This document provides recommendations to improve operation of divider block lubrication systems. It suggests installing non-bypass filters before lubricator pumps to prevent trash from damaging pumps. Installing pressure gauges and purge ports on pump discharge allows monitoring for issues. Using reset pressure indicators and double poppet check valves helps locate blockages. Testing divider blocks regularly helps ensure integrity is maintained. Balancing high differential pressure systems and checking pumps/gearboxes prevents premature wear. Following these guidelines enhances system reliability and performance.

1. Operation and Maintenance of
Divider Block Lubrication Systems
BY CURTIS ROYS
c
Atmospheric Rupture Assembly
on Back of Anchor Cross
S.S. Tubing
S.S. Liquid Filled
Pressure Gauge
Purge Port Connection
Lubricator Gear Box
Pressure Indicators
With Memory
Lubricator
Pump
Master
Divider Valve Assembly
proflo
Divider Block Monitor
& Shutdown Protection
Oil Supply
NeoMag
Cycle Indicator
Discharge Side
of Lube Pump
High Pressure
In-Line Filter
Injection
Check Valves
Cylinder or
Rod Packing
Injection points
Secondary
Divider Valve Assembly
(All lubrication systems do not
require secondary divider valves)
Base Section
Discharge Check Valves
U.S. $19.99 / CAN. $29.99
Set
Mode
T
C
C "PROTECTING COMPRESSORS WORLD WIDE"
Midland, Texas 1-800-664-4033
C. C. Technology Inc.
prO
flOCLASS I, DIV II
Groups A,B,C,D
NRTL/C
IrDA PORT
AVG 20
RR
M o d e l - P F 1
US Copyright Registered 2001
T
C
C
Injection
Check Valves
Cylinder or
Rod Packing
Injection points
3201 West Wall St. Midland, Texas 79701
Office: (432) 520-6700 Fax: (432) 520-6707
Toll free: 1-800-664-4033
Visit Us on the Web: www.cct.nu
email: curtis@cct.nu
CCT- Delta-P
Filter Adapter
with Low Pressure
Non By-Pass
In-line filter
25
50
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100
125
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2. This manual is dedicated to all the people, compressor operators and companies I have
had the pleasure of doing business with during the past 25 years.Aspecial thanks to Dan
Toth and Ariel Corporation for allowing me to train the people attending the training
school each month in their facility in Mount Vernon, Ohio. Thanks to David McCoy and
all the field service personnel atAriel Corporation for their confidence and support in my
goal to educate the compressor industry for troubleshooting and operation of the divider
blocklubricationsystem.
There are many trials and tribulations while designing, installing and troubleshooting
divider block lubrication systems on slow speed and high speed compressors. Without
the learning process and the mistakes made and corrected during my learning stages, this
manual would not have been possible. All of the sections of this training manual are
concepts formed from several years of experience and practical field application. If the
principles in this manual are utilized in operation and maintenance of the divider block
system,theoperatorshouldexperienceyearsoftroublefreedependableservice.
From the end user to the design engineer of divider block systems, you are always
welcome to call C C Technology for brainstorming, troubleshooting or design
applications. I appreciate the opportunity to provide assistance in the design, installation
troubleshootingand/oroperationofdividerblocklubricationsystems.
Copyright (C) 2004 by C CTechnology Inc.
All rights reserved. Printed in the United States of America. No part of this publication may be
reproduced in any part without written permission from the author. For information on lubrication
products or to obtain copies of this publication contact C C Technology 3201 West Wall St. Midland
Texas,79701orcall(432)520-6700,fax(432)520-6707.
“ACKNOWLEDGEMENT”
C. C. Technology Inc.
T
C
CC C TechnologyC C Technology
All trademark names in this manual are the property of theirrespective companies and not associated with C CTechnology Inc.
