www.vogelag.com General information Flow limiters are used in large circulating-oil lubrication systems. The task of a flow limiter is to divide up the volumetric flow of the main line into parallel individual volumetric flow quantities and to limit these according to requirements, or to keep them constant. The volumetric flow produced does not depend on the system pressure and is nearly independent of viscosity. It is also possible to switch from the rated volumetric flow of the SP/ SMB10 to a reduced starting flow (1 : 4) to keep cold bearings from overflowing The SP/SMB 10... flow limiter was developed specially for mounting plates. The advantage of this design is its simple and compact construction. Using interchangeable plug-in nozzles, the volumetric flow of the flow limiter can be set stepwise from 0.210 to 8.18 l/min.That makes it possible to adjust the volumetric flow rates at a later date. The SP/SMB 10... Group comes with a visual/electronic gear wheel-type flow indicator. 1-3003-US Flow limiter SP/SMB10 ... Design The SP/SMB 10 flow limiter consists of the following: flow limiter housing (with sensor) flow limiter regulating assembly (with control piston, plug-in nozzle and pressure spring) gear pair flow limiter cover (with sight glass, seals, plugs and fastening screws) baseplate. The housing, gears and cover consist of an anodized aluminum alloy to ensure corrosion-resistance and low weight. A round glass disk conforming to DIN 8902 (pressed hard glass) is used for the sight-glass pane. The pane floats in the cover to avoid distortion and premature failure. The housing accommodates a sensor that is actuated by pin magnets embedded in the gear. Fig. 1 Flow Limiter SP/SMB 10... on baseplate with gear wheel- type flow indicator and changeover valve Flow limiter SP/SMB 10... 1-3003-US 2 Zentral- schmierung Zentral- schmi erung Mode of operation With the flow limiter SP/SMB 10...flow limiter, the total volumetric flow Q is divided up into individual flow lines Q, by the parallel layout of the volume limiter on the mounting plate. The system pressure, being the input pressure p 1, is thus maintained for all flow limiters. Every flow limiter has a control piston with a plug-in nozzle as a differential pressure regulator. The differential pressure (p 1 -p 2 ) at the interchangeable plug-in nozzle D 1 in the control piston is based on a balance of forces p 1 A = p 2 A + F resp.. p1/2 = p 1 - p 2 = F/A = constant. It follows that: The difference in pressure in front of and behind variable nozzle D 2 is held constant by a balance in pressure. Only one respective nozzle of the two plug-in nozzles D 1 and D 2 is active in this respect. In the starting phase, oil flows through both nozzles, but only the smaller of the two (D 1 ) is active. Starting phase p II > p I The starting volumetric flow should not, however, be greater than 1/4 the volumetric flow in normal operation. Operation In normal operation (see Fig. 3 for changeover-valve switch position) only nozzle D 2 is actuated. p I > p II For this function the system pressure p I must always be greater than the sum of the pressure drops in and downstream of each flow limiter. p I > (p 1 - p 2 ) + p 3 For this reason the pumps volumetric flow should exceed all the individual flow quantities by approx. 