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Application Manual
What it does
Oil Mist lubrication is an automatic, centralized system that
CONTINUOUSLY delivers fresh, clean oil to multiple, and
often widespread, machine elements. There are numerous
advantages to Oil Mist, in addition to the improvements in
safety, productivity, housekeeping, and lubrication that are
achieved by automatic centralized systems in general.
Continuous delivery, at rates closely approximating actual
bearing-surface needs, eliminates the overlubrication that is
necessary to insure adequate supply between periodic
applications. LUBRICANT CONSUMPTION can often be
reduced by as much as 80%.
In many cases, continuous lubricant delivery by Oil Mist
permits elimination of energy-wasting oil sumps. Reductions
in POWER consumption of more than 25% are common.
BEARING TEMPERATURES are often lowered dramatically,
not by actual cooling, but because most of the power
consumption reduction represents heat that is not generated
in churning excess lubricant.
Pressurization of housings, with continuous outward air flow,
extends MACHINE LIFE by helping to exclude dirt and
corrosive atmospheres. Oil Mist is even used to protect
equipment on standby and in storage.
How it does it
The heart of the system is the mist generator. Air from
normal factory air supply passes over a venturi inside the
generator, which accelerates the flow. This creates low
pressure and high velocity at the venturi discharge. As air
passes through the venturi it draws oil from the generator
reservoir into the high velocity air stream. The combination
of low pressure and high impact explodes the oil into tiny
How to apply it
BASIC STEPS TO DESIGN AN ALEMITE
OIL MIST SYSTEM
1. DESCRIBE each element to be lubricated and
CALCULATE its Oil Mist flow requirement in CUBIC FEET
PER MINUTE (CFM).
2. Select APPLICATION FITTING TYPES and determine
their PLACEMENT and VENTING provisions.
3. Select the DESIGN MANIFOLD PRESSURE (DMP).
4. Determine FITTINGS SIZES.
5. Select an appropriate Oil Mist GENERATOR.
6. ROUTE and SIZE air and mist distribution PIPING.
7. Select FITTNGS CONFIGURATIONS that will be most
convenient to install and connect to distribution system.
8. Select ACCESSORIES.
9. Plan ELECTRICAL CIRCUITRY.
FITTINGS PLACEMENT
PLACE SPRAY FITTINGS to discharge close to the
lubricated elements, preferably less than one inch away.
REMOTE POSITIONING of spray fittings is permissible if
their outputs are ducted to and flow through the lubricated
elements because of relative positions of fittings and vents,
and if passages downstream from the fittings are horizontal
or sloped downward toward the elements.
TO SPRAY DIRECTLY on elements moving at speeds up
to about 1600 linear feet per minute, keep spacing between
spray fittings and moving surfaces under 1/20 inch per inch
water column manifold pressure. At higher speeds, install
spray fittings 1/8 to 1/4 inch from the moving surfaces and
use higher mist pressures-40 in. H20 above 2000 lfm and
up to 80 in. H20 at much higher speeds.
From CONDENSING FITTINGS the oil flows by gravity
directly to the grooves supplying the sliding surfaces. The
fitting location should be as close to the grooves as
possible.
MIST FITTINGS may be installed in any location, providing
the mist flow envelops or passes through the elements to
be lubricated.
VENTING
VENTING must be provided for the escape of carrier air from
closed housings.
MINIMUM VENT AREA is equal to twice the total flow area of
the application fittings supplying flow to that vent. Vent areas
of this size will produce housing back pressures equal to
about 20% of manifold pressure.
Wherever possible, relative POSITIONS of VENTS,
APPLICATION FITTINGS, and LUBRICATED ELEMENTS
should produce forced flow from application fittings to
lubricated surfaces.
VENTING can be by means of approximately located
DRILLED HOLES or, frequently, by existing ports in the
housing. LABYRINTH SEALS will usually provide adequate
venting, although a small one might have insufficient
clearances for this purpose, and require the addition of a
drilled hole. CONTACT SEALS can be notched to provide
venting, but this is not recommended because of the
likelihood that notching will not be provided when seals are
replaced.
