HSA TD Nozzles

Owner’s Manual
Operating Instruction & Spare Parts list

PDD-OM-00000 MAR2004
Lincoln – Spray Lubrication System

Type – H S A-TD-25 - 30
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Lincoln Helios (India) Ltd, Devanahalli Road, Off Old Madras Road, Bangalore – 560 049 Tel: 080-8472727, 8472424
E-Mail: mktg@lincolnindia.com www.lincolnindia.com
Owner’s Manual
Table of Contents
1. Functional Description 3-6
2. Operation of spray nozzle 7, 8
3. Spray lubrication system 9
4. Diagram of HSA-TD-25 nozzle 10
6. Bill of materials of HSA-TD-25/26 12
11. Bill of materials of HSA-TD-27-30 17
12. Starting of system 18
13. Maintenance 19
14. Trouble shooting 20, 21
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Lincoln – Spray Lubrication systems type HSA.
Functional description of HSA.
Lincoln spray lubrication type HSA for applying adhesive lubricants to heavy-
duty pinion gears of rotary kilns and tube mills, also to racks of side-guards
manipulators in rolling mills.
The specially developed adhesive lubricants are characterised by an high

resistance to pressure and to shearing and by a very low consumption. Their
consistence in the range of NLGI class 00 and NLGI class 0. Their solids content
is up to 12% for start-up lubricants and 5% - 8% for operating lubricants.
Generally adhesive lubricants are delivered by piston pumps and finely

distributed onto the surfaces to be lubricated using compressed air and wide-
angle spray nozzles.
The pump and the type of wide-angle spray nozzle depend on the desired
degree of automation of spray lubrication system. Electrical container pumps
(model 215) or pneumatic barrel pumps (model SAF) are used for pumping the
lubricant.
As for the wide-angle spray nozzles, a distinction is made between uncontrolled

nozzles and controlled nozzles.
Both models are available as individual nozzles with bracket and as nozzle
assemblies mounted on a mounting plate.
The only uncontrolled nozzle available is model SD (HSA-TD2), while controlled

nozzles may come in different models, depending on their design (type of
electrical monitoring, with bracket or on mounting plate). Please refer to the
following type explanation for the models available:
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Example of type designations:
SDL MNR
SDL HKR ESG
SD = Spray nozzles
L = Air controlled
M = Nozzle body with thread M12 for fastening on

mounting plates
H = Nozzles body with 8.5 mm bore for individual
mounting using a bracket.
N = without monitoring (monitoring at the
metering device)
K = with monitoring
R = with lubricant feedback
ES = electrically mounted nozzle (mechanical position switch)

EN = electrically monitored nozzle (proximity switch)
G = with screw-in thread.
The designation wide-angle spray nozzle illustrates the spraying pattern resulting from
the use of commercially available adhesive lubricants:
The number of nozzles depends on the width of the pinion gear to be lubricated. One
nozzle can lubricate a surface approx. 150mm wide (at distance between nozzle to gear is
approx. 180mm). For 1-pinion drive and 2-pinion drives, we recommend to lubricate the
load-carrying tooth profile of the driving pinion. The schematic of a spray lubrication
system for a 1-pinion & 2 pinion drive with a pneumatic pump type SAF is shown in
page 5 and 6.
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Operation of the Wide-Angle spray nozzles.
The air line and grease line are connected to spray nozzle of their respective ports. Refer
to Fig.1 in page no.8. The lubricant which has been delivered by the pump flows through
the delivery channels which have been bored in the nozzle and reaches the piston (Item
A), which blocks its path. Because the delivery path is blocked, the pressure in the
delivery channel rises and this results in the piston (Item B) being moved. The valve plate
(Item C) is pressed against the compression spring (Item D) by the piston (Item B). The
air valve opens and the air supply to the nozzle is freed.
Through a channel, which is not shown in Fig.1 the air reaches the air piston (Item E).
The air pressure, which is now in existence in front of the air piston, now causes the air
piston to move and the annular groove of the piston (Item A) moved into the delivery
path of the lubricant. The lubricant which has up till now been held behind the piston
(Item A) can now continue its way through the connecting channels to the nozzle element
(Item F).
At the same time, the compressed air reaches the nozzle element (Item F). The lubricant
and compressed air thus take different paths and are mixed only after they have left the
nozzle.
If the nozzle is functioning correctly, then the piston (Item A) presses the piston rod (Item
G) and the passage for the lubricant is freed at the same time piston rod (item G)and
actuates proximity switch (Item H).
Should the lubricant for any reason fail to be supplied, then there will be no overpressure
in front of the piston (Item B); the valve plate (Item C) will not open and the air piston
(Item E) with piston (Item A) and piston rod (Item G) will not be moved.
As a result the lubricant divider valve will not function and the proximity switch will not
be activated within the pre-set time. A fault signal will be given.
If compressed air is not supplied to the nozzle then the air pressure necessary for moving
the air piston (Item E) and piston (Item A) will not be available. Thus lubricant cannot be
discharged, causing the lubricant divider valve to be blocked; the proximity switch is not
activated within the pre-set time and a fault signal is given.
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Wide-Angle spray nozzles.
Fig. 1
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Operational description of grease spray lubrication system.
The working logic of grease spray system which is most suitable for the drive pinion of
girth gear has been summarized as under with reference to the schematic drawing of this
manual Fig. No 5 and 6.
The mechanical and electrical assemblies are to be inter-connected as per the drawing
and the system shall be switched on through the local control panel. The pneumatic barrel
mounted pump starts running as the solenoid energized and opens the air supply. The
lubricant being pumped to the distributor model SSV through the lubricant lines
connected after filtering through the filter.
The distributor SSV distributes the lubricant in a progressive manner and lubricant is fed
to the spray nozzles under the required pressure. Due to this, the spray nozzle starts its
operation and opens the port for the air to enter the nozzle element. The air passes
through a separate internal path and comes out of the nozzle tip gets atomized and is
sprayed to the pinion.
In view of the interlinked operations of grease and air path, the nozzle will not operate if;
either adequate grease pressure or air pressure is not available. The limit switch /
proximity switch provided at the nozzle immediately gives indication of fault signal can
be used for closing the air solenoid valve which will stop air supply to the pump as well
as to the nozzles and for indications at your PLC thereby ensuring safety of the pinion
and gear against lack of lubrication.
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Spray nozzle model HSA TD 25
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Bill of materials - Spray nozzle model HSA TD 25 / 26
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Bill of materials - Spray nozzle model HSA TD 27 - 30
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1. Starting up
1.1 Pneumatic barrel pump model SAF

