Bijur Delimon DR4 User manual

Page 1 of 12 BA_2009_2_GB_DR4
Operating instructions
Change over
valve DR4
INDEX
Page
1. General ................................................................................. 2
2. Safety .............................................................................. 2 – 4
A. Valve type ............................................................................. 4
B. Function ............................................................................... 4
C. Inspection ............................................................................. 5
D. Monitoring ...................................................................... 5 – 7
E. Accessories ................................................................... 7 – 9
3. Application ........................................................................... 9
4. Principle of operation .......................................................... 9
5. Dimensions ................................................................ 10 – 11
6. Specification ...................................................................... 12
7. Service / Start-up ............................................................... 12

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1. General
Before installing and operating this equipment, we highly recommend that you become thoroughly familiar
with these instructions. DELIMON does not accept liability, expressed or implied, for any direct or
inconsequential injuries to personnel or damage to equipment, including process interruption, arising from
the misuse or misapplication of its products. Application and / or modification of product beyond its
intended purpose is strictly prohibited.
DELIMON reserves the right to make modifications, changes and/or amendments to both products and to
these instructions as may become necessary to assure ongoing technical clarity.
The content of this technical publication is the sole graphic and intellectual property of DELIMON and is
protected by local and International Copyright Law. As such, it may not be copied, reproduced or used for
any purpose other than that intended by the Company; i.e. as a guide to proper installation, maintenance
and operation of its equipment by qualified personnel and their supervisors. Use of this information for
any other purpose or intent requires the expressed written permission of DELIMON GmbH.
Contact Information: For assistance with product, replacement parts, service or training.
DELIMON GmbH Branch Office
Arminstraße 15 Am Bockwald 4
D-40277 Düsseldorf D-08344 Grünhain-Beierfeld
Phone : [phone] E-mail : [email protected]
Fax : [phone] www.bijurdelimon.com
2. Safety
These instructions provide basic guidance which must be followed during installation, operation and
maintenance. It is assumed that personnel performing required tasks are skilled in the areas of electrical
and mechanical millwright trades plus all local and federal safety requirements. These instructions should
be kept near the point of use and made available for reference at all times.
2.1 Identification of safety warnings in the operating instructions
To minimize risk to people working with this equipment, safety warnings included within these instructions
must be observed. Potential safety issues are identified through use of the following general danger
symbols:
Safety Sign, per DIN 4844, provides warning of potential general danger.
Safety Sign, per DIN 4844, provides warning of potential electrical danger.
ATTENTION
Caution designation utilized to signify that damage to machinery and function may result if guidance is not
properly followed.
Instructions affixed directly to machines and equipment must always be observed and maintained to
ensure that they are fully legible. Examples of such instructions would be:
Rotational direction arrows for shafts and couplings.
Identification of fluid connections, direction of flow and substance contained in pipes.
Important Note: There is always increased risk of slipping or falling whenever spilled or leaking
lubricants are present. In all cases, they should be properly removed and disposed of.
Safety Sign, per DIN 4844, provides warning of an increased risk of slipping and falling
due to the presence of water, oil, grease or other foreign substances on pavements,
floors and walkways.