VENT PORTS can often serve as OIL OVERFLOW OR
DRAIN ports. In an oil-sump application the vent can be
placed just above the normal sump oil level to provide an
overflow path for any excess oil delivered by the Oil Mist
system. Such vents should be located so that liquid oil will
not splash out through the port. For a dry-sump application
the vent can be placed at the bottom of the housing to drain
all liquids.
VENTS should generally be PROTECTED from outside
contaminants. Holes in the sides of housings should slope
downward to the outside. Vent ports in the tops of housings
should have shielded vent fittings installed.
3. DESIGN MANIFOLD PRESSURE (DMP) is the pressure
drop across the application fittings at which the fittings sizes
are selected. It is the intended output pressure of the Oil Mist
generator. The ALEMITE STANDARD DMP IS 20 INCHES
WATER COLUMN. Occasionally, other pressures are
recommended to better meet specific application
requirements. In general, lower DMPs permit closer oil
output control. Higher DMPs are used to produce higher
output velocities from spray type application fittings to
penetrate air barriers around high-surface speed elements
(over 2000 linear feet per minute). Also, spray and
condensing fittings operate more efficiently with higher
pressure drops across them.
8. ACCESSORIES
The basic Oil Mist system components are:
a. An air line filter/water separator to assure a clean air
supply to the Oil Mist generator. (INCLUDED with some
models of Alemite Oil Mist generators, purchased
separately for others).
b. An air pressure regulator to control the atomizing air
pressure to the generator - the BASIC SYSTEM
ADJUSTMENT. (INCLUDED with some models of
Alemite Oil Mist generators, purchased separately for
others).
c. An Oil Mist generator which includes a venturi nozzle, oil
life tube, reservoir, and oil flow adjusting screw.
d. Mist distribution system to convey the Oil Mist to the
application fittings.
MODERATE SERVICE
CFM = 2x1/40=0.05
CFM CALCULATIONS
Moderate Service
cfm=DR/40
Heavy Service
cfm=DR/20
cfm=DR/14
Where
PLAIN BEARINGS
CFM CALCULATIONS
Moderate Service
cfm=LD/100
Heavy Service
cfm=LD/60
cfm=LD/30
10
GEARS
CHAINS
CFM CALCULATIONS
CFM CALCULATIONS
PDR
ROLLER Chain, power transmitting cfm =
320
Where
(100S )
S 3
cfm = WD
100
600
Where P = Pitch of chain or sprocket, in inches
D = Pitch diameter of small sprocket, in inches
R = Number of rows of chain rollers
W = Width of chain in inches
S = rpm of small sprocket
CONVEYOR Chain cfm = 3DW + 0.1LW
500
Where D = Diameter of drive sprocket, in inches
W = Width of chain, in inches
L = Length of chain, in inches
SILENT Chain
( )
11
12
13
14
15
AIR PIPING
PRESSURE DROP PER 100 FEET OF PIPE-psi
AIR FLOW
@100psi
@75F
(cfm)
1/8
.269I.D.
16
15
13
20
23
35
14
45
23
33
PIPE SIZE
1/4
.364I.D.
3/8
.493 I.D.
100
1/2
.622 I.D.
3/4
.824 I.D.
