replace
3. Mounting position incorrect Re-position the Rotalube using chain
gauge
4. Oil/air feed line delivery failure Replace or repair feed lines