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2. Safety (continuation)
2.2 Personnel qualification and training
Personnel performing work required to install, operate, maintain or inspect this equipment must be
adequately trained and qualified. In this regard, determination of competency, understanding and
supervision levels required for individual assignment is left to the purchaser of the equipment. However,
should assistance with on-site training be desired, please contact your local DELIMON office for
assistance.
2.3 Dangers in case of nonobservance of the safety instructions
Failure to properly follow all safety instructions may result in hazard to personnel, the environment or to
machinery and equipment. Failure to follow these instructions may also additionally void warranties and
nullify claims for damages. Examples of such instances follow:
Failure of machinery or operating systems to function properly
Failure to observe proper methods of maintenance and repair
Unnecessary creation of hazards to personnel by means of electrical shock, mechanical injury or
exposure to potentially hazardous chemicals
Unnecessary creation of environmental hazards through chemical leaks
2.4 Safety conscious working
All Safety Instructions resulting from National, Local or User mandated regulations, as well as those
contained within this instruction, must be observed at all times.
2.5 Safety instructions for the user/operator
Users should always take care that only authorized and skilled personnel are allowed to perform
installation, maintenance and inspection work.
Installation, maintenance and inspection of lubrication systems should only be performed while
machinery and equipment being serviced is in “Shut-Down Mode”.
Protective covers and guards, provided to ensure that contact with moving parts is eliminated during
machine operation, (e.g. couplings, pulleys, gears, etc.), must be replaced following maintenance
and repair.
Use “Common Sense”! When hot or cold machine parts can lead to potential dangers, those parts
must be handled in such manner so as to avoid human touch; i.e. shielding is required.
Leaks from shaft seals, reservoirs, piping or fittings should be repaired so as to not cause potentially
hazardous materials from escaping to the work area. In instances where such leaks have occurred,
all local and National rules and regulations for their recovery and disposition must be followed.
All potential hazards resulting from exposure to electrical sources must be eliminated. Please refer
to VDE and local power company rules and regulations for guidance.
Before restarting system and equipment, refer to instruction in Section 7; Start-Up Procedure.
2.6 Safety instructions for maintenance, inspection and installation work
Before installing or servicing lubrication equipment and machinery, management should insure that only
persons who are fully trained, skilled and authorized to perform such work are assigned to such tasks.
Major installation or modification work should only be performed during shut-downs. It is also imperative
that shut-down procedures recommended by equipment manufacturers be followed. Pumps, lubricators
and distribution systems which deliver potentially hazardous materials to the environment must be
thoroughly cleaned. All safety devices and protective equipment, disabled or removed during cleaning,
must be immediately reinstalled and reactivated prior to machine use.
Safety Sign, per DIN 4844, Use Safety Glasses or Goggles.
Advice: Whenever working with compressed air, wear safety glasses
Safety Sign, per DIN 4844, Use Breathing Mask.
Advice: Observe EC-Safety Data Sheet for materials of consumption
and additives used and use personal protective equipment.

Page 4 of 12 BA_2009_2_GB_DR4
2. Safety (continuation)
2.7 Unauthorized conversion and manufacture of spare parts
The modification and/or manufacturing of parts for use as spare or replacement parts in DELIMON
lubrication equipment, without the written consent and approval of DELIMON Engineering, is strictly
prohibited. Any such modification and/or manufacture of component parts shall immediately render any
and all warranties as null and void.
2.8 Unacceptable modes of operation
The operational integrity and reliability of all equipment supplied is warranted only when said equipment is
utilized in strict accordance with parameters established in Section 1; Introduction. Maximum operating
parameters outlined in Engineering Data Sheets must never be exceeded.
2.9 Guidelines & standards
1., 2. and 3. guideline (see data sheet: R&N_2009_1_GB)
3.0 Notes on environmental protection and waste disposal
During proper operation, various component parts of lubricating systems are subject to special
requirements as set forth by Environmental Legislation.
General requirements for handling lubricants are specified in their respective safety data sheets.
Used lubricants are hazardous forms of waste and therefore require special handling and supervision
with regard to § 41 paragraph 1, sentence 1 and paragraph 3 no. 1 of KrW-/AbfG (Closed-Loop Waste
Management Act).
Used oils must be handled in compliance with AltölV (Waste Oil Ordinance).
Any devices or components which become contaminated with lubricant must be disposed of by a certified waste
management company. Additionally, records indicating proper conformance to waste management practice and
law must be filed according to NachwV (Ordinance on Waste Recovery and Disposal Records).
GENERAL PRODUCT CHARACTERISTICS
Hydraulically controlled
Working pressure adjustable from 40 to 350 bar
Motion indicator with optional electrical monitoring
A. VALVE TYPE DR4
B. FUNCTION
Non-return (adjusting of 200 bar)
Non-return (adjusting of 150 bar)

