Training Manual

TRAINING
MANUAL
Contents
Purpose 4
Your New Sloan Watchman Lubrication System 4
System Overview 5
Design 5
How it Works 6
Series Progressive Lubrication 7
System Design: Your Custom Lubrication System 9
Calculating Lubrication Rates 10
Multi-Zone Divider Block Systems 11
Oil Supply 12
The SLS Pump 15
Motor Driven Lubricator 19
Engine Driven Lubricator 21
Gauge Assembly 21
SB Divider Block 23
Calculating Displacement 25
Divider Blocks 26
Check Valves: General 28
Omni-Check Valve 29
Single Poppet Check Valves 29
Omni Gas-Trap 30
Balancing Valves 31
Mechanical Indicators 31
Magnetic Proximity Switch 32

© 2016 SLOAN LUBRICATION SYSTEMS

 Wizard V Monitor 33
Specifications 33
Overview 35
Installation 37
Installation and Startup 38
Watchman Pre-Installation Considerations 38
Electrical Hook-Ups 39
Tubing 39
Installation Instructions 40
Pre-Startup Priming Procedure 42
Final Inspection and Verification of Operation 43
Operation and Adjustment 44
Maintenance 45
Preventative Maintenance Scheduling 45
Services 45
Annual Maintenance 46
Divider Block Maintenance 47
Other Maintenance Items 47
Troubleshooting Guide 48
Wizard Registers A Failure 48
Following Pin Indicators 49
Contact Information 50

[Link] | 1.800.722.0250
Training Manual | Purpose

Purpose
The purpose of this manual is to serve as a guide during the Sloan Lubrication System training class, as well
as to serve as a reference at a later date. This manual contains proprietary information that is the result of
Sloan’s decades of experience in the field of industrial lubrication. Sloan provides this information as a service
to our customers.

Our primary goal at Sloan is to provide truly outstanding service to our customers, and to do everything within
our means to keep their lubrication systems running trouble free.

It is important to note that the “Maintenance and Troubleshooting” sections contain a wealth of situation
based troubleshooting advice, recommended replacement intervals for wear parts and guidelines for regular
maintenance. Following these guidelines is an excellent way to prevent unwanted down time and costly
repairs, however it is important to note that the complexities of real world situations often present new or
unexpected challenges that are not able to be covered in these pages.

Should unexpected challenges arise, we are always on call. With our experience and troubleshooting skills we
can often get you back up and running with unprecedented speed.

REMEMBER: We are only a phone call away at 1-800-722-0250

Your New Sloan Watchman

Lubrication System
The Sloan Watchman Lubrication System is a state of the art fully-automated centralized lubrication system.

The system is designed to be a direct bolt-in replacement to an existing automated system or an upgrade to an
outdated pump to point system.

Our modular design allows our system to be adapted to any application and any mounting requirements.
Most of the pictures in this manual depict the standup configuration with all the key elements installed on
one frame. Actual field installations may be different. It is common to have certain elements of the system
mounted remotely. The basic operating principles of the system do not change and the information in this
manual applies to all configurations.

4 © 2016 SLOAN LUBRICATION SYSTEMS

Watchman System Overview
System Elements
• Oil Supply and Pre-Filtration DIVIDER BLOCK
• Motor or Shaft Driven Force Feed
PROXIMITY SWITCH
• Lubricator
WIZARD MONITOR
• Gauge Assembly
• Divider Block GAUGE ASSEMBLY
• Wizard Monitor VENTED FILL CAP
• Proximity Switch
• Mechanical Indicators
• Check Valves
• Welded Stand LEVEL GAUGE
• Stainless Tubing
15 GALLON TANK (other sizes avilable)
• Shutoff Valve
SHUTOFF VALVE
Optional Accessories
Y STRAINER
We can meet any custom need!
PURGE POINT
• Oil Supply Heating
PUMP MANIFOLDS
• Automatic Level Control
• Low Level Alarm
• Desiccant Ventilation MOTOR
• Sealed Cabinets for Harsh Environments PUMPS
• Speed Reducer LUBRICATOR BOX

SHAFT COUPLING

SPEED REDUCER

Design
The Sloan Watchman Lubrication System is designed with simplicity of operation and troubleshooting in mind.

• All components are easily accessible for service or drop-in replacement

• Our modular design allows for simple adaptation to any requirement
• All replacement parts are in stock and ready to ship

Sloan manufactures the components of our Lubrication System to the highest standard in the industry,
and we back them up with 24 hour customer service.

[Link] | 1.800.722.0250 5
Training Manual | How it Works

How it Works
Oil Flow Through the Sloan Lubrication System 7

1. Oil enters the tank via the vented cap or an

external supply. GRAVITY FEED
TO PUMP

2. Gravity pulls the oil through the supply line at PRESSURIZED

OIL TO BLOCK 6
the bottom of the tank.

3. The oil passes through the y-strainer to the pump

inlet manifold

[Link] pump draws oil in through the inlet check on

the down-stroke. 1

5. The oil is pressurized as the pump strokes

upward and is forced out through the discharge 2
check. 4 3
5

6. Pressurized oil moves up the supply line to the

gauge assembly.

7. Passing through the filter, the oil moves to the

divider block where it is metered to precise
increments and delivered to the lubrication
points.

Reliably Simple
With the Sloan system, air entrapment is a thing of the past; each component in the system
is located to eliminate spaces for air to collect. Once the system is purged, it stays purged.

Our purging procedure is covered in detail in the “Startup” section.

6 © 2016 SLOAN LUBRICATION SYSTEMS

Series Progressive Lubrication
The Sloan Lubrication System is a series progressive lubrication system.

In a series progressive system, pressurized oil from the pumps flows through a divider block, which splits the
flow of oil into the required volume for each delivery point and acts as the primary failsafe mechanism in the
system. In order for the block to cycle, each piston must be able to freely deliver its set amount of oil before
the next piston in the series can cycle.

If one piston is unable to deliver a shot of oil to the proper point, the passage of oil will remain blocked to the
next piston in the series. This will lock the entire block.

At this point, two things will happen:

First, the pressure generated by the pumps will continue to build until it reaches the breaking pressure
of the rupture disk. The rupture disk will burst, returning the oil to the supply tank.

Second, the magnetic proximity switch (MPS) will stop sending signals to the wizard monitor, which triggers
a shutdown alarm. This alarm can be used to notify personnel or automatically shut down the equipment to
prevent damage.

The operation of the divider block is covered in greater detail in the SB divider block section
of this manual.

Oil Flow Through the Sloan Lubrication System

The Sloan system offers many advantages over its predecessor, the Pump to Point lubrication system.

It is necessary to understand how a Pump to Point system works to illustrate the difference.

A Pump to Point lubrication system employs a single pump for each delivery point on a compressor. This
means that for 50 delivery points on an engine/compressor, there would need to be 50 individual pumps,
and a bank of lubricator boxes to put them all into. The number of pumps alone means that the cost to install
Pump to Point on a large compressor can be significantly higher than that of a Sloan system.

[Link] | 1.800.722.0250 7
Training Manual | How it Works

Oil Flow Through the Sloan Lubrication System

For each delivery point on the Pump to Point system, there is a single pump. The series progressive system
gives you the ability to add lube points without adding another pump.
SERIES PROGRESSIVE LUBRICATION IN ACTION

The picture depicts a Pump to Point Lubrication System, and a similarly sized Series Progressive System.
This picture depicts a Pump to Point lubrication system, and a similarly sized series progressive system.

For each delivery point on the Pump to Point system, there is a single pump. The Series Progressive
The Clear
System Advantage
gives you the ability to add lube points without adding another pump.
Reduced Installation Cost: The Sloan system reduces the amount of tubing to be run long distances. Divider
blocks can be mounted remotely near the delivery points, with each divider block requiring only one inlet line,
THE CLEAR ADVANTAGE
reducing installation time and cost.
Reduced Installation Cost – The Sloan System reduces the amount of tubing to be run long
Reduced Operation Cost: The series progressive system delivers oil with far greater accuracy than a Pump to
distances. Divider Blocks can be mounted remotely near the delivery points, with each Divider
Point system. It monitors and displays the flow rate for easy reference. The Sloan System also draws oil from a
Block requiring only one inlet line, reducing installation time and cost.
much larger supply – a 15 gallon tank – and it has the ability to continuously feed from a header system. Larger
tanks are available upon request.
Reduced Operation Cost – The Watchman System delivers oil with far greater accuracy than a Pump
to Point system. It monitors and displays the flow rate for easy reference. The Sloan System also
In contrast, Pump to Point systems draw oil from the reservoir in the lube box which needs frequent refilling.
draws
Flow oil from
rates a much
in a Pump larger
to Point supply
system are–set
a 15
forgallon tank – and
each individual it has
pump. theisability
This done bytocounting
continuously
drops over
feed from a header system.
time in the sight glass of the pump. There is no safeguard and each pumps output needs to be verified on a
regular basis to confirm it maintains the required delivery.
In contrast, Pump to Point systems draw oil from the reservoir in the lube box which needs frequent
refilling. Flow rates in a Pump to Point system are set for each individual pump. This is done by
counting drops over time in the sight glass of the pump. There is no safegaurd and the flow rate
remains the same once the operator has set it.