The pneumatic barrel pump model SAF is tested in the factory with lubricant. To do this, the air
is removed from the pump, and is filled with lubricant. During storage and delivery, the lubricant
remains in the pump.
When the pump is put into operation, it is therefore not necessary to remove the air from the
pump.
Note:
When changing the barrel, please make by all means sure that no dirt or foreign particles will
enter the barrel.
The lid must smoothly rest on the rim of the barrel.

Do not start up the pump unless it has been put on a full lubricant barrel.
1.2 Spray panel mounting plates

During transport the mouthpieces of the spray nozzle are covered with adhesive tape, which must
be removed before they are put into operation. The spray panel mounting plate is fixed in such a
way that, the spray panel plate and the flank of the tooth are parallel.
1.3 Testing the operation of spray nozzles

• Switch on the system
• Lubricant and compressed air emerge from the spray nozzles.
• Check the function of the nozzles on the mounting plate.
• The spray pattern of the nozzles must be checked by using a strip of paper which is fixed
at a distance of about ~200mm from the nozzle. An even surface of 80mm in height
should be sprayed with lubricant across the completed width of the teeth. The spray
pattern should be achieved within 5 minutes operation.
• If the spray pattern is not horizontal loosen the nozzle inset holding screw (i.e.
Item no. 32 & 33 in case of HSA TD 25 / 26, Item no 33 & 34 incase of HSA TD
27, 28, 29, 30) and rotate nozzle element to get the desired angle of pattern.
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1.4 Checking the automatic starting up
• Switch on the system through switching on the main switch and the interlocking contact
of the drive.
• The pulse time begins to run.
• Once pulse time has elapsed, the holding time starts up.
• The SAF pump begins to operate.
• The cycle time begins to run at the pulse generator.
• The nozzles spray.
• When the cycle time has elapsed, the pause time begins to run.
• Once the pause time has elapsed, the cycle is repeated.
2. Maintenance
The following part of the system must be checked at regular intervals:
2.1 Strainer assembly.

Increasing contamination of the strainer assembly indicated by the constantly rising
pressure shown on the pressure gauge. In this case, the strainer assembly should be
cleaned and the coarse and fine filters if necessary , to be replaced.
2.2 Air filter

Drain the moister at least once in a day and clean the bowl at least once in a week.
2.3 Pressure regulator