ID-in
1/4 tube
3/8 tube
1/2 tube
0.194
0.305
0.444
1/8 pipe
1/4 pipe
3/8 pipe
AREA-in2
@12fps
@15 fps
@18fps
@20fps
@24fps
0.030
0.073
0.155
0.148
0.365
0.774
0.185
0.457
0.968
0.222
0.548
1.161
0.246
0.609
1.290
0.296
0.731
1.548
0.269
0.364
0.493
0.057
0.104
0.191
0.284
0.520
0.954
0.355
0.650
1.193
0.426
0.780
1.432
0.474
0.867
1.591
0.568
1.041
1.909
1/2 pipe
3/4 pipe
1 pipe
0.622
0.824
1.049
0.304
0.533
0.864
1.519
2.666
4.321
1.899
3.333
5.402
2.279
3.999
6.481
2.532
4.444
7.202
3.039
5.333
8.643
11/4 pipe
11/2 pipe
2 pipe
1.380
1.610
2.067
1.496
2.036
3.356
7.479
10.179
16.778
9.349
12.725
20.974
11.218
15.267
25.165
12.464
16.965
27.963
14.957
20.358
33.556
21/2 pipe
3 pipe
2.469
3.068
4.788
7.393
23.939
36.963
29.925
46.207
35.905
55.440
39.898
61.601
47.878
73.927
3/16 hose
1/4 hose
3/8 hose
0.188
0.250
0.375
0.028
0.049
0.110
0.138
0.245
0.552
0.174
0.307
0.690
0.207
0.368
0.828
0.231
0.409
0.920
0.276
0.491
1.104
1/2 hose
3/4 hose
1 hose
0.500
0.750
1.000
0.196
0.442
0.785
0.982
2.209
3.927
1.227
2.761
4.909
1.473
3.313
5.890
1.636
3.682
6.545
1.964
4.418
7.854
11/4hose
11/2hose
1.250
1.500
1.227
1.767
6.136
8.836
7.670
11.045
9.204
13.254
10.227
14.726
12.272
17.672
16
100
5.3
3.7
3.0
2.4
2.1
180
8.8
5.4
4.1
3.0
2.5
300
10.5
6.1
4.6
3.7
2.9
500
12.2
7.2
5.5
4.4
3.5
800
18.0
8.5
6.5
5.1
4.0
1500
11.0
8.8
6.1
4.9
2500
15.0
10.4
7.1
5.4
5000
14.4
9.0
6.
Table Notes:
1. Table is for manifold where condensed oil flow is opposite the mist flow.
2. Table is for installations in continuous operation. For systems operating one or two shifts daily, divide slope in Table by 2.
17
INLET 1/4 OD
TUBE FTG
ORIFICE
OUTLET
1/4 NPTF (m)
OUTLET
1/8 PTF* (m)
DIAMETER
LENGTH
FLOW
AREA
381303-4
381303-6
381303-10
381303-16
381290-2
381290-4
381290-6
381290-10
381290-16
.032
.045
.055
.078
.089
.44
.44
.44
.44
.44
.00078
.00159
.00237
.00484
.00622
PREFERRED ARRANGEMENT.
INLET AND OUTLET CAN BE
INTERCHANGED
WHERE NECESSARY.
PART NO. INCLUDES:
381289-2,-4,-6,-10, OR -16 FTG
328301-4 COMP. NUT
328302-4 COMP. SLEEVE
18
ORIFICE (BAFFLED)
SIZE
LENGTH
FLOW AREA
SLOT .014 R
.38
.0003
SLOT .020 R
.38
.0006
2 SLOTS .020 R
.38
.0012
3 SLOTS .020 R
.38
.0018
5 SLOTS .020 R
.38
.0030
6 SLOTS .020 R
.38
.0036
PREFERRED ARRANGEMENT.
INLET AND OUTLET CAN BE INTERCHANGED WHERE NECESSARY.
19
DIAMETER
.024
.035
.042
.055
.067
ORIFICE
LENGTH
1.38
1.38
1.38
1.38
1.38
FLOW AREA
.000452
.000962
.00138
.00237
.00352
20
NO. OF
TOTAL
.067 DIA.
1.38 LG.
AREA
SQ. IN.
326370-1
383588-1
384280-1
.00352
326370-2
383588-2
384280-2
.00704
326370-3
383588-3
384280-3
.01056
326370-4
383588-4
384280-4
.01408
326370-5
383588-5
384280-5
.01760
326370-6
383588-6
384280-6
.02112
326370-7
383588-7
384280-7
.02464
326370-8
384280-8
.02816
326370-9
384280-9
.03168
384280-10
10
.03520
383617-11
11
.03872
383617-12
12
.04224
383617-13
13
.04576
383617-14
14
.04928
32670-10
*SAE Short
383617-10
21
22
TABLE OF COMPONENTS
CODE
COMPONENT
SOL A
TS-2
OH
OIL HEATER
HPS
LPS
LLS
TS-1
TS-3
AH
AIR HEATER
**CAP.
CAPACITOR
SOL R
NOTES:
1. This is the interconnection diagram for Oil Mist generators, but most models do not incorporate all the electrical
components.