8 © 2016 SLOAN LUBRICATION SYSTEMS

Optimized Lubrication Rates – The Sloan Lubrication System monitors the flow of oil with such
Optimized Lubrication Rates: The Sloan system monitors the flow of oil with a high degree of accuracy
allowing the operator to optimize the lubrication rate for the compressor. The Sloan system delivers precisely
the amount of oil needed – no more, no less.

Fail Safe Equipment Protection: A properly installed and maintained Sloan system will prevent lubrication
failure from damaging your equipment. The divider block fully protects the system while the Wizard Monitor
confirms the dividers operation. If oil is not being delivered to a lube point, a safety shutdown will occur. A
Pump to Point system cannot provide this degree of protection.

It is not uncommon for a new Sloan Lubrication System installation to pay for itself within one year in
oil savings alone.

System Design:
Your Custom Lubrication System
Every Watchman is a Custom Lubrication System.

The most important considerations are the number of delivery points and the flow rate. These two
determining factors govern the size and shape of the system, which effects mounting considerations, location,
and what accessories are required.

In order to design your system, we need to know:

• Compressor or Engine model

• Horsepower
• RPM
• Diameter and Stroke of compressors
• Number of cylinders and delivery points per cylinder/packing
• Process gas type
• Cylinder pressures
• Delivery Pressures

Once we have the specifications, we calculate the optimum flow for each individual delivery point. The table
on the next page shows the formulas we use to determine the optimum rates in pints per day.

[Link] | 1.800.722.0250 9
Training Manual | How it Works

Calculating Lubrication Rates

TWO CYCLE POWER CYLINDER LUBRICATION RATES
Horsepower • 8 • 24
= Total Pints per 24 Hours
Constant
[see below]
Use the following constant value that applies to your engine:

Cooper Bessemer Clark - Dresser

GMWA & GMWC 7000 HSRA & HRA-T 4000
GMW 7500 RA,HMA,HMB&TMB 5000
GMVB 8600 BA,HRA&TRA 6000
All Others 10000 HBA,HLA,TLA,HBAT 7000
TCV 8000

FOUR CYCLE POWER VALVE GUIDES

Each guide requires 0.05 pints per 24 hours. Use the same or double rate to
starting air distributor if necessary. No external cylinder lubrication is required.

COMPRESSOR CYLINDER LUBRICATION RATES

Bore • Stroke • RPM
= Pints per 24 Hours Required
Constant to each Cylinder
[see below]
Use the following constant that corresponds to your compressors’ service:
STEAM CYLINDERS need 1 pint/ 1 million square foot swept area - Constant =
16,000
NATURAL GAS Needs 1 pint/ 2 million square feet = 32,000
OR 1 pint/ 3 million ft2 =48,000
HYDROGEN & PROCESS GAS - same as above
1 pint/ 2 million ft2 = 32,000
1 pint/ 3 million ft2 = 48,000
1 pint/ 4 million ft2 = 64,000
AIR CYLINDERS Need 1 pint/ 5 million square foot – K = 80,000
ROD PACKING Deliver same as one cylinder feed

FULLER ROTARY VANE RoFlo ROTARY VANE

Varies to Spec Varies to Spec

Divider Block Layout

Once the flow rate for each delivery point is determined, we can then design the layout of the divider
assemblies.

We do this by figuring out what ratio of the total system flow rate is necessary for each individual delivery
point. These ratios are then translated into volume required per cycle of each divider block piston; that
governs what size piston section is used for each individual outlet.

10 © 2016 SLOAN LUBRICATION SYSTEMS

We also consider the delivery pressure of each lube point. A divider block section will wear out faster if there
is a large pressure differential between its two delivery points. A large pressure differential will cause the
piston to move slowly in one direction, and then slam back quickly in the opposite direction. When the piston
reaches the end of the bore moving too quickly, the end of the piston slowly deforms from repeatedly striking
the end plug. We design all of our systems so that both outlets of a single section deliver oil to approximately
the same pressure.

In cases where pressure differentials exceed 1500 PSI, we install pressure balancing valves to even out the
pressure differential. One is installed on each “lower” pressure point to rasie and even out the delivery
pressure requirement.

Multi-Zone Divider Block Systems

A simple lubrication system might have just one single divider block feeding oil to several delivery points.
This is called a single-zone system. Larger systems may have a single primary divider block feeding two or
more secondary blocks; this is still considered a single-zone system.

It is also common to have two or more completely separate zones, each with their own primary and
secondary blocks. This is considered to be a Multi-Zone System. Each zone is controlled and monitored
separately. For example, a gas transmission engine with a separate compressor zone and power zone are
referred to as a Dual-Zone System, or systems whose specifications require that more than one type of oil be
used for different applications.

A Dual Zone System will have another set of pumps and a separate gauge. The second zone is
monitored separately by the Wizard, and the flow rate for both zones are independently adjusted and
displayed simultaneously.

Dual-Zone Divider Block System

[Link] | 1.800.722.0250 11
Training Manual | How it Works

Oil Supply
• The standard oil supply featured by the Sloan
Lubrication System is a 15-gallon powder-coated
steel gravity feed tank.

• The Sloan system is available with other custom

options to suit specific needs, including:
• Reservoir sizes 15, 35 or custom
• Stainless tanks
• Tank-less systems for existing supplies

• Each tank is fitted with a vented cap with a mesh

screen.

• The outlet spud protrudes 1 inch above the

bottom of the tank creating a sump to capture
contaminants.

• A ½ OD stainless outlet line passes through a

Y-strainer designed to capture particulates.

• Each tank has an angled drain valve so that

captured contaminants can be regularly removed.

• Multiple accessories are available for your

oil supply:
• Automatic level maintainers for remote tanks
or manifold systems
• Low level alarms
• A combination heater/thermostat for extreme
environments
• A desiccant filler/breather for humid
environments

General Description: Gravity Feed Systems

The standard tank has a 15-gallon capacity. Lubricant is gravity-fed from a point 1 inch above the bottom of
the tank, through a Y-strainer/filter and into the pump inlet manifold.

Once in the pump manifold, the suction of the active pump will pull the oil through the inlet and discharge
it at pressure.

12 © 2016 SLOAN LUBRICATION SYSTEMS

Though this is a simple system, there are several conditions that require proper maintenance and monitoring.
Otherwise, operation may become compromised.

These primarily include particulate and chemical contaminants. For more information, see the “Maintenance
and Troubleshooting” section.

Operation: Gravity Feed Systems

• Once the inlet ball valve is turned to the on position, oil will feed via gravity into the pump manifold.

• At this point the system needs to be purged of air. Loosen the ¼ OD tubing nuts on the inlet fitting of both
pumps, and allow a small amount of oil to drain out of each until there are no more air bubbles.

• Once the inlet manifold is fully purged, the SLS pumps are ready for operation. Operate the pumps manually
to purge air from the supply line up to the gauge assembly, or use the Sloan Purge Gun.

Maintenance and Troubleshooting: Gravity Feed Systems

The most common problem with oil supplies is contamination.

Any amount of water that gets into your lubrication system will cause failure.
• There are high-tolerance moving parts within the system that will be damaged by even a tiny
amount of rust.
• Likewise, particles smaller than a grain of sand can score piston bores and damage parts.

• The best way to avoid water or other contaminants is to protect your oil supply.
• Do not store oil drums outside, keep them fully sealed, and never let water collect on the rim.
• Over time, individual drops of water accumulate in the bottom of the tank. If they are not regularly
drained off using the angled drain valve on the tank, they will eventually reach the top of the sump and
flow down the ½ OD inlet.

• Condensation can build up over time within the tank.

• This is most common in humid environments where there are large temperature fluctuations.
• If condensation builds up too rapidly despite regular draining of the sump, a desiccant filler breather may
be an option.
• Clean out the Y-strainer at regular intervals. This is a filter that captures particulate, and prevents it from
damaging the pumps. Over time it will clog if not cleaned.

• To clean the Y-strainer, shut off the oil supply at the ½ ball valve and open the ¼” drain plug. Be
prepared to collect the oil and debris in a pan. After cleaning the Y-strainer, the system needs to be
purged again.

[Link] | 1.800.722.0250 13
Training Manual | How it Works

General Description: Header Systems

Lubrication systems that do not require tanks generally get their oil supply from a pressurized header or from
the crank case of a large compressor.

These oil supplies are of varying pressures and qualities. It is very important to filter out all contaminants,
and reduce the pressure of these supplies. Each of these systems is supplied with a 3 micron absolute spin
on filter protected by an in line check, followed by a pressure regulator. There is a priming connection on top
of the filter.

The pumps are designed to operate at an inlet pressure of 10 psi; Pressure greater than this can
cause oil to bypass the piston and fill up the lube box.

Operation: Header Systems

• Header type oil inlet supply packages also need to be
fully purged before the system can be put into operation.

• Fill the filter with oil before installation.

• Open the ball valve and allow the system to pressurize,

or use the priming connection on the filter.

• Using the same technique as above, loosen the ¼” OD

tube nuts on the inlet fitting of the pumps, and allow oil
to flow through until all the air is purged.

• The pumps can then be manually pumped to purge the

system up to the gauge assembly.

Maintenance and Troubleshooting: Header Systems

External oil inlet supply packages are also subject to contamination.

• The 3 micron spin on filter does not remove water.