Check proper functioning of pressure gauge.
2.4 Solenoid valve

These should be cleaned at fairly long intervals of time.
2.5 Air lubricator

Check oil level once a day and pour oil once in 4 days.
2.6 Air pressure switch

Check the functioning of air pressure switch once in a month.
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3 TROUBLE SHOOTING:
No lubricant is emerging at the nozzles and there is over pressure reading at the pressure
3.1
gauge, I.e. the pump discharges.
SLNO CAUSE REMEDY
3.1.1 Lubricant filter blocked:
Lubricant emerges from the safety valve of the Remove strainer assembly, clean if possible replace the
over pressure mechanism strainer.
3.1.2 Divider valve blocked:
Lubricant emerges from the safety valve of the Remove all feed lines from the divider valve. If lubricant
over pressure mechanism continues to emerge from the divider valve, dismantle the
piston from divider valve clean / re-assemble.
3.1.3 Divider valve leakage:
Lubricant line at outlet side of divider vlave is Check system line for loose fittings, re-tighten fittings,
leaking repalce defective tubes.
3.1.4 No air supply
No compressed air is available or air pressure is Check pressure gauge on the spray unit and
too low. maintenance unit, if necessary increase air pressure.
Check compressir and air lines. Check the filter element
on the water separator.
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Owner’s Manual
3.2 No lubricant is emerging at the nozzles and there is no pressure reading at the pressure gauge.
SLNO CAUSE REMEDY
3.2.1 There is no lubricant left in the barrel Replace barrel.
The pump has sucked in air. Dis-engage the pump outlets coupling and open needle
valves on top of the pump which are provided for air
3.2.2 venting. Switch on the pump till air less grease emerges
from the needle valve. Put back the pump outlet
couplings and close needle valves.
Lubricant lines are leaking. Check system lines for loose fittings. Re-tighten fittings /
3.2.3
replace defective tubes and fittings.
Suction valve contaminated or defective. Lift the pump out of barrel. Remove suction valve, clean /
3.2.4 replace if required. Put back suction valve assembly.
Note:
when re-assembling , after cleaning or repalceing the
suctionvalve, the pump has to be vented as described
under 3.2.2
Pressure valve contaminated. Lift the pump out of barrel. Remove pressure valve
3.2.5 assembly clean / replace if required. Put back pressure
valve assembly.
Check valve contaminated Lift the pump out of barrel. Remove coupling nut and
3.2.6 remove tubing.. Unscrew the check valve, clean or
replace if necessary
Solenoid valve for pump operation does not open Clean and possibly replace solenoid valve.
3.2.7
or close.
3.3 Air emerges constantly at the nozzles.

SLNO CAUSE REMEDY
Valve plate does not seal correctly, Clean and possibly replace valve plate, Replace
3.3.1
compression spring broken compression spring
Clogged nozzle prevents lubricant from being Remove lock nut and screw. Draw out nozzle element
3.3.2
discharged. and clean with petrol.
3.3.3 Valve piston does not move Remove valve piston and clean bore and piston.
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Owner’s Manual

Operating Instruction & Spare Parts list

Lincoln – Spray Lubrication System

1. Functional Description 3-6

2. Operation of spray nozzle 7, 8

3. Spray lubrication system 9

4. Diagram of HSA-TD-25 nozzle 10

5. Diagram of HSA-TD-26 nozzle 11

6. Bill of materials of HSA-TD-25/26 12

7. Diagram of HSA-TD-27 nozzle 13

8. Diagram of HSA-TD-28 nozzle 14

9. Diagram of HSA-TD-29 nozzle 15

10. Diagram of HSA-TD-30 nozzle 16

11. Bill of materials of HSA-TD-27-30 17

12. Starting of system 18

14. Trouble shooting 20, 21

Lincoln – Spray Lubrication systems type HSA.

Functional description of HSA.

The specially developed adhesive lubricants are characterised by an high

Generally adhesive lubricants are delivered by piston pumps and finely

As for the wide-angle spray nozzles, a distinction is made between uncontrolled

The only uncontrolled nozzle available is model SD (HSA-TD2), while controlled

Example of type designations:

M = Nozzle body with thread M12 for fastening on

ES = electrically mounted nozzle (mechanical position switch)

Operation of the Wide-Angle spray nozzles.

Wide-Angle spray nozzles.

Operational description of grease spray lubrication system.

Spray nozzle model HSA TD 25

Spray nozzle model HSA TD 26

Bill of materials - Spray nozzle model HSA TD 25 / 26

Spray nozzle model HSA TD 27

Spray nozzle model HSA TD 28

Spray nozzle model HSA TD 29

Spray nozzle model HSA TD 30

Bill of materials - Spray nozzle model HSA TD 27 - 30

1.1 Pneumatic barrel pump model SAF

The lid must smoothly rest on the rim of the barrel.

1.2 Spray panel mounting plates

1.3 Testing the operation of spray nozzles

1.4 Checking the automatic starting up

2.1 Strainer assembly.

2.2 Air filter

2.3 Pressure regulator

2.4 Solenoid valve

2.5 Air lubricator

2.6 Air pressure switch

3.3 Air emerges constantly at the nozzles.

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