15 %, i.e., Q = 1,15 ( Q i ). The downstream gear wheel-type flow indicator uses a dynamic pulse generator (24 V DC) to emit a continuous sequence of pulses proportional to the volumetric flow. The proportionality factor K1 is derived from the swallowing capacity of one revolution of the gear pair (K1 = 12.0 ml/pulse). The sequence of pulses can be displayed and monitored by pulse-monitoring equipment, group monitoring units or a central evaluation station. p 1 Pressure upstream of the active plug-in nozzle p 2 Pressure downstream of the active plug-in nozzle p 3 Pressure downstream of ZK p I Operating pressure p II Control pressure (p I + 10 bars) D 1 Plug-in nozzle / starting phase D 2 Plug-in nozzle / normal operation A Cross-sectional area of the control piston RK Control piston F Spring force ZK Gear wheel-type flow indicator UV Changeover valve IW Pulse monitoring unit IA Pulse display and programming unit Functional diagram Fig. 3 Functional diagram SP/SMB 10... Fig. 2 Design of Flow limiter SP/SMB 10... IW F ZK RK D 2 D 1 p 1 p 2 D 3 p 3 P I P II IA Fig. 4 Connection of gear wheel-type flow indicator E1 Plug DIN 43650 1 2 3 SH UV Flow limiter SP/SMB 10... 1-3003-US 3 Key to order codes Flow limiter SP/SMB 10.. - for mounting plates - Reference Order baseplate separately (see page 7-9). Also see plug-in nozzle tables on pages 4 to 5) Technical Data Flow limiter General information Type ........................................ selectable 2-way flow limiter valve with volumetric flow control Application .............................. for mounting plates Fitting position ........................ any (make sure the filter is mounted in a vertical position) Ambient temperature range ... 0 to + 70 C Material ................................... AlCuMgPb F38, neutrally anodized Weight ..................................... 1.4 kg Hydraulic Nominal volumetric flow ( also see related tables) ........................................... stepwise from 0.21 bis 8.15 l/min Working pressure p 1 .................6 to 50 bars Control pressure P II ................16 to 60 bars Required differential pressure between input pressure p 1 and output pressure p 3 ........... 6 bars Lubricant ................................. mineral oils, synthetic oils and ecofriendly oils Lubricant temperature range .. 0 to + 90 C 1 ) Operating viscosity ..................... 20 to 600 mm/s Gear wheel-type flow indicator Sensor.....................................Hall sensor Power.......................................24 V DC 10% Max. switched current.............20 mA Connection..............................plug, DIN 43 650 Type of enclosure....................IP65 Proportionality factor ..............12.0 ml/pulse 1) Only when ambient temperature < 60 C. SP/SMB 10/2 E1 /_ _ _-_ _ _ Volumetric flow control /0 = without electrical monitoring E1 = with electrical monitoring (PNP technology, 24 V DC) (continuous pulse sequence, proportional to volumetric flow) Order description Nozzle type D 1 Part number 24-2710- _ _ _ _ Nozzle type 0 = without electrical monitoring 1 = with electrical monitoring Order example (SP/SMB10/2E1/050-100) Flow limiter, type SP/SMB and size (10), outfitted with nozzle (/2), with electrical volumetric flow check (E1), nozzle sizes 050-100 mm with a rated volumetric flow ratio of 1:4 = 210:850 ml/min (D 1 = 050, D 2 = 100) (/050-100). Part number 24-2710-1003 Nozzle type D 2 Flow limiter SP/SMB 10... 1-3003-US 4 Plug-in nozzle table for flow limiters with a starting/operating volumetric flow ratio of 1 : 4 Nominal volumetric flow 1 ) Flow limiter Flow limiter 1:4 Order description Part number [ ml/min ] [D 1 -D 2 ] 210 : 850 SP/SMB 10/ 2 E1/050-100 24-2710-1003 260 : 1020 055-110 -1004 300 : 1220 060-120 -1005 360 : 1430 065-130 -1006 410 : 1660 070-140 -1007 480 : 1910 075-150 -1008 540 : 2170 080-160 -1009 610 : 2450 085-170 -1010 690 : 2750 090-180 -1011 760 : 3060 095-190 -1012 850 : 3390 100-200 -1013 930 : 3740 105-210 1014 1020 : 4100 110-220 -1015 1120 : 4490 115-230 -1016 1220 : 4880 120-240 -1017 1320 : 5300 125-250 -1018 1430 : 5730 130-260 -1019 1550 : 6180 135-270 -1020 1660 : 6650 140-280 -1021 1780 : 7130 145-290 -1022 1910 : 7630 150-300 -1023 2040 : 8150 155-310 -1024 Plug-in nozzles - see the following table 