• Filters need to be changed yearly. In order to change the filter shut off the supply ball valve.
• Remove the filter.
• Fill the new filter with oil before installing.
• Open the ball valve and allow the system to pressurize or use the priming connection on the filter.
• Using the same technique as above, loosen the ¼” OD tube nuts on the inlet fitting of the pumps, and
allow oil to flow through until all the air is purged.
• The pumps can then be manually pumped to purge the system up to the gauge assembly.

14 © 2016 SLOAN LUBRICATION SYSTEMS

The SLS Pump
General Description
• The SLS pump comes in 3 piston sizes for different
displacements
• 3/8” Pumps to 3500 Psi (.038 in3 / stroke max)
• 1/4” Pumps to 8000 Psi (.018 in3 / stroke max)
• 3/16” Pumps to 7500 Psi (.010 in3 / stroke max)

• Modular interchangeable piston cylinders

• A hardened steel roller rocker for long life

• Corrosion resistant black nitride plating

• Available in pressurized and vacuum

Pressurized pump | Vacuum pump

Operation
• In the pressurized pump, the oil is supplied to the inlet at a pressure slightly above atmosphere, and
the downward stroke of the piston pulls oil into the pumping chamber. The upward stroke of the piston
pressurizes the oil and forces it out the discharge check valve. There is a check valve on the inlet that
prevents the oil from pumping back up the inlet.

• The pump is designed to be driven by a cam-shaft, which can accept multiple drive types.

• The roller rocker rides up and down on the cam lobe and prevents excessive wear.

• The pump piston can be manually actuated by pushing on the plunger, allowing for manual purging.

• To adjust, turn the regulating screw at the front of the pump clockwise to reduce the output or shut off the
pump or counter-clockwise to increase output.

• The regulating screw restricts the amount of time that the rocker arm contacts its cam, thus lowering the
flow rate.

• The torque nut at the base of the regulating screw must be loosened in order to make adjustments and
re-tightened once the desired flow rate is achieved.

[Link] | 1.800.722.0250 15
Training Manual | How it Works

Adjustment Stem Up / Adjustment Stem

Piston is Engaged Down / Piston is
Disengaged
• Pump in the on
position
• Pump in the off
position

• Flow adjusted to
the maximum
• No flow

Maintenance and Troubleshooting

• The SLS pump is one of your lubrication system’s main wear components. Any part that operates based on
this principal will eventually wear out. You can increase this part’s lifespan by always supplying it with quality
contaminant-free oil. It has a lifespan that is relative to the severity of operating conditions and will need to
be serviced or replaced at certain intervals.
The specific wear surfaces of the pump are:
• Internal Check Valves
• Pump Piston
• Roller Rocker
• Spring
• Piston Seal

• Sloan lubrication systems are designed so that the desired flow rate is as close to the center of the active
pump’s range of motion as possible.

16 © 2016 SLOAN LUBRICATION SYSTEMS

• Once the pump adjustment screw has to be set above 75% of its potential range, the pump can no longer be
guaranteed to operate for another duty cycle and needs to be replaced.

Pressure Pump Diagram

• Each standard Sloan system is equipped with an installed spare pump. We recommend that at each PM cycle,
the operator switch the pump in operation for the next duty cycle. This ensures even wear between the
pumps and that they will be ready for replacement around the same time.

• If the system is turned on before all the lines, manifolds and pumps are fully purged, the pumps can air-lock.
In the event of an air-lock, air becomes trapped between the suction and discharge checks of the pump and
it cannot draw oil.

[Link] | 1.800.722.0250 17
Training Manual | How it Works

• If the pumps are fully open and the plungers are moving up and down normally, but no oil is being pumped
there are 2 possibilities. Either there is no oil flowing to the pumps or the pumps are air-locked.

• To fix an air-locked pump: First, make sure that the supply line is fully purged and that there is plenty of oil for
the pump. Then loosen the discharge check valve and operate the pump manually. Once you see oil
pumping from around the threads of the discharge, you may tighten it back down. You are now ready
for normal operation.

Check Valve opens

to relieve airlock

Fixing an air-locked pump

• Water can leak into the reservoir of the lubricator box if the pump gaskets are not installed correctly.

• Do not over-tighten pump bolts!

18 © 2016 SLOAN LUBRICATION SYSTEMS

 MOTOR DRIVEN LUBRICATIOR

Motor Driven Lubricator

GENERAL DESCRIPTION

1. Our standard
General motor drive consists of
Description
an electric C-face motor mounted to a
1. Our standard motor drive consists of an electric
rightmotor
C-face anglemounted
[Link] a right angle reducer.

2. The
2. The shaftshaft
of theofreducer
the reducer is mounted
is mounted to the shaft
ofto the
the shaft ofbox
lubricator thevia
lubricator
a Lovejoy box via awith
Coupling 1
a Lovejoy
spider. Coupling with a spider. 4

3. The reducers and lubricator boxes are available

3. The reducers and lubricator boxes are
in a variety of gear ratios to allow for a wide
available in a variety of gear ratios to
flexibility in flow rate.
allow for a wide flexibility in flow rate.
[Link] lubrication zone will have its own pump 2
Each 3
4.
with anlubrication zone
installed spare on will have manifold.
the same its own
pump with an installed spare on the
same manifold.
Each pump is driven by an eccentric lobe on the cam shaft. As the cam shaft rotates, the lobe pushes up on
Each pump is driven by an eccentric lobe on the cam shaft. As the cam shaft rotates, the lobe pushes
the roller rocker of the pump to initiate a piston stroke. As the lobe rotates back down, the spring on the pump
up onthe
returns thepiston
rollertorocker of the
the down pump
position to initiate
which draws aa suction
piston from
stroke.
theAs
oil the lobe
supply, rotates
filling back chamber
the pump down, the
spring
for on stroke.
the next the pump returns the piston to the down position which draws a suction from the oil
supply, filling the pump chamber for the next stroke.
The primary wear parts of the motor drive assembly are:

• The primarylobes
The eccentric wear
onparts of shaft
the cam the motor drive assembly are:
- these wear
against the roller rocker on the pump.
• The eccentric lobes on the cam shaft. These wear against the roller rocker on the pump.
• The bearings and shaft inside the lube box - these will
especially wear if the
• The bearings lube
and box inside
shaft is not filled with oil,
the lube box. or These
if will especially wear if the lube box is not filled
the with
oil is contaminated.
oil, or if the oil is contaminated.

• The oil seal can begin to leak if the shaft is not aligned
• The oil seal can begin to leak if the shaft is not aligned properly, or if it is replaced improperly
properly, or if it is replaced improperly after servicing
after servicing cam lobes.
cam lobes.

• The
• The pump
pump gaskets,
gaskets, which which
should should be replaced
be replaced the same with the pumps.
time as the pumps.
• Gearing in the reducer and lube box will wear over time, but with proper maintenance, you can
• Gearing
ensure a longer
in the reducerworking
and lubelife.
box will wear over
time, but with proper maintenance, you can ensure
Lubricator box
a longer working life.

[Link] | 1.800.722.0250 19
Training Manual | How it Works

Operation
Once power is supplied to the motor, either from the control unit of the compressor, or from the Hand/Off/
Auto switch on the electrical control package of the system, the motor will begin to turn.

• The motor can rotate in either direction

• Before start-up, make sure that the oil supply lines are
purged of air all the way to the pump. Otherwise, they
can airlock (see pump section).

• The lubricator box and reducer need to be filled with

oil. The same oil used by the system or any 30 weight
gear oil is acceptable. The lubricator should be filled to
within ⅛ to ¼ of an inch of the top of the sight glass.

• The reducer needs to be filled to just below the top with

30 weight gear oil.

• For pump adjustment information see the pump

section.

Maintenance and Troubleshooting

• Replace the oil in the lubricator box and the reducer yearly.

• Frequently check the level of oil in the lube box. If the box is constantly filling up, it is a sign that either the
pumps are wearing out and oil is bypassing the piston, or the inlet pressure is too high.

• Shaft alignment is extremely important. Improperly aligned shafts can ruin oil seals, causing the box to leak.
It can also cause premature wear of gears and other components.

• Contamination in the lubricating gear oil can cause malfunctions and unsafe conditions. Make sure that the
pump gaskets are properly installed to prevent water from entering the system.

• Inspect the inside of the lube box yearly. The presence of metal shavings signals that the gear components
are nearing the end of their lives. Any type of grit can damage components and should be removed.

• Inspect individual cam lobes for wear. Over time, they will become grooved, which causes lube rates to drop
off. Grooved or worn cams must be replaced.

• Drop-in replacements are available for all components of the motor drive. If there are multiple concerns,
it is often best to replace the unit from spares and send the used one back for evaluation and repair, or
replacement if needed.

• Do not over-tighten pump bolts!

20 © 2016 SLOAN LUBRICATION SYSTEMS

Engine Driven Lubricator
General Description
Engine-driven lubricators are driven by a shaft coming out of the compressor.

The advantage is that no electrical considerations need to be made for the motor. Also, as the engine RPM
changes, so does the shaft speed, and thus the flow rate. However, despite time saved from not having to wire
a motor, it will take some time to customize the mounting bracket to adapt the new lubricator to the footprint
of an obsolete one.

Maintenance and Troubleshooting

The only appreciable difference between an engine-driven and an electric motor-driven lubricator in terms of
maintenance is that there is no longer a motor and sometimes no reducer. The rest of the maintenance items
for motor driven lubricators are the same.