Roys

3. Recommended Upgrades, Preventive Maintenance and Additions
to Benefit Divider Block Systems...............................................................................page 2,3
Lubrication System Design:
Lubrication System Design Sheets.............................................................................. page 41,42,43,44,45,46
Lubrication Rates:
CalculatingBaseLubricationRates:
CompressorCylinders&RodPacking...........................................................................page18
LubeOilRecommendationsforVariousGasStreamComponents...................................page 19
Operational Procedures:
Optimizing Divider Block Lubrication Systems .............................................................page 4,5
Locating Blockage In Divider Block Lubrication Systems .............................................page 6,7,8,9
Pressure Testing Divider Blocks...................................................................................page 10
TestingforLeakingCheckvalves...................................................................................page13
BalancingHighPressureLubeSystems.........................................................................page15,16,17
LubricatorPumps.........................................................................................................page5
PressureGauges..........................................................................................................page5
PurgingAirFromDividerBlockLubricationSystems......................................................page14
CheckValveInstallation................................................................................................page13
DividerBlockIdentificationTwin&Single.......................................................................page10,23
Divider Block Cross Porting.........................................................................................page 24,25,26,27,28
Troubleshooting the Divider Block Lubrication System..............................................page 38,39,40
Lubrication System Components & Accessories:
Filtration......................................................................................................................page5
CheckValves...............................................................................................................page12
Reset Pressure Indicators w/Memory...........................................................................page 11
Atmospheric Rupture Assembly ..................................................................................page 11
Lubrication System Purge Gun.....................................................................................page 14
SB & Trabon Divider Block Assembly Instructions........................................................page 20
Lincoln Divider Block Assembly Instructions................................................................page 21
Dropsa Divider Block Assembly Instructions................................................................page 22
No-Flow Switches and Cycle Indicators:
DNFT & PROFLO Jr. Comparison ...............................................................................page 29
PROFLOJr.InstallationProcedure................................................................................page30
PROFLO Jr. Troubleshooting........................................................................................page 31
PROFLOJr. Wiring&TestingforCorrectOperation........................................................page32
NeoMagCycleIndicator-OperationandInstallation.........................................................page33
Kenco.........................................................................................................................page40-9-A
Lincoln........................................................................................................................page40-9-B
Trabon/Lubriquip.........................................................................................................page40-9-C
Proflo Divider Block Monitor & Shutdown Protection:
Proflo Button Operation................................................................................................page 34
ProfloInstallationProcedure.........................................................................................page35
Proflo Wiring Instructions............................................................................................page 34
Fluid Flow Trending Software Download & Viewing Procedure.....................................page 36-37
CCTechnologyProducts...........................................................................InsideBackCoverPage
TABLE OF CONTENTS
T
C
C
QUICK DIRECTORY
3201 West Wall St. Midland, TX 79701
(432) 520-6700 Nation Wide 1-800-664-4033 Fax: (432) 432-520-6707
C. C. Technology Inc.
Visit Us On the Internet www.cct.nu
1

4. 3201 West Wall St. Midland, Texas 79701
Office: (432) 520-6700 Fax: (432) 520-6707
Toll free: 1-800-664-4033
Visit Us on the Web: www.cct.nu
email: curtis@cct.nu
RECOMMENDED UP-GRADES, PREVENTIVE MAINTENANCE
AND ADDITIONS TO BENEFIT OPERATION OF ALL
DIVIDER BLOCK LUBRICATION SYSTEMS
1.InstallNonBy-PassFiltersonSuctionSideofLubricatorPumps
Several situations have existed where trashin the lubricator pump created a low flow condition.The low flow
condition is extremely hazardous to the compressor and can possibly cause phantom shutdowns or the cylinders,
packing, rods or rings to fail prematurely. Filtration prior to the lubricator pump is essential.A25 to 100 micron filter
on the inlet side of the pump is extremely beneficial.This filter should be a non by-pass design, easy to remove, clean
and/or replace. The non by-pass filter will give field service technicians and operators a quick fix for trash problems
on the inlet side of the pump.(See page 5 Filtration) Note: Do Not use a typical automotive type filter. A typical
automotive filter will by-pass when the filter becomes clogged introducing trash into the lubricator pumps, divider
blocks and check valves.Always check with the filter manufacturer to ensure the filters installed on the compressor
are non by-pass which will alleviate the problem of trash into the system.