2. Terminal boxes having the same terminal strip numbering are recommended for Modular Design Generators.
3. These terminal numbers are used in the recommended elementary diagrams (in this section) for all Oil Mist Units, even
though most models do not incorporate all the electrical components.
4. The recommended elementary diagrams in this section are intended to be representative of the majority of desired
hookups. Where feasible, likely alternatives are shown.
5. Some circuits will require removal of jumpers 2-5, 5-6 and/or 9-10.
**High volume Thermo-Aire Generators only.
23
Function of CR Contacts:
1. With CR contacts in location #1, machine cannot be started without Oil Mist system, and will shut down when there is low
oil level, low manifold pressure, or high manifold pressure.
2. With CR contacts in location #2, machine cannot be started without Oil Mist System, but once machine is started, failure of
the Oil Mist system will energize red light, but will not shut down the machine.
24
25
26
RECOMMENDED WIRING DIAGRAMS FOR OIL MIST SYSTEMS WITH OIL AND AIR
HEATERS AND INDIVIDUAL SIGNALS
This wiring diagram is recommended where Oil Mist is lubricating a machine segment of a multiple-machine operation, and
neon pilot lights are used (with master warning signals) to indicate the cause of malfunction.
Malfunction of the Oil Mist system energizes the warning signals, but does not stop the machine. The circuit shows air heater
on a separate power input.
The circuit can include 4 CR relay (15) for interlocking machine start with proper Oil Mist system operation. When 4 CR is
used, 4 CR contacts in the start circuit are normally open.
27
28
FLOW AREA
.00078
.00159
.00238
.00478
.00622
.0003
.0006
.0012
.0018
.0030
.0036
.0036
.00045
.00096
.00138
.00353
.00353
.00705
.01058
.01410
.01763
.02115
.02468
.02820
.03173
.03526
.03878
.04231
.04583
.04936
DIA.
.047
.064
.087
.111
.125
.028
.040
.055
.070
.089
.096
AREA
.00173
.00322
.00477
.00968
.012??
.00062
.00126
.00238
.00385
.00622
.00724
.132
.022
.038
.060
.118
.230
.240
.480
.720
.960
1.20
1.44
1.68
1.92
2.16
2.40
2.64
2.88
3.12
3.36
.096
.035
.052
.060
.078
.096
.096
.136
.166
.191
.213
.234
.250
.266
.290
.302
.313
.328
.344
.358
.00724
.00096
.00212
.002??
.004??
.00724
.00724
.01453
.02164
.02865
.03563
.04301
.04909
.05557
.06605
.0716?
.07???
.08???
.09294
.10066
.018
.030
.040
.090
.180
.190
.380
.570
.760
.950
1.14
1.33
1.52
1.71
1.90
2.09
2.28
2.47
2.66
.185
.029
.052
.078
.159
.300
.310
.620
.930
1.24
1.55
1.86
2.17
2.48
2.79
3.40
3.41
3.72
4.03
4.34
.236
.035
.066
.095
.198
.370
.380
.760
1.14
1.52
1.90
2.28
2.66
3.04
3.42
3.80
4.18
4.56
4.94
5.32
.277
.040
.078
.112
.230
.420
.460
.920
1.38
1.84
2.30
2.76
3.22
3.68
4.14
4.60
5.06
5.52
5.98
6.44
MIN. VENT
29
PLAIN BEARINGS
A. Moderate Service
B. Heavy Service
C. Heavy Service, High Loss
SILENT CHAIN
CONVEYOR CHAIN
cfm = PDR
320
(S/100)3
cfm = WD
600
(S/100)3
CAMS
For heavy-duty bearings, with oil sumps, very lightly loaded: cfm = DR/80. Double-lip seals: D = D/40.
NOTES
NOTES
NOTES