210 SP/SMB 10 /2E1/ 550-050 24-2710- 1050 0.50 050 24-0455-2574 260 -055 - 1055 0.55 055 -2575 300 -060 - 1060 0.60 060 -2576 360 -065 - 1065 0.65 065 -2577 410 -070 - 1070 0.70 070 -2578 480 -075 - 1075 0.75 075 -2579 540 -080 - 1080 0.80 080 -2580 610 -085 - 1085 0.85 085 -2581 690 -090 -1090 0.90 090 -2582 760 -095 - 1095 0.95 095 -2583 850 -100 - 1100 1.00 100 -2584 930 -105 - 1105 1.05 105 -2585 1020 -110 - 1110 1.10 110 -2586 1120 -115 - 1115 1.15 115 -2587 1220 -120 - 1120 1.20 120 -2588 Continued on next page! Plug-in nozzle table for flow limiters with a starting/operating volumetric flow ratio of 1 : 1 [ml/min] [D 1 - D 2 ] [ mm] [Type] Part number Nominal volumetric flow 1 ) Flow limiter SP/SMB 10... Order description Flow limiter SP/SMB 10.. Part number Plug-in nozzle D 2 Complete spare part Flow limiter SP/SMB 10... 1-3003-US 5 [ml/min] [D 1 - D 2 ] [ mm] [Type] Part number Plug-in nozzle table for flow limiters with a starting/operating volumetric flow ratio of 1 : 1 Nominal volumetric flow 1 ) Flow limiter SP/SMB 10... Order description Flow limiter SP/SMB 10.. Part number Plug-in nozzle D 2 Complete spare part Plug-in nozzle D 1 Complete spare part [ mm] [Type] Part number 5.50 550 24-0455-2629 1) at a service viscosity of 300 mm/s. 1320 SP/SMB 10 / 2 E1 /550 -125 24-2710- 1125 1.25 125 24-0455-2589 1430 -130 - 1130 1.30 130 -2590 1550 -135 - 1135 1.35 135 -2591 1660 -140 - 1140 140 140 -2592 1780 -145 - 1145 1.45 145 -2593 1910 -150 - 1150 1.50 150 -2594 2040 -155 - 1155 1.55 155 -2595 2170 -160 - 1160 1.60 160 -2596 2310 -165 - 1165 1.65 165 2597 2450 -170 - 1170 1.70 170 -2598 2600 -175 - 1175 1.75 175 -2599 2750 -180 - 1180 1.80 180 -2600 2900 -185 - 1185 1.85 185 -2601 3060 -190 - 1190 1.90 190 -2602 3220 -195 - 1195 1.95 195 -2603 3390 -200 - 1200 2.00 200 -2604 3560 -205 - 1205 2.05 205 -2605 3740 -210 - 1210 2.10 210 -2606 3920 -215 - 1215 2.15 215 -2607 4100 -220 - 1220 2.20 220 -2608 4290 -225 - 1225 2.25 225 -2609 4490 -230 - 1230 2.30 230 -2610 4680 -235 - 1235 2.35 235 -2611 4880 -240 - 1240 2.40 240 -2612 5090 -245 - 1245 2.45 245 -2613 5300 -250 - 1250 2.50 250 -2614 5510 -255 - 1255 2.55 255 -2615 5730 -260 - 1260 2.60 260 -2616 5960 -265 - 1265 2.65 265 -2617 6180 -270 - 1270 2.70 270 -2618 6410 -275 - 1275 2.75 275 -2619 6650 -280 - 1280 2.80 280 -2620 6890 -285 - 1285 2.85 285 -2621 7130 -290 - 1290 2.90 290 -2622 7380 -295 - 1295 2.95 295 -2623 7630 -300 - 1300 3.00 300 -2624 7890 -303 - 1305 3.05 305 -2625 8150 -310 - 1310 3.10 310 -2626 Flow limiter SP/SMB 10... 1-3003-US 6 Hydraulic changeover valve Type ...................................... hydraulic 3/2-way valve Material ................................. AlCuMgPb F38, neutrally anodized Weight ................................... 0.42 kg Fig. 5 hydraulic changeover valve Order Information hydraulic changeover valve ....Part number... 24-1883-2093 Electrical changeover valve Type ..................................... electrical 4/2-way valve Rated votage .......................... 230 V AC, 50 Hz or 24 V DC Weight ..................................... 6.5 kg Order Information Electrical changeover valve 230 V AC ................................................ Part number.. 24-1254-2487 Electrical changeover valve 24 V DC ................................................ Part number.. 24-1254-2486 Fig. 6 Electrical changeover valve Oil filter with shut-off valve Material: Housing.............................. AlCuMgPb F38, neutrally anodized Cloth ..................................... V4A Mesh spacing ....................... 0.1 mm Weight ..................................... 2.3 kg Order Information Oil filter with shut-off valve... Part number 24-0651-3041 Fig. 7 Oil filter with shut-off valve Dummy element Application ............................ to blank off unused mounting plate outlets Material ................................. AlCuMgPb F38, neutrally anodized Model: ................................... with mounting screws M8 30 and sealing rings Weight ..................................... 0.8kg/each Order Information Dummy element ..................... Part number 24-0711-2406 Fig. 8 Dummy element Flow limiter SP/SMB 10... 1-3003-US 7 Mounting plate for a flow limiter und hydraulic changeover valve Material ................................... AlCuMgPb F38, neutrally anodized Weight ..................................... see the following table Fig. 9 Baseplate for 1 to 6 SP/SMB 10 flow limiters Number of flow limiters Dim. A Weight Part number [ n ] [ mm ] [ kg/each ] 1 162 2.00 24-0714-3231 2 243 2.75 24-0714-3232 4 405 4.25 24-0714-3234 6 567 5.75 24-0714-3236 Flow limiter SP/SMB 10... 1-3003-US 8 Baseplate for 1 to 6 flow limiters, hydraulic changeover valve and oil filter Material ................................... AlCuMgPb F38, neutrally anodized Weight ..................................... see the following table Number of flow limiters Dim. A Weight Part number [ n ] [ mm ] [ kg/each ] 1 221 2.25 24-0714-3241 2 302 3.0 24-0714-3242 4 464 4.5 24-0714-3244 6 626 6.0 24-0714-3246 Fig.10 Baseplate for 1 to 6 flow limiters, hydraulic changeover valve and oil filter Flow limiter SP/SMB 10... 1-3003-US 9 Baseplate for 1 to 6 flow limiters, electrical changeover valve and oil filter Material ................................... AlCuMgPb F38, neutrally anodized Weight ..................................... see the following table Number of flow limiters Dim. A Weight Part number [ n ] [ mm ] [ kg/each ] 1 247 2.5 24-0714-3261 2 328 3.2 24-0714-3262 3 409 4.0 24-0714-3263 4 490 4.8 24-0714-3264 5 571 5.6 24-0714-3265 6 652 6.4 24-0714-3266 Fig.11 Baseplate for 1 to 6 flow limiters, electrical changeover valve and oil filter Flow limiter SP/SMB 10... 1-3003-US 10 Example of a circulating-oil lubrication system Before lubrication begins the lubricant is heated inside the pressurized-oil station (1). The delivery line (2) cuts in when the specified lubricant temperature is reached. The lubricant now flows back to the pressurized-oil station (1) via the delivery line (2), enabled warm-up lines (3) and return line (4). (The flow limiters (5) are not monitored in this period of time.) The flow limiters (5) are switched to when the specified lubricant temperature is reached. The hydraulic (6) and/or electrical changeover valve (7) on the flow limiters (5) actuates startup plug-in nozzle D 1 . This nozzle reduces the rated volumetric flow to a lower starting flow of 1:4. At the same time, electrical monitoring of the flow limiters is activated. A thermostat (8) on the return line (4) determines the returning lubricants temperature. When the specified lubricant temperature is reached, the hydraulic (6) and/or electrical changeover valve (7) switches to normal-operation nozzle D 2 . The nozzle adjusts to the full rated volumetric flow. Group pulse monitoring units (9) see to evaluation of the signals arriving from the flow limiters (5). Progressive feeders (10) can be additionally installed downstream of the flow limiters (5). 1 Pressurized-oil station 2 Delivery line 3 Warm-up line 4 Return line 5 Flow limiter with changeover valve 6 Hydraulic changeover valve 7 Electrical changeover valve 8 Thermostat 9 Group monitoring units 10 Progressive feeders 11 Control pressure line 1 2 3 4 3 5 5 7 6 8 9 10 10 Fig.12 Example of a circulating-oil lubrication system 11 9 Flow limiter SP/SMB 10... 