Gauge Assembly
General Description
The gauge assembly serves several purposes:
OIL OUT
• Pressure Monitoring PRESSURE GAUGE

HIGH PRESSURE FILTER

• High-pressure Filter
BLOWOUT ASSEMBLY

• Main Line Rupture Relief/Indication PURGE POINT

OIL IN
• High Volume Purge Point

Once the pumps pressurize the oil, it goes to the gauge assembly. The gauge assembly consists of the
elements listed above attached to a single manifold referred to as the anchor block.

The pressure gauge on the gauge assembly offers an accurate pressure reading for the divider block system. It
will also indicate an excessive pressure differential across the piston sections.

[Link] | 1.800.722.0250 21
Training Manual | How it Works

The High-Pressure Filter

This filter utilizes a 10 micron sintered bronze element to protect the extremely tight tolerance of the pistons
in the divider block downstream. The filter is easy to change at regular turnarounds. It is designed so that the
element gaskets and springs are installed vertically to protect the gaskets upon installation. Old filters are
mounted horizontally and the gaskets are difficult to seat properly.

To change the filter, unscrew the threaded cap at INTERNAL GASKET

the base of the filter housing. Once loose, lower the
SMALL SPRING
threaded cap. The filter element and springs will
FILTER ELEMENT
follow. You may need to pry the internal gasket out.
Replace the used pieces with new as shown. LARGE SPRING

THREADED CAP
TIP: Place a shop rag below the housing to catch any LARGE O-RING
oil in the housing.

Proper orientation of High Pressure Filter components

Main Line Rupture Relief Assembly

This device is the primary pressure relief for the entire system. It prevents the lubrication system from
reaching dangerous pressures in the event of a blocked line. It includes a pressure rated, colored aluminum
blowout disc that is designed to rupture at a given pressure, relieving system pressure to atmosphere in the
event of a downstream blockage.

The main line rupture assembly also has a clear plastic tube that oil will flow through in the event of a rupture.
This serves as visual indication to the operator that a rupture has occurred, and will indicate which zone is the
problem to aid in troubleshooting.

When you change rupture disks make sure to remove the used or blown disk!

Do not over-tighten the blowout assembly. It will cause the pressure at which the disk blows to decrease.

SIGHT TUBE BLOWOUT CAP/NUT RUPTURE DISK BLOWOUT BASE/BODY

Mainline Rupture Assembly

22 © 2016 SLOAN LUBRICATION SYSTEMS

Purge Point
The gauge assembly also has a purge point with
a terminal check valve. This point can be used for
high volume purging of the divider block and the
lubrication lines. The fitting on the purge point
also has a test nut. This nut is provided to protect
in the case of failure of the terminal check during
operation, and to test divider assemblies during
preventative maintenance. PURGE POINT

SB Divider Block
Understanding Your Divider Block
The engraving on each divider block provides valuable information that you will need to understand. Use the
diagram below to understand the markings on your divider block.

SLOAN LOGO

DISPLACEMENT AND DIRECTION

M.F.G. DATE CODE

SB SERIES INDICATION

PRESSURE RATING

Divider Block Engravings

[Link] | 1.800.722.0250 23
Training Manual | How it Works

Divider Assembly Components

Parts Breakdown
7
1. Divider Section (See Front) 3

2. SB-D-Baseplate Intermediate baseplate

3. SB-D-Top Top end section

4. SB-D-Bottom Bottom inlet section

9

5. SB-D-T3 Tie rod, 3-section

SB-D-T4 Tie rod, 4-section

SB-D-T5 Tie rod, 5-section 8 6

2
SB-D-T6 Tie rod, 6-section

SB-D-T7 Tie rod, 7-section

SB-D-T8 Tie rod, 8-section 1

4
SB-D-T9 Tie rod, 9-section

6. SB-D-SectionBolt Plunger section bolt 2/section

7. SB-D-SP Side section plug

5
8. SB-D-FP Front section plug

9. SB-O-V006 Intermediate O-ring (Viton)

Optional Parts
• SB-D-Top-Lincoln Top section, Lincoln Bolt Centers
• SB-D-Bottom-Lincoln Bottom section, Lincoln Bolt Centers
• SB-D-CrossportRight Crossport plate, right
• SB-D-CrossportLeft Crossport plate,left
• SB-D-CrossportBoth Crossport plate, both

Displacement
SB Divider Sections in3 (cm3)

• SB-D-03T Divider Section 3T .003 (.049)

• SB-D-06T Divider Section 6T .006 (.098)

Reset Fault Indicators
• SB-D-09T Divider Section 9T .009 (.147)
• 500# (blue) SB-D-PI500
• SB-D-12T Divider Section 12T .012 (.197)
• 1000# (yellow) SB-D-PI1000
• SB-D-18T Divider Section 18T .018 (.295)
• 1500# (red) SB-D-PI1500
• SB-D-24T Divider Section 24T .024 (.393)
• 2000# (orange) SB-D-PI2000
• SB-D-30T Divider Section 30T .030 (.492)
• 2500# (purple) SB-D-PI2500

Other Replacement • 3000# (brown) SB-D-PI3000

Parts • 3500# (gray/black) SB-D-PI3500
• Proximity Switch SB-D-MPS
NOTE: All Divider Sections are also
• Cycle Indicator SB-D-CI
©with
SLOAN SYSTEMS 2016 | [Link]
available SingleLUBRICATION
Outlet
• Outlet check valve SB-V-C
T Designates Twin Outlets
• Divider Test Stand SB-D-TestStand S Designates a Single Outlet

24 © 2016 SLOAN LUBRICATION SYSTEMS

Calculating Displacement
• CALCULATING
CALCULATING
Determining DISPLACEMENT
DISPLACEMENT
the total displacement of a divider
assembly
•• Determining
Determining the
thetotal
total displacement of
• Each section is stamped withdisplacement of
a number designating
a divider assembly
theapiston
divider assembly
size. This represents the displacement.
Each section is stamped with
withaanumber
ForEach section
example, a 6Tissection
stampedrepresents number
a 0.006 cubic
designating
designating
inch [Link] piston
theAddpiston size.
size.
up all This
theThis represents
represents
numbers and
the displacement.
the displacement.
multiply For example,
For example,
by 2. A four section block witha 6T
a 6T
sections
section represents a 0.006 cubic
section represents a 0.006 cubic inchx 2
12T+12T+6T+6S has a displacement of inch
.036
ordisplacement.
.072 in3 per cycle.
displacement. Add
Addup upall
allthe
thenumbers
numbersand and
multiply
multiplyby
by2.
[Link]
foursection
sectionblock
blockwith
with
sections 12T+12T+6T+6S has a displacement
sections 12T+12T+6T+6S has a displacement
of
of.036
.036xx22or
or.072 in3per
.072in percycle.
3
cycle.

Determine
Determinethe
•• theflow flowrates
ratesbased
basedon on
cycle times
cycle times
• Determine the flow rates based on cycle times
The
• TheThe cycle
cyclecycle
timetime
time isisthe
is the thenumber
numbernumber of
ofseconds
seconds
of seconds ititfor the block to move the cycle indicator one full cycle. Start
it takes
takes
a timer for
takeswhenforthe theblock
the cycle to
block tomove
movethe
indicator thecycle
begins indicator
to move
cycle one
in one
indicator full
fullcycle.
direction
one andStart
cycle. keep atiming
Start atimer
timer when
until
whenthethe cycle
indicator
the cycle begins to
indicator
move in thatbegins
indicator direction
begins to move
toagain. in
inone
moveUsing one direction
the constantand
direction keep
derived
and keepintiming until
the second
timing the
theindicator
untilstep, divide by begins
indicator the to
cycle
begins move
time.
to move
• The
in
in that direction again. Using the constant derived in the second step, divide by the cycletime.
that
result direction
is the flow again.
rate Using
in pints the
per constant
24-hour derived
periods. in the second step, divide by the cycle time.
• For
Theexample:
result 216
is the/32 seconds
flow rate =
in6.8 pints
pints perper 24
24-hour
The result is the flow rate in pints per 24-hour periods. hours.
periods.
For
For=example:
PPD example: 216 /32 seconds = 6.8 pints per 24 hours.
Pints Per Day 216 /32 seconds = 6.8 pints per 24 hours.

(displacement)
(displacement)••3000
3000 (displacement)
(displacement)••3000
3000
==flow
flowPPD
PPD OR
OR ==cycle
cycletime
time
cycle time
cycle time flow PPD
flow PPD

• •Determine
• Determine
the cycle
Determinethe
time required
thecycle
cycletime
to deliver
timerequired
requiredto
a specific flow rate
todeliver
deliveraaspecific
specificflow
flowrate
rate
• Use the constant from step two and divide by the desired flow rate in Pints/24
Use the constant from step two and divide by the desired flow rate in Pints/24hours. The resultThe
hours. is the cycleis
result
Use the constant from step two and divide by the desired flow rate in Pints/24 hours. The result is
time,
the in seconds, thatseconds,
the block mustthe
make to deliver the required amount required
of oil.
thecycle
cycletime,
time,inin seconds,that
that theblock
blockmust
mustmake
maketo todeliver
deliverthe
the requiredamount
amountof
ofoil.
oil.
• For example: 216 / 6.8 pints per day = 32 seconds cycle time.
For
Forexample:
example:216
216//6.8
6.8pints
pintsper
perday
day==32
32seconds
secondscycle
cycletime.
time.
• The Constant in the formula above is 3000. The formula below shows where the constant comes from.
•• The
TheConstant
Constantin
inthe
theformula
formulaabove
aboveisis3000.
[Link]
Theformula
formulabelow
belowshows
showswhere
wherethe
theconstant
constantcomes
comesfrom.
from.
86400
86400 = 2992.2 (rounded to 3000)
11day
day==86400
86400seconds;
seconds;11pint
pint==28.875
28.875in
3
in3 = 2992.2 (rounded to 3000)
28.875
28.875

[Link] | 1.800.722.0250 25
Training Manual | How it Works

Divider Blocks
General Operation
The discharge of the high pressure filter is tubed to the inlet of the SB divider valve assembly, which is
designed to make the proper proportional delivery to each lubrication point. Each discharge line from the
divider valve is clearly identified showing which of the equipments’ lubrication points it feeds. Be certain each
line goes where it should.

The divider assembly uses a “series progressive” cycling principle. It operates as follows:

The oil flow from the pump can only move one piston at a time. When that piston moves, it displaces a
given volume of oil to its designated lube point. The piston movement also opens the system’s flow to
move the next piston, which makes the next delivery. This cycle repeats itself. In this manner, every line must
receive its prescribed amount in turn before the next line can deliver. Each delivery is accurately monitored.

Note that each piston can make a delivery out each side of its section. Those outlets can be internally
combined together as well (this is the difference between a Single and a Twin divider section). The volume of
each delivery depends on the section’s piston size and internal porting.

All lines can potentially receive the same amount depending on their respective piston sizes. Each divider block
has been designed for your specific application, so take care to locate the feeds as tagged. These feed rates
and locations are tagged on the panel and are shown on your operational schematic.

In many cases, one primary divider valve feeds several secondary valves where many oil lines are required.
Always refer to the operational schematic for your specific divider valve arrangement.

Operation
The SB divider valve assembly is an extremely accurate metering device. Each section is individually machined
and each piston is match-fit to ensure an extremely tight piston to bore tolerance. Total divider valve
displacement is the sum total of all the piston displacements. For example, 6 feeds at .006 in3 = .036 in3 total
delivery per cycle.

In operation, the pump flow makes each piston move to the right, top to bottom, then to the left, top to
bottom, completing the cycle of the divider. Since each piston must move in each cycle, just one piston’s
movement to determine the entire valve’s cycle. During each cycle, the divider actuates the proximity switch
and is monitored an open/close electrical impulse to the Wizard monitor.

REMEMBER that each divider valve piston delivers twice during a single cycle of the divider valve.

26 © 2016 SLOAN LUBRICATION SYSTEMS

Maintenance and Troubleshooting: Theory
The divider block is the primary wear part of your lubrication system.

• A large percentage of lubrication related shutdowns are due to improperly maintained and tested
divider blocks.

• The divider block has a lifespan that varies, depending upon the applications for which it is used.

• Divider blocks are honed with a piston to bore clearance measured in the millionths of an inch (0.000001).

• As the blocks cycle over time, the pistons and bores wear and the clearance increases.

• As the clearance increases, the accuracy of the delivered volume decreases.

• The only way to verify a divider block is to test it for certain pressure characteristics.

• The values were determined by measuring the volume delivered by individual outlets into high-pressure
environments.

• When the divider block will not deliver lubricant reliably for another duty cycle, it is time to replace it.

NOTE: The integrity of the entire lubrication system relies on the accuracy of the volume of oil
delivered by each piston section.

[Link] | 1.800.722.0250 27
Training Manual | How it Works

Maintenance and Troubleshooting: Practice

• During yearly preventative maintenance, replace all divider block assemblies.

• Test rigs must be verified. If they cannot generate and hold the required pressure, they need to be repaired.

• Blocks are to be tested to factory guidelines specified on the SB divider blocks. Any individual piston sections
that do not pass the pressure test need to be replaced.

• There are 2 pressure characteristics that need to be tested.

• The first test is cycle pressure. This is how much pressure needs to be generated to cause the
pistons to move against atmospheric pressure. This verifies that the piston is able to move freely
within the block.

• Completely purge the block with oil and then pump slowly, watching the pressure gauge on the
pump. Any reading under 500 PSI is acceptable.

• The second test is a bleed down test. This test determines how much oil can leak back along the wall of
the piston at pressure. This test verifies that the piston to bore clearance is still within specification. If the
clearance becomes too large over time the divider block can no longer deliver its oil at pressure, instead
the oil can “bypass” or bleed back to a lower pressure delivery point.

• After performing the cycle pressure test, a test cap is placed on the bottom right outlet of the divider
block. The block should lock and build pressure.

• Build the pressure to 3000lbs and start a timer for 1 minute.

• If the pressure drops less than 500lbs, the block is good.

• Move up to the next outlet and repeat. Each outlet must be tested in this manner.

Check Valves: General

• Poppets provide positive sealing under tough conditions

• Insure immediate oil delivery at start-up

• All 303 stainless steel components

• Use one at the end of each oil line

28 © 2016 SLOAN LUBRICATION SYSTEMS

 s provide positive sealing under tough conditions
immediate oil delivery at start-up
stainless steel components
e at the end of each oil line

Omni-Check Valve
CHECK VALVE
SB-V-C-Omni
For compressor service to 8000 PSI
mni
ressor service to 7500 PSI
• The “Omni-Check” soft seal double poppet check
valves provide positive sealing under all conditions
up to 8000 PSI. The Max temperature rating is 400
mni-check”Degrees
soft seal
F. double poppet check valves
e positive sealing under all conditions up to 8000
• Available withrating
e Max temperature any fitting combination.
is 400 Degrees F.
le with any fittinginclude
• Options combination.
hard seat stainless steel balls (SSB)
ns include hard
insteadseat stainless
of soft seat poppets steel
and balls (SSB)
Buna seals for
d of soft seatammonia
poppetsservice.
andBuna is limited
Buna sealsto 250˚F.
for ammonia
. Buna is •limited to 250˚F.
(Please specify service and seat type when ordering.)
specify service and seat type when ordering.)
• SSB checks by
ecks are identified are a groovebyaround
identified the body;
a groove around the body.

re stamped with a “B”.

• Viton “O” rings are standard, Buna “O” rings stamped
with a “B.”

Single
POPPET Poppet
CHECK VALVES Check Valves
minal SB-V-C-Terminal
SB-V-C-Outlet
tlet
• For power cylinders, rotary vane compressors,
wer cylinders, rotary
vacuum pumps,vane compressors,
material vacuum
handling equipment

, material handling equipment

• SB-V-C-Terminal 1/8” FPT X 1/8” MPT Check
Terminal 1/8” FPT X 1/8” MPT Check
Outlet 1/8” MPT X 1/8”
• SB-V-C-Outlet FPT
1/8” MPTCheck (same
X 1/8” FPT Check as
(same as
above, reversed)
reversed)
ct size for• tight
Compactlocations - only
size for tight 1-1/8”
locations long.
- only 1-1/8” long.
valves are available in any fitting configuration.
• Check valves are available in any fitting configuration.

[Link] | 1.800.722.0250 29
 Training Manual | How it Works

OMNI GAS-TRAPT
Omni Gas-Trap
he Omni Trap is a device that guarantees there is always a pool of oil on the “outside” of a check
Theeliminates
lve, which Omni Trap isthea device that guarantees
possibility thereback
of gas passing is always a pool
into the lubeof oil on the
lines. “outside”
Check valvesofwork
a check
thevalve, which
est wheneliminates the possibility
oil is on both of gas
side of the passing
valve back intoEven
mechanism. the lube
the lines. Check valves
best check valveswork the best
can allow when oil is on both
small
uantitiesside of the
of gas to valve
escapemechanism. Even the best
past the poppets check
or ball whichvalves
cancan
leadallow small quantities
to inconsistent oil of gas to escape
delivery and past the
poppets or ball which can lead to inconsistent oil delivery and other serious forms of damage. If you have been
her serious forms of damage. If you have been having check valve, gas blowback issues, or just want
having check valve, gas blow-back issues, or just want added protection for oil delivery, use the SB Omni Gas
dded protection for oil delivery, use the SB Omni Air Trap on the lubrication system delivery points.
Trap on the lubrication system delivery points.

pecifications:
Specifications:
Inlet: 1/4” Female
• Inlet: NPT NPT
1/4” Female
Outlet:• 1/4” Male
Outlet: 1/4”NPT
MaleorNPT
1/8”orNPT
1/8” NPT
• Material:
Material: StainlessStainless
steel steel
• Working Pressure:
Working Pressure: 7500 PSI 7500 PSI

ptions: Options:
• SB-V-C-T-4
SB-V-C-T-4 - Omni-Trap
Omni Trap with 1/4” male NPT Stem
with 1/4” male
• SB-V-C-T-2 - Omni Trap with 1/8” male NPT Stem
NPT Stem
• Commonly used with: Omni Check Valve
SB-V-C-T-2 - Omni Trap with 1/8” male
(SB-V-COmni)
NPT Stem
Commonly used with: Omni Check
Valve (SB-V-COmni)

BALANCING VALVES
alancing valves are used in high-pressure applications to balance the delivery pressure across a
vider block. The purpose of installing balancing valves is to improve the lifespan and reliability
divider blocks. Balanced delivery pressures allow the pistons to move back and forth at an even
eed preventing wear.

Balancing valves are used on

compressors that have a high
differential between stages

Balancing valves are custom tuned to a

pressure that suits your application

Balancing valves are an excellent

solution for difficult applications

Omni Gas-Trap in action

30 © 2016 SLOAN LUBRICATION SYSTEMS

Balancing Valves
Balancing valves are used in high-pressure applications to balance the delivery pressure across a divider block.
The purpose of installing balancing valves is to improve the lifespan and reliability of divider blocks. Balanced
delivery pressures allow the pistons to move back and forth at an even speed preventing wear.

• Balancing valves are used on compressors that

have a high differential pressure between stages

• Balancing valves are custom tuned to a pressure

that suits your application

• Balancing valves are an excellent solution for

difficult applications

Mechanical Indicators
Magnetic Cycle Indicator
• P/N SB-D-CI
• Available for all divider block manufacturers
• Extremely reliable spring-free design
• Can be used as a backup to calculate displacement
• US Patent 8575921

Each new block shipped by the Sloan Lubrication

Systems Company is equipped with our exclusive
Magnetic Cycle Indicator. This device uses patented
captured magnet technology to transfer force from
the movement of the piston in the divider block
into motion of a visible ring magnet. Using the
“displacement to seconds per cycle” formula, the
cycle indicator can be used to calculate flow rate.

The SB-D-CI has no internal springs. Instead,

magnetic force holds the pin in place, and it cannot
fall out.

Magnetic Cycle Indicator with and without cap

[Link] | 1.800.722.0250 31
Training Manual | Wizard V Monitor

Resettable Pin Indicators

• Used to indicate outlets of the divider valve that are
experiencing abnormally high pressure
• Available with multiple preset cracking pressures
• Excellent troubleshooting aid

When one of the reset indicators pops out on a

divider block, it means that the piston section it is
installed on has experienced pressure above its
cracking pressure. The cracking pressure is chosen
based on the overall operating pressure of the
system, and is the level at which problems may arise.

A popped indicator often means that there is a problem with a secondary divider block or a delivery port.

If the mainline rupture has blown, then the pin indicators can be followed to the delivery port that is having
the problem.

Magnetic Proximity Switch

• The Magnetic Proximity Switch uses the same principle as the cycle indicator to trigger an electronic switch
that communicates with the Wizard Monitor

• The explosion-proof MPS is the only switch of its kind

• It is more reliable and more compact than any other switch

32 © 2016 SLOAN LUBRICATION SYSTEMS

Wizard V Monitor
The Wizard V Monitor is the current standard for all
Sloan Lubrication Systems.

The Wizard V was designed in cooperation with the

engineering team at Sloan and industry professionals
worldwide. We have met the goal of creating a
monitor that integrates seamlessly with modern
control systems and enhances the benefits they
provide.

The Wizard V utilizes state of the art technology,

with a conversational touch-screen interface,
providing the user with valuable information and
better protection.

Specifications
The Wizard V has been designed to integrate and communicate with PLC type control systems. We have gone
to great lengths to insure that the Wizard V is compatible with all types of control systems, and still be capable
of operation as an isolated stand-alone control.

The Wizard V also has the ability to log data and run software updates via a universal USB device.

[Link] | 1.800.722.0250 33
Training Manual | Wizard V Monitor

Input and Output Capabilities

Following is a list of all input and output capabilities.

Power supply 90-264 VAC, 47-63 Hz / 12-48VDC 15W Max

Inputs
4 - Zone Proximity switches (low voltage dry contact)
1 – TDS
1 – Arm/Disarm Circuit
2 - 4-20mA Analog
1 – IR receiver

Outputs
4 - Zone Alarm Relays 250V Max 5A(NO)/3A(NC)
1 - Power Fail Relay 250V Max 5A(NO)/3A(NC)
1 – 4-20mA Analog

Communication
1 - RS485 Modbus slave
1 – RS485 Modbus master with pass-through connector
1 – 10/100 Ethernet

Storage
On-board 256MB – minimum 2 years of logging @ 1 entry / minute.
External USB – CSV file format

34 © 2016 SLOAN LUBRICATION SYSTEMS

Overview
The Wizard monitor is designed to provide constant monitoring of your lubrication system, thereby protecting
the critical lubricated equipment. It gives operators an indication of the current system status and flow rate
that is easy to see and understand. The Wizard can monitor up to 4 zones of lubrication and provides an
independent alarm circuit for each zone.

Each zone functions the same. An input from a divider block proximity switch or other metering device,
combined with the known displacement per cycle of that input allows for calculation of the flow rate and
ensures that the flow rate stays above a set point. If the flow rate drops, an alarm relay changes state and,
depending on how the zone is configured, either stays there until reset or resets automatically upon the
resumption of normal flow.

Standard features in the Wizard V monitor include a 3.5” color LCD touch-screen, easy setup menus, color
status LEDs, and data logging capabilities. The hardware is also capable of a variety of analog and digital
communications that will be enabled in future software versions.

Front Panel
The Front panel of the Wizard contains the LCD
screen, the status LEDs, a USB connection and 8
buttons.

Each button corresponds to a button or location on

the screen. If you see an “A” label on the screen, you
can press the A button to select that option. You can
also touch the screen itself to select the same option.
This allows an operator to use the basic functions
of the monitor without getting the screen dirty.
Some menu items are only accessible by touching
the screen itself. Those menu items do not have a
corresponding number or letter label.

Details for each menu item and screen are

located in the section marked “Programming” later
in this manual.

Examples of common usage scenarios are

located in the “Operation” section.

[Link] | 1.800.722.0250 35
Training Manual | Wizard V Monitor

Back Panel
The rear panel of the Wizard contains all of the electrical connections as shown below. At a minimum, the
Wizard needs power and a single zone input to function properly.

Power can be supplied as either AC or DC. See the specifications for acceptable voltage ranges. The zone
inputs should be a dry contact switch, either a relay or magnetic reed switch will work. The Wizard looks for
continuity between contacts #1 and #4 for each input. The TDS input is used to temporarily display the total
flow for each active zone as well as reset any alarms. The Arm/Disarm input is used to remotely arm or disarm
the alarm function of the monitor. Each input is explained in more depth in the section marked “Operation”
later in this manual.

36 © 2016 SLOAN LUBRICATION SYSTEMS

 To install, remove all electrical plugs that will be used from
supply is turned off, and install each supplied plug onto th
removable green screw connectors for heavier wires and va

For the screw connectors, strip the insulation from the e

Installation
connector, and tighten the screw. Make sure are no stray
connection to another wire.
The Wizard mounts in either a JIC style enclosure or a hazardous location enclosure with a 5 3/8” diameter or
For the
larger opening. If providing your own enclosure, please ensure crimp
that type connectors,
the Wizard there
monitor will be are two
protected options: 20
from
excessive moisture and dust. way. Trim the ends of the wires so that they are clean, ins
stop, and snap the clear portion of the connector down.
connector
To install, remove all electrical plugs that will be used from will cut
the rear panel. through
Make the
sure the insulation
power supplyby
is itself. NOTE:
monitor,
turned off, and install each supplied plug onto the wires. There are connections are made –only
two types of connectors on pinsgreen
removable 1 and 4. The
screw connectors for heavier wires and vampire tap connectors for smaller signal wires.
After all electrical connections are made, connect the plu
For the screw connectors, strip the insulation from the end ofmonitor
the each wire,
ininsert the wire into
the enclosure. Thethe connector,
Wizard is secured by tw
and tighten the screw. Make sure are no stray wire strands that could make an inadvertent connection
necessary to make these screws extremely totight, but the
another wire.

T
For the crimp type connectors, there are two options: c
20-22 and 24-26 AWG. Both operate the same way.
p
Trim the ends of the wires so that they are clean,
insert the wires into the connector until they stop,
A
and snap the clear portion of the connector down.
t
No wire stripping is necessary, as the connector will
cut through the insulation by itself.

After all electrical connections are made, connect

the plugs to the back of the monitor and mount the
monitor in the enclosure. The Wizard is secured by
two captive 10-32 thumb screws. It is not necessary
to make these screws extremely tight, but they
should be snug.

Test the power to make sure that the connections

were made properly and if possible test each input.

A Wizard installed in a JIC enclosure

34 © SLOAN LUBRICATION SYSTEMS 20

[Link] | 1.800.722.0250 37
Training Manual | Installation and Startup

Installation and Startup

This section covers installation and startup procedures. This section and the troubleshooting section should
cover the most common questions and concerns for operation and maintenance of the lubrication system.

REMEMBER: There are always new challenges that can arise with custom installations.
Never hesitate to give us a call if you have any questions or unexpected difficulties.

Lubrication System
Pre-Installation Considerations
To choose a suitable location for mounting the Sloan system, take the following into account:
The location should be easily accessible and should provide a firm mounting base for the unit. Try to avoid
areas of excessive vibration or high heat, and keep the unit sheltered from the elements as much as possible.
Although cold weather is not necessarily a problem, the unit does not tolerate rain, snow or ice. Since the Sloan
system is self-contained, it need not be mounted against the machine being lubricated. Locate it so as not to
be in the way when machine overhaul or disassembly is required.

In cases where the pump/tank assembly is mounted separately from the panel assembly, be sure to consider
tank filling and panel inspection requirements. In all cases, allow sufficient clearance around each assembly for
easy servicing.

Location and Visibility

The proper location for the Sloan system is determined more by preference than necessity. It can be mounted
nearly anywhere, but be sure to consider the length and routing of tubing runs to be made. It may make the
most sense to locate the unit out of the way, but also centrally, if possible. Convenient accessibility is more
important than having the shortest possible lube lines. For example, the system can be nicely mounted against
a building wall and the tubing lines to the machine can be run overhead or below floor grating.

38 © 2016 SLOAN LUBRICATION SYSTEMS

Electrical Hook-Ups
Consider the electrical requirements as well. If you would rather not have AC voltage and conduit runs on or
near the machine, then mount the system away from the machine, perhaps where the electrical supply is more
convenient. The Wizard monitor requires 110 VAC to operate, so a manual switch in the supply needs to be
provided. Your motor may be any one of a variety of voltages. Check your system schematic, bill of materials or
the nameplate on the motor for the requirements. Also, provide a switch in the motor circuit.

In terms of electrical consideration, also determine the best method for turning the unit on. When the
machine is running, the pump and monitor must be running. They can be switched on manually or wired to
automatically turn on with the machine. Your system can even be wired to automatically turn on before the
machine starts up to provide pre-lubrication.

Other installations may require an interlock, insuring that the system is operating normally before the machine
is permitted to start. These considerations should be made by those individuals who are familiar with the
entire operating criteria of the machine itself and how it fits into the operation of your entire facility.

If your system will be operated automatically, it is a good idea to make provisions to allow manual operation as
well as for purging, testing or maintenance purposes.

Also consider what happens when the system signals a lubrication failure. It will show a Red failure light and
will transfer its internal fault relays, permitting remote signals, horns, lights, or automatic shutdown of the
machine. Remember, the system is designed to protect oil delivery. If it signals a lubrication failure, it cannot
be ignored. Serious damage to the machine could result without proper lubrication. Think carefully about what
is to be done with the lube failure contacts. They are rated for 10 amps/110VAC or 5 amps/220VAC or 30VDC.

Tubing
Determine whether existing tubing or new tubing is to be run to the lube points. If the Sloan system is
replacing a force-feed lubricator, and the existing downstream tubing is in good shape, the feeds can be run to
the old lubricator location and tied into them. Unions are provided for this purpose. Existing tubing must be
clean and pressure-tested at least twice the operating pressure required. Use our portable hand pump or a
similar device for purging and testing.

IMPORTANT! Never re-use old soft copper tubing, as it may not be able to withstand the pressures required
in the event a line should become blocked. We recommend using welded or seamless stainless steel tubing.
All ¼” OD fittings required are included with your system and have the stainless steel sleeves to accept the
stainless tubing. Welded or seamless tubing with wall thickness of .035 inches or better is acceptable. Locate
tubing where it can be run neatly and tied down securely. It should also be located where it is out of the way of
traffic areas, inspection ports or other areas that have to be easily accessed.

[Link] | 1.800.722.0250 39
Training Manual | Installation and Startup

Installation Instructions
Coupling Alignment
Having chosen a suitable location for the Watchman, bolt it down to a level surface securely through the
four mounting feet. After tightening the bolts, remove the reducer- to- pump coupling guard to check the
coupling alignment. If the coupling has pulled out of alignment, damage to the reducer or pump drive box
bearings may result. Adjust the mounting bolts on the feet, reducer or pump drive box and shim as necessary
to re-align coupling.

Tubing
Refer to the panel outlet tags and operational schematic to identify lube outlet locations and the lube points
they are to serve on the machine. Tubing should be run neatly. Straps, clamps and plates are available for flat
bundles from 2 to 8 lines. All tubing must be supported to prevent vibration and chafing. Locate tubing runs
on the machine so as to avoid obstructing access areas. Consider maintenance requirements and install tube
unions where tube lines may need to be removed for servicing and at high points in tubing runs so air can be
completely removed from the system.

Omni Check Valves

Install new Omni Check valves at the end of each
oil line, as near as possible to the lubrication point.
Unless otherwise specified, we have included our
omni double poppet, soft seat check valves with
the system.

Electrical Supply
Supply electrical conduit as required by your area classification to the Wizard monitor and the motor. Switches
should be provided for both as referred above in the pre-installation considerations. If the tank is equipped
with a heater and thermostat, provide a switched 110VAC supply for the heater through the thermostat. Please
note, the heater is on the left hand end, the thermostat is on the right. If a level controller is mounted on the
tank front, it includes a high-low level switch, which can signal those conditions in the tank. You can provide for
remote indication through this switch if desired.

40 © 2016 SLOAN LUBRICATION SYSTEMS

Wizard Wiring
The Wizard monitor module is mounted in its enclosure with two screws through the faceplate. Remove
them and pull the module out of the enclosure. All available wiring connections are made through removable
plugs and are clearly marked on the back surface of the monitor. Input connections for 110VAC or 24 V DC
are attached here, as well as power failure relay connections and 12 VDC power output connections to the
processor board below. All wiring to the Wizard module should be long enough to permit removal of the
module from its enclosure without disconnecting it.

The power failure relay will transfer on loss of power to the Wizard. When power is lost, so is the Wizard’s
ability to protect lubrication delivery. If a failure alarm is to be indicated when the Wizard loses power, the
alarm circuit should be wired through the power failure relay contacts as well as the lube failure contacts.

In some cases, especially those with mechanically (not electric motor) driven pumps, or in cases where a
machine absolutely cannot be shut down, even if there is a power failure to the Wizard, the power failure
relay should not be used. In the standard system, if the motor and Wizard monitor are operated from
the same circuit, the power failure relay contacts should be used, as a power failure will cause the pump to
stop operating.

Also on the back of the Wizard, the processor board’s Relay Contacts are also clearly marked for each
available zone. Each can be wired as normally closed or normally open as necessary. The relays are switched
when their corresponding lube zone falls below its set alarm limit and switches to “fault” mode.

Next to the unit’s power input, there are 4 proximity switch inputs. Each input includes two ports for wiring the
proximity switch. These four inputs correspond with the four available lube zones as indicated on the unit.

Once the Wizard is properly wired, it can easily be moved and replaced using the plug-in connections. When
re-installing the Wizard module in the enclosure, take care to neatly pack the wires in the rear of the box to
avoid stressing the connectors. You can also refer to the Wizard operations manual or give us a call to answer
any questions.

Motor Wiring
Please refer to the motor data plate for details on the voltage required. Provide suitable flexible
conduit to the motor connection box to permit removal of the motor from its mounting flange to
facilitate reducer replacement.

[Link] | 1.800.722.0250 41
Training Manual | Installation and Startup

Pre-Startup Priming Procedure

The lubrication system, like any other hydraulic system has two main enemies: dirt and air. It is important
that all lines and components be purged of air and run through with new, clean oil to eliminate
contamination.

The standard system is already cleaned, purged and tested with 10 weight mineral oil, unless it has been
specified that another lubricant be used. Upon delivery, the tank has a small amount of oil in it, and the lines
are purged to the pump, to the panel, through the divider assembly and out through the bulkhead unions to
the rear of the panel where the field tubing lines are connected.

If the oil is supplied from another source, or if the tank has been separated from the pump itself for mounting
considerations, be certain that the supply line to the pump is full of oil, and that it has been allowed to run until
the oil supply is clean.

1. Fill the tank with the lubricant to be pumped. If the lubricant is not compatible with standard mineral
oil, the oil in the tank must be drained, and the pump operated until all mineral oil is discharged out of
the system.

2. Fill the lubricator pump drive box with lubricant until the gauge glass is nearly full. Be sure that all
internal moving parts are sufficiently covered with oil. This oil is not consumed, and is present only to
lubricate the drive.

3. Purge the air. Momentarily loosen the inlet fittings to each pump unit to verify a good, clean supply
of oil. Then loosen the inlet fitting at the divider valve and stroke the pumps with their hand plungers,
operate the motor drive to verify lubricant discharge to the divider, or use a purge gun filled with new,
clean, and compatible oil to purge the entire panel of air. Operate the pump until discharge is clean and
air-free then tighten the fitting. Next, loosen a fitting on each divider valve outlet to be sure the whole
assembly is fully purged. When each point flows clean and air-free, re-tighten each fitting. To this point,
you have purged the entire system and it is ready for operation.

4. All downstream lines MUST also be filled with clean, air-free lubricant. Remove all inlet
connections from the terminal check valves and operate the pump until clean lubricant is delivered
to the end of all lines. Please note, to speed up this process, a priming connection is provided on the
gauge assembly just below the gauge valve. It is a checked and capped connection where our portable
hand pump can be connected for fast purging. It is recommended that you have this hand pump not
only for this purging operation, but for the testing of lube system components in the future.

5. Special NOTE: Where extremely long tubing lines have been run, you may want to purge each line
individually. To do this, remove the line to be purged from the back of the panel. Connect the hand
pump using a union and pump until the line is full and clean. Remove the hand pump and union and
re-install the line.

42 © 2016 SLOAN LUBRICATION SYSTEMS

Final Inspection and
Verification of Operation
1. Tighten fittings. After all lines are purged, tighten all tube fittings and operate the system with both
pumps wide open.

2. Cycle light. Verify that the divider block is cycling as shown by the Wizard cycle light. It should blink on
and off with each cycle. The display on the Wizard shows the actual flow rate.