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C. INSPECTION
Stage A
D. MONITORING
1 x Proximity switch with mounting bracket (Denco)

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D. MONITORING (continued)
2 x Proximity switch with mounting bracket
mounting bracket
see page 10 and 11,
Dimensions
1 x Limit switch with mounting bracket
mounting bracket
see page 10 and 11,
Dimensions

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D. MONITORING (continued)
with one motion indicator pin
with two motion indicator pins
E. ACCESSORIES
without

Page 8 of 12 BA_2009_2_GB_DR4
E. ACCESSORIES (continued)
2 pressure gauges with adaptors
Mounting bracket (for fixing onto the basic frame)

Page 9 of 12 BA_2009_2_GB_DR4
E. ACCESSORIES (continued)
2 x pressure gauges (with adaptor) and mounting brackets (for fixing onto the basic frame)
3. Application
The DR4 is an hydraulically operated directional control valve for use with dualine or non-return systems.
4. Principle of operation
The reversing valve’s switching pressure depends on the spring pressure, which can be set for
installation. After the activation of all dual-line metering valves in the lubricating system, pressure is built
up against a guide piston, which in turn acts on a rocker arm. If the force acting on the rocker arm is
equal to the spring force, it moves into the other end position. This directs a control current towards one
end of the piston, which determines the direction of flow. The piston moves, thereby freeing at the other
end the passage to the tank. Accordingly the pump’s delivery flow is directed into the opposite line and
the pressure is taken off the originally pressurised line back to the tank.
An electric switch, which is activated by means of a pin attached to the control piston in the direction of
flow, is mounted on the reversing valve. When the switch is activated by the pin, either to open or close it,
a signal is sent to the control to either stop the pump or start a switching interval.
The diagram and the details on pages 4 clarify the mode of operation. The following mode of operation is
available for use in dual-line lubrication systems.
On the DR4 valve (non-return system), the two pipelines do not return to the reversing valve but the
reversal pressure is sufficient for the operation of all the measuring valves.

Page 10 of 12 BA_2009_2_GB_DR4
5. Dimensions

Page 11 of 12 BA_2009_2_GB_DR4
5. Dimensions (continued)

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6. Specification
Pressure adjustment range: .................................................................................................... 40 ... 350 bar
Maximum Flow rate: ............................................................................................................ 650 ccm/minute
Temperature range: ........................................................................................................ - 20° C to + 100° C
Useable lubricants:
Oil or grease .................................................................................................................... max. NLGI class 2
Weight: ................................................................................................................................................ 7.0 kg
Material:
Metal parts (body etc.) ........................................................................................................................... Steel
Seals ...................................................................................................................................................... Viton
7. Service / Start-up
Adjustment
It will be noted that the control of pressure is accomplished through the use of a spring in compression
between the adjusting bonnet and the piston assembly. To raise the operating pressure on the system the
adjusting bonnet, should be turned clockwise after slackening off the locknut. When the pressure is correct,
tighten up the locknut so there will be no further movement of the adjusting bonnet.
Maintenance
The valve will operate for many years without any maintenance provided that new clean lubricant is
pumped into it. If the valve is clogged with dirt, it can be disassembled. It is important to note which pistons
are assigned to which boreholes. Clean the valve in solvent. Put the pistons in the right boreholes and re-
assemble the valve. As the pistons are produced and fitted into the corresponding boreholes with very tight
tolerances, it is not possible to mix up the pistons on site.
Fault finding
Besides ingress of contamination, the most common reason of failure is when the valve has been applied
with a greater flow rate than the maximum stated in the specification. Excessive flow will cause the flow
directing piston to "bounce" when moving across and find a position which will lock-up the valve. To release
it from this state, after exhausting any pressure, the piston closure plugs can be removed and the pistons
pushed fully to one end of their bores.