1-3003-US 11 Replacing plug-in nozzles Interrupt oil feed to flow limiter above shutoff valve (at oil filter, if required). Control piston held under spring pressure! Slowly screw out stop screw (hexagonal head, WAF 12) together with washer. Burn injury hazard! Escaping oil is possibly hot! Remove control piston with plug-in nozzles (D 1 /D 2 ) and pressure spring. Attention! When reinstalling the plug-in nozzles make sure they are not mixed up! Consult the rated volumetric-flow table on pages 4-5 for the selection of plug-in nozzles. Dismantling/installation of plug-in nozzle D 1 Dismantling/installation of plug-in nozzle D 1 Remove plug-in nozzle D 1 (with washer) from control piston. A roughly 6 mm rod (never use a pointed object like, for instance, a scriber) can be used to help press it out. Press new plug-in nozzle D 1 and washer firmly into the control piston all the way to the stop with the nozzle opening pointing upward (nozzle type legible). Dismantling/installation of plug-in nozzle D 2 Loosen and remove retaining ring from the control piston. Remove plug-in nozzle D 2 (with washer) from the control piston. A roughly 6 mm rod (never use a pointed object like, for instance, a scriber) can be used to help press it out. Press new plug-in nozzle D 2 and washer firmly into the control piston all the way to the stop with the nozzle opening pointing upward (nozzle type legible). Insert retaining ring in control piston. Insert pressure spring in the borehole. Insert control piston with new plug-in nozzle(s) in the borehole over the pressure spring without skewing. Check to make sure the control piston moves easily by pressing it against the pressure spring. Skewing leads to malfunctions. Screw in stop screw with washer. Open the shutoff valve. Designation Part number Flow limiter SP/SMB10... without nozzle, with electrical 24-1883-3020 monitoring Gasket set for SP/SMB 10... 24-0404-2341 Oil filter with shut-off valve Filter insert 24-0651-2200 Gasket set for filter 24-0404-2293 Interchangeable strainer 24-2104-2009 Hydr. changeover valve Gasket 24-0404-2281 Gear wheel-type flow indicator Sight glass (with flange, seals and shims) 24-0758-2113 Replacement parts Accessories Designation Part number Group monitoring unit 84-8011-0369 Fig. 13 Replacing plug-in nozzles 1 Stop screw with washer 2 Plug-in nozzle D 1 (startup 1:4) with washer 3 Retaining ring 10x1 4 Plug-in nozzle D 2 (normal operation 1:1) with washer 5 Control piston 6 Pressure spring 7 Flow limiter housing Flow limiter SP/SMB 10... 1-3003-US 12 W e
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1 0 / 2 0 0 4 Willy Vogel AG 2. Industriestrasse 4 68766 Hockenheim Germany Tel. +49 (0) 62 05 / 27-0 Fax +49 (0) 62 05 / 27-101 info@vogel-berlin.de www.vogelag.com Willy Vogel AG Motzener Strasse 35/37 12277 Berlin, Germany PF 97 04 44 . 12704 Berlin Tel. +49 (0) 30-720 02-0 Fax +49 (0) 30-720 02-111 info@vogel-berlin.de www.vogelag.com VOGEL France SAS Rue Robert Amy, B.P. 130 49404 Saumur cedex France Tel. +33 (0) 241 404 200 Fax +33 (0) 241 404 242 info@vogelfrance.com www.vogelfrance.com Notice! All products from Willy Vogel AG may be used only for their intended purpose. If operating instructions are supplied together with the products, the provisions and information therein of specific relevance to the equipment must be observed as well. In particular, we call your attention to the fact that hazardous materials of any kind, especially the materials classified as hazardous by EC Directive 67/548/EEC, Article 2, Par. 2, may only be filled into VOGEL central lubrication systems and components and delivered and/or distributed with the same after consultation with and written approval from Willy Vogel AG. No products manufactured by VOGEL are approved for use in conjunction with gases, liquefied gases, pressurized gases in solution and fluids with a vapor pressure exceeding normal atmospheric pressure (1013 mbars) by more than 0.5 bar at their maximum permissible temperature.