2. Install Discharge Manifolds and/ora Pressure Gauge on the Discharge Side of the LubricatorPump
A discharge manifold assembly consists of an anchor cross, purge port, pressure gauge and atmospheric
rupture disc, all of which should be incorporated into all well designed divider block lubrication systems. The
pressure gauge is a critical instrument to monitor divider block operation and lubrication system pressure. Fluid
movement of the pressure gauge indicates proper operation of the divider block system. Erratic movement or sudden
drops in pressure indicate by-passing or sticking pistons in the divider blocks or the presence of air or gas in the
system.The pressure gauge gives the field service technicians or operator an inexpensive tool to recognize problems
with by-passing pumps or divider blocks before major damage to the cylinders and packing occur. Note: Never
assumethelubricatorpumpordividerblockswillnotby-passbecauseitisnew.(Seepage5PressureGauges)
3.InstallaPurgePortontheDischargeSideofLubricatorPump
An addition of the CCT pump discharge manifold (PCA) will allow a purge gun to be easily connected to the
lubrication system and eliminate air from entering the system . The manifold is designed to provide field service
technicians or operators easy access to purge the divider block system of air before startup or after any maintenance
on the lubrication system. A check valve must be in place at the purge point to ensure air free oil is in the system
when the purge gun is removed.This eliminates phantom shutdowns and air locking problems. (See page 14 Purging
AirFromDividerBlockSystems)
4.InstallResetPressureIndicatorsonDividerBlocks
An essential tool to allow field service technicians or operators to easily and immediately locate excessive
system pressure or blockage in individual divider blocks, tubing runs or injection points. (See Page 11 Pressure Ind.)
5. Install an Oil Head Fitting (OHF) and Extreme Duty Check (XDC)Valve
The OHF ensures a minimum of 1 inch of oil head in front of the check valve.The oil head keeps a liquid seal
on the check valve and increases reliability for many years. It is never recommended to install check valves in a
verticalorhorizontalpositionwhichwouldnotallowforaliquidseal.(Seepage13)
6.InstallBasePlateCheckValves
Base plate check valves should always be installed on each working outlet of the divider block base plate to
stabilize the operation of the divider block and eliminate gas or air from entering the divider block due to faulty or
failed injection check valves. This will minimize phantom shutdowns until the faulty injection check valves can be
replaced.(Seepage12CheckValves)
3201 West Wall St. Midland, TX 79701 (432) 520-6700 1-800-664-4033 fax: (432) 520-6707
2

5. 3
7. Double Poppet S.S. CheckValves
Install the CCT ( XDC) Extreme duty double poppet 10,000 PSI check valve at all injection points.The poppet
o-ring seal is extremely effective for positive sealing. Install the Oil Head Fitting where high pressures or temperatures
exist and in the presence of gases known to create problems with elastomer seals. Failed check valve problems have
been alleviated with the installation of the Oil Head Fitting (OHF) and Extreme Duty Check (XDC). (See page 12
CheckValves)
8. Review DividerBlock System Design forMaximum Efficiency and Recommended Oil Consumption
To insure adequate oil supply to high pressure cylinders and packing, the divider block system should be
designed to eliminate over lubricating lower pressure suction and interstage cylinders and packing. The total system
does not need extra lubrication when only one or two cylinders and packing are operating with high discharge
pressures. The high pressure injection points should reflect the needed amount of oil without over lubricating the
medium to low pressure points. This will increase the efficiency of the compressor, reduce operating costs and
eliminate problems associated with excessive lubrication. Contact the compressor manufacturer or a professional
divider block system designer. Fill in one of the Design Sheets on pages 41 thru 43 or on the CCTwebsite (www.cct.nu)
specific to your compressor and email or fax it to C C Technology. This will enable the design engineer to check your
systemforcorrectdividerblocks.
9.TestDividerBlocksforPressureIntegrity
All divider blocks are metal to metal sealing surfaces and the possibility of by-passing is always present. By-
passing could be a result of excessive clearance between the piston and bore of a new divider block or from millions of
cycles each year creating wear between the piston and bore. Note: Never assume tolerances between the piston and
bore are acceptable even if the divider block is new and the piston is cycling properly. Test all divider blocks for
integrity at least every two years with the CCT Single Point Test Device (SPTD). When injection pressures are
over 1000 PSI, the divider blocks should be tested for integrity or replaced every 24 months. Divider blocks are
much less expensive to replace than compressor cylinders, rods or packing, not to mention the cost of labor and
lostrevenuefromdowntime. (SeePressureTestingDividerBlockspage10)
10.InstallBalancingValvesonDividerBlockSystemswithHighdifferentialPressure
Use of balancing valves are recommended to assist divider blocks to accurately proportion lubricant when
differential injection pressures of approximately 1200 PSI to 1500 PSI are present in a divider block system. Balancing
valves should be installed on all low pressure injection points when 1200 PSI to 1500 PSI differential pressure exists in
the system.This will eliminate divider block by-pass problems and create a fluid movement of the divider block system
eliminating excessive wear to the divider block piston. Differential pressure is the actual difference between the
pressure needed to inject oil into each cylinder or packing lubrication points. The divider block system will not
typically see final discharge pressure of the compressor. Pressure gauges must be installed in the lubrication line with
each balancing valve to enable field service technicians or operators to monitor and balance the system correctly. (See
Balancing High Pressure Divider Block Systems pages 15,16,17)
11. LubricatorGearbox Overflow into CompressorFrame
Several lubricator pumps have been discovered by-passing oil into the lubricator box. If tubing is connected
from the lubricator box to the compressor frame to move excessive oil out of the lubricator tank it is impossible to
detect a by-passing lube pump. Remove the tubing designed for overflow of the lubricator tank and plug the tank and
frame tubing fitting. If the pump is by-passing it will be very noticeable by overfilling the lubricator box. If the operator
prefers to keep the by-pass tubing in place it should be removed from the compressor frame every 6 to 12 months and
left open to the atmosphere for several hours. If the lube pump is by-passing excessive oil will drip excessive oil from
the tubing. This indicates to operators or service technicians the lubricator pump is faulty. Pressure test lubricator
pumps every 12 months to ensure the pump will build sufficient pressure to blow the atmospheric rupture disc in the
system. If the sight glass on the lube box is covered or stained with dirty oil, you will never know if the oil level is
correct. Clean the sight glass and lube box every year and inspect the cam lobes in the box for wear. Never assume
the lubricator pump will not by-pass because it is new or has been refurbished.
12. LubricatorCamshaft and PumpWear
It is absolutely necessary for the operator to remove all lube pumps, completely drain the oil from the lube box
andcheckforwearonthepumprockerarms,camlobesandinternalgearsofthelubricatorreservoirevery12months.
(Recommended Upgrades & Maintenance Continued) Visit Us On the Internet: www. cct.nu
3201 West Wall St. Midland, TX 79701 (432) 520-6700 1-800-664-4033 fax: (432) 520-6707

6. A Divider Block Lubrication System is designed to receive oil from a positive displacement pump and divide the oil in precise
amounts to be injected into each point to be lubricated (packing gland, cylinder, etc.). The divider block system is capable of
lubricating as many points as needed by addition of divider block sections to the system but must be engineered for each
individual application to insure that the correct amount of lubricant is dispensed to each lubrication point. Divider block systems
that are designed with a combination of the compressor manufacturers recommended lube rates and the field experience of
the designer will eliminate problems due to insufficient lubrication or excessive oil consumption. The divider block system
consists of filtration, a lubricator pump, divider block metering sections, pressure indicators, check valves and flow monitoring
shutdown devices.
The Divider Block Lubrication System is termed a single line progressive system because it contains only one oil supply line
from the pump discharge to the master divider block and from the master divider block to the secondary blocks. A master
divider block is the first divider block downstream from the lube pump. A secondary divider block is any divider block receiving
oil from the master divider block. If one piston in the system stops moving, a blockage has occurred and the remaining pistons
stop moving. This results in a complete loss of oil flow to the cylinders and packing. The blockage creates a higher than normal
system pressure as the lube pump continues to inject oil into the stalled system trying to move the pistons and overcome the
blockage. The excessive pressure is signaled by a pressure gauge installed on the discharge side of the pump. The exact point
of blockage is indicated by pressure indicator pins (See page 9 Figure “D”) mounted on the front of the divider block. The
system continues to build pressure until it is relieved to the atmosphere by means of an atmospheric rupture assembly (page
11). Notice:All divider block systems must have an atmospheric rupture Installed on the discharge side of the pump.
The Divider Block Lubrication System Cannot Tolerate: (1) Foreign Material of Any Kind (2) Air or Gas Anywhere in
the System (3 ) Leaks ofAny Kind.
Optimizing
Divider Block
Lubrication Systems
INTRODUCTION
DESCRIPTION & OPERATION
Lubrication System Components
Atmospheric Rupture Assembly
on Back of Anchor Cross
Atmospheric Rupture
Assembly
Injection Check Valve
Base Section
Discharge Check Valve
Tubing
Pressure Gauge
Purge Port Connection
Lubricator Gear Box
Reset
Pressure Indicator
With Memory
Lubricator Pump
Master
Divider Valve Assembly
Oil Flow
Indicator
Port Plug
Piston Enclosure
Plugs
Discharge Side
of Lube Pump
Injection
Check Valves
Cylinder or
Packing Gland
Injection Points
Injection
Check Valves
Cylinder or
Packing Gland
Injection Points
Reset Pressure Indicator
With Memory
Mechanical No-flow Shutdown
Divider Block with
NeoMag
Cycle Indicator
Divider Block Section
Divider Block with
Cycle Indicator Pin
proflo Jr. No-Flow Shutdown
LUBE SENTRY
527-100-130
LUBRIQUIP - HOUDAILLE
TRABON AND MANZEL
MODEL #
ELECTRIC
SWITCH
200 00 051
25
0
0
0
0
01
30
0
0
0
0
5
T
C
C
4
Secondary
Divider Valve Assembly
(All lubrication systems do not
require secondary divider valves)
Base Section
Check Valves
Visit Us On the Internet: www. cct.nu
“Proflo”
Divider Block Monitor
& Shutdown Protection
Set
Mode
T
C
C "PROTECTING COMPRESSORS WORLD WIDE"
Midland, Texas 1-800-664-4033
C. C. Technology Inc.
prO
flOCLASS I, DIV II
Groups A,B,C,D
NRTL/C
IrDA PORT
AVG 20
RR
M o d e l - P F 1
US Copyright Registered 2001
High Pressure
In-Line filter
CCT- Delta-P
Filter Adapter
with Low Pressure
Non By-Pass
In-line filter
CLASS I, DIV. I Groups A,B,C,D
NRTL/C
M o d e l - J r 1
US Copyright Registered 2004
proflo Jr.
"PROTECTING COMPRESSORS WORLD WIDE"
Midland, Texas 1-800-664-4033
C y c l e
I n d i c a t o r
R A T E D
3 0 0 V D C
1 2 0 V A C
@ . 5 a m p s
P R O T O Y P E 1S E R I A L #
2 - M I N U T E SA L A R M
RED - N.O. ORANGE - N.C.
YELLOW - SWITCH CLOSURE OUT
GREEN - GND.
NeoMag
Cycle Indicator
25
50
75
100
125
150
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7. LINCOLN
OPTIMIZING AND DIVIDER BLOCK LUBRICATION SYSTEMS
Oil Supply:
The basic lubricator uses a box suction pump which pulls oil
from the reservoir. This system depends on oil supplied to the
lubricator reservoir through an oil level controller by gravity
feed from an overhead oil supply or by a pressurized oil supply
from the engine or compressor crankcase. The lubrication
system using box suction pumps is a perfect environment for
sludge and water to form. This is normally attributed to old or
inadequate gaskets, high temperatures and leakage through
the lubricator pump hand priming assembly. Inspect and clean
the lubricator reservoir annually. When possible it is
recommended to utilize a single pump and pressurized oil
supply for all lubrication systems.
Filtration:
Dirt or foreign material of any form cannot be tolerated and will
cause serious damage or blockage to all lubrication system
components. If contamination does not cause immediate
malfunction or damage, it will greatly reduce the expected life
of all components of the divider block system. Installation of a
spin on type non-by-pass filter before entering the lube
system is essential for protection of the lubricator pump.
Utilizing a 10 to 25 micron high pressure in-line filter
downstream of the lubricator pump will provide years of
trouble free service from all divider blocks.
For optimum reliability and performance change or clean all
filter elements every three (6) to six (12) months depending on
the application of the divider block system and the
environment.
Lubricator Pumps:
The lubricator pump of choice is the pressurized inlet pump.
These pumps eliminate priming problems and contamination
problems associated with box suction lubricators by receiving
filtered, pressurized oil directly to the suction inlet of the pump.
The pistons in all lubricator pumps are metal to metal wearing
surfaces precision fitted to extremely close tolerances. With
use, lubricator pumps start to wear, piston clearance becomes
excessive and without warning the pump will leak oil past the
piston into the lubricator gear box. If the lube pump becomes
difficult to adjust for lube rates or system cycle time becomes
erratic, check for lubricator pump bypass. By-passing pumps
can also be recognized by the lubricator reservoir
continuously overfilling with oil. If tubing from the lubricator
reservoir is plumbed into the compressor crankcase to
eliminate overflow, a by-passing pump cannot be detected
unless removed from the reservoir and tested with shop
controlled testing procedures.
Note: All lubricator pumps should be pressure tested annually
for reliability to demonstrate the ability to build sufficient
pressure to inject oil through the divider block system, into the
injection points and rupture the atmospheric disc..
Pressure Gauges, Purge Port & RuptureAssembly:
Pressure Gauge: The pressure gauge is essential for monitoring
the lube system operation. Any problems with the lube system will
immediately be indicated by the pressure gauge. The pressure
gauge should swing with a fluid movement with no erratic pressure
changes. If the pressure gauge builds excessive pressure and
drops immediately to an extremely low pressure, check for system
blockage, (page 6,7,8,9), air in system (page 14), by-passing divider
blocks, (page 10) or leaking check valves (page13). The pressure
gauge should indicate adequate pressure needed to inject oil into
the final discharge cylinder. If the gauge does not indicate ample
pressure, the lube pump cannot be adjusted for consistent lube
rates or cycle time, immediately test the lube pump for by-passing.
Purge Port: The purge port is necessary for purging the system
before start-up or after maintenance on the lube system.
Atmospheric Rupture Assembly: The atmospheric rupture
assembly is the only exit for the oil if the system should encounter
blockage or excessively high pressure.
Divider Blocks:
All divider block pistons are metal to metal surfaces, precision fitted
to extremely close tolerances. In low to medium pressure service
divider blocks should be pressure tested every 12 to 24 months.
This test will confirm the piston tolerances are close enough to build
adequate pressure to force oil into the injection point without by-
passing. Note: To insure proper operation, all new divider blocks
should be pressure tested before installation. (See Pressure
Testing Divider Blocks page 10).
Check Valves:
Check valves are an essential part of every lubrication system.
Leaking check valves enable air or gas to enter the lubrication
system and can be associated with phantom shutdowns and/or
blown atmospheric rupture discs. Double ball metal seat or double
poppet soft seat check valves are both excellent check valves
depending on the application. Discharge check valves installed on
the base plate of the divider block will alleviate air or gas from
entering the divider block should an injection check valve fail. (See
Check Valve Information (page 12) and Check Valve Installation
andTesting page 13)
proflo Monitor Pages 34,35,36 , and Mechanical No-Flows
:
For troubleshooting proflo see page 32.
See page 39,8-C, & 40,9-A,B,C for troubleshooting mechanical no-flows.
5
S.S. Double Poppet
Soft Seat Check
7500PSI
C.S. Double Ball
Metal Seat Check
8000PSI
S.S. Base Plate
Discharge Check
7500PSI
PART# 0-750014
7500 PSI
ULTRA-CHECK
PART# 0-80018
8000 PSI
CC TECH
750018R
HIGH PRESSURE
In-Line Fiter
S.S. Washable Element
HIGH PRESSURE
In-Line Fiter
Bronze Element
LOW PRESSURE
Delta-P
Non By-Pass Filter
PREMIER CCT-HVLP
CCT / Alemite / SB / Trabon DropsA
proflo Jr. Lincoln Kenco
CCT / Lincoln
TRABON
Purge Port for Prelube
Before Startup
Pressure Cross Assembly
Installed on Lubricator Pumps
Atmospheric
Rupture Assembly
Trabon/Lubriquip
Alemite & SB

8. Locating Blockage
in Divider Block
Lubrication Systems
DIVIDER BLOCK IDENTIFICATION
DIVIDER BLOCK ASSEMBLY DESCRIPTION
CONTAMINATION BLOCKAGE
SEPARATION BLOCKAGE
AIR
Figure A. Components of The Divider Block Assembly
(see pages 20,21,22)
The divider block assembly consists of an inlet and end
section, intermediate sections plus a minimum of three
divider blocks. The divider block baseplate assembly is held
together with tie rods and nuts. (Figure A). Each divider
block contains a piston of predetermined size to inject a
calculated amount of oil into each point receiving
lubrication.
A Master Divider Block is the first divider block downstream
from the lube pump. A Secondary Divider Block is any
divider block receiving oil from the master divider block.
(Figure E, page 9).
BLOCKAGE IN THE SYSTEM
If blockage occurs in the divider blocks, lube lines, check
valves or injection points the system will build excessive
pressure attempting to overcome the blockage. Excessive