3. Lube failure testing. Test lube failure output by holding the hand plungers down on both pumps
while running. This will stop the divider block from cycling and the Wizard will transfer its lube failure
contacts when the lube failure low flow limit is reached.

4. Verify failure circuit (when applicable). The above lube failure condition on the Wizard is indicated by
a flashing digital display and the red failure alarm light. When this occurs, verify that the alarm or shut-
down circuit which you have wired downstream of the Wizard performs as required.

5. Reset Wizard. After the above is verified, reset the Wizard to its normal operating condition, indicated
by the green normal light and constant display. This can be accomplished by turning the power off and
back on, or by pushing the reset button on the Wizard’s face, or TDS switch.

6. Visual inspection. Continue operating the system to visually verify oil discharge at the end of
each oil line. Inspect for leaking fittings and components. Any leakage, no matter how little, needs
to be addressed.

[Link] | 1.800.722.0250 43
Training Manual | Maintenance

Operation and Adjustment

Refer to the operational schematic, which shows the divider displacement and recommended flow rates.
The flow rates shown are our recommendation and should be verified to be accurate and proper for your
application.

Check that the Wizard has the proper divider displacement and lube failure shut-down limits programmed.
The procedure for checking and/or changing these inputs is described in detail in the Wizard manual under
“Operation and Start-Up.”

After verifying the above, adjust the active pump stroke while operating to achieve the proper flow rate on the
current flow rate display. In most standard systems, the pump size and speed have been provided to deliver
the designed flow rate with one pump. The second pump is an installed spare and should be shut off. To do
this, turn the adjusting stem under hand plunger clockwise all the way down and tighten the lock nut until the
pump shuts off. If higher delivery is required, both pumps can be operated together for twice the capacity.

Bring the machine up to normal operating conditions and verify flow rate display again. Under some
operating conditions, the flow rate display will fluctuate from one cycle of the divider to the next. If this
fluctuation appears excessive, the display can be set to the average mode. This displays the average flow
rates of the last ten cycles. If the display is to show the average flow rate all the time, refer to the Wizard
Manual under “advanced features.”

44 © 2016 SLOAN LUBRICATION SYSTEMS

Maintenance
Preventative Maintenance Scheduling
The purpose of preventative maintenance scheduling is to protect machinery, prevent down time and
increase revenue.

Every component of a lubrication system has a lifespan. Some components, such as divider blocks and pumps,
are replaceable wearing parts. By their nature, these parts need to be inspected and changed on a regular
basis.

A properly designed preventative maintenance program will ensure that the lifespan of these parts is
maximized, but that they are replaced at a regular turnaround interval as opposed to failing in the field.

REMEMBER: If a safety mechanism triggers a shutdown, then it has done its job.

Services
The cost of regular maintenance and replacement parts is negligible in comparison to the cost of shutdowns
and damage to equipment.

We provide free consulting services to our customers to help them figure out how to make their systems run
trouble free. We also provide 3 tiers of Preventative Maintenance Services.

Train/Consult
• We make sure that you have the equipment, know how, and spare parts to do PM in house.

Divider Spares/Replacement Program

• At each predetermined interval, you take your blocks off and send them in to us.
• We repair/replace back to like new condition.

Onsite Yearly PM
• Our technician does a full system evaluation and all necessary PM work at regular intervals
• Most common in troublesome applications:
• Cement
• Corrosive environments
• High-pressure systems
• Refineries

[Link] | 1.800.722.0250 45
Training Manual | Maintenance

Annual Maintenance
The following timeline is a suggestion for annual maintenance. Due to variable conditions from Sloan
Lubrication Systems services as well as varying customer usage, this timeline is just a starting point. It may
need to be adjusted based on the realities in the field.

NOTE: Specific items may require customization.

Annual Maintenance Items

• Replace high-pressure filter element.

• Replace 3 micron spin on filter.

• Drain and replace oil in right angle gear reducer (SBCO models) – use 90 weight gear oil.

• Drain and replace oil in lubricator reservoir. While the lubricator is drained, remove a pump that has been
in service and check for cam wear and debris in the bottom of the box, which can indicate cam, bearing or
pump wear.

• Drain condensate and dirt from bottom of tank. Use the condensate drain valve for this purpose unless a
high volume of contamination is found. If highly contaminated, drain entire tank using 1/2” spuds on either
end of tank, flush and re-fill with clean oil.

• Clean the Y-Strainer screen on the oil supply located under the tank.

• Replace Rupture Disc. Tighten lightly to 14 in. lbs.

• Purge air from system – start with the oil supply to the pumps, then work your way up to the gauge assembly
and then the divider block. Be sure to open the supply line to the divider block when purging to prevent air
from entering the block. Don’t forget to purge each line out to the terminating check valves as well!

• Open both pump adjustments wide open (turn adjusting screw all the way counter-clockwise).

• Turn on the system and hand stroke each pump to verify increased oil delivery on the Wizard monitor to
ensure both pumps are primed and operating properly.

• Shut-off the spare pump(s) (turn full clockwise), and adjust active pump stroke for proper oil delivery on the
Wizard monitor. Alternating active and spare pumps yearly will ensure the longest life for both.

46 © 2016 SLOAN LUBRICATION SYSTEMS

Divider Block Maintenance
• We recommend testing all divider blocks during yearly maintenance. The information provided in testing can
be used as a baseline to determine life expectancy of piston sections for your application. That information
can also be used to increase the time between tests once a life expectancy is determined.

• Blocks are to be tested to the factory guidelines specified in this manual. Any individual piston sections that
do not pass the pressure test need to be replaced.

• There are 2 pressure characteristics that need to be tested.

• The first test is cycle pressure. This is how much pressure needs to be generated to cause the pistons to
move. This verifies that the piston is able to move freely within the block.

• First completely purge the block with oil and then pump slowly and watch the pressure gauge on the
pump. Anything under 500 psi is within spec.

• The second test is a bleed down test. This test determines how much oil can leak back along the face
of the piston at pressure. This test verifies that the piston-to-bore clearance is still within spec. If the
clearance becomes too large, the divider block can no longer deliver its oil at pressure. Instead the oil can
“bypass” or bleed back and will not be delivered to that point.

• After performing the cycle pressure test, a test cap is placed on the bottom right outlet of the divider
block. The block should lock and build pressure.

• Build the pressure to 3000lbs and start a timer for 1 minute.

• If the pressure drops less than 500lbs it is good.

• Move up to the next outlet and repeat. Each outlet must be tested in this manner.

Other Maintenance Items

• Omni check valves should be replaced every 5 years. All delivery checks should be double poppet checks
installed so that the O-rings have wet seats. (See “Check Valve” section.)

• The pump pistons are another wear part. Because the Wizard monitors the flow rate, the operator can verify
that the pumps are still pumping. As the pumps wear over time, they will need to be adjusted to keep up with
the specified flow rate. The pumps have reached their end of life when the adjustment knob is threaded out
by more than 75% of its total travel.

[Link] | 1.800.722.0250 47
Training Manual | Troubleshooting Guide

Troubleshooting Guide
This guide presents several common scenarios that operators will encounter during a shutdown. Use this
guide to help identify the cause of shutdowns, but remember that actual shutdown scenarios can be far more
complex. If more than one mode of failure is present in the system, the problems can be significantly more
difficult to diagnose.

The best way to prevent complex failures is to follow our annual maintenance guidelines.

Wizard Registers A Failure

Wizard Registers A Failure: Rupture Disk Blown
• Safe operating pressure has been exceeded.

• Look for popped pressure indicators (see pressure indicator section.)

• Always cycle a new block before you put it on.

• It is possible for the pistons to drift while in storage.

• To fix this, make sure pressure is off the block.

• Make sure the MPS and cycle indicator are not mounted on the same block.

Wizard Registers A Failure: Disk Not Blown - Cycle Indicator Moving

• If the cycle indicator is moving your lube rate is either below the alarm level, or you have an electrical
problem.

• Reset Wizard and check flow rates.

• Check to see if the proximity switch is counting.

• Check if the proximity switch housing loose.

48 © 2016 SLOAN LUBRICATION SYSTEMS

Wizard Registers A Failure: Disk Not Blown - Cycle Indicator NOT Moving

• Cycle Indicator is not moving.

• Check your oil supply (empty/plugged)

• Check your lube box

• Loose cams/ broken shaft

• Check your pumps

• Broken rocker

• Airlocked

• Look for loose connections or broken tubing

Following Pin Indicators

• If a pin indicator pops on a section it indicates a problem from that section

• If that outlet goes to a secondary divider block, check that block for popped pins.

• Follow the pins to the final downstream point and work backwards

• Your most common problem will be worn divider block sections

• Purge the divider block from its inlet (you may need to loosen outlets)

• If it is locked or takes more than 500 psi to cycle, replace the divider block with a spare and test
it at your bench

• If it is not the divider block it could be check valves going bad.

(Check these after you determine that it is not the block)

• If you ever crack a line at a terminal and get bubbles of gas, your check is bad. This can migrate back
and lock the divider block.

• Fouling of the delivery port. This could be a sign of something going wrong in the compressor.

[Link] | 1.800.722.0250 49
Contact Information
If you have any additional questions or just need some help, call us at
any time at 1-800-722-0250.

After hours, leave a message and someone will be in touch shortly.

We are also available via email at sales@[Link], or you can contact any
of us personally on our cell phones or via email.

THANK YOU!

50 © 2016 SLOAN LUBRICATION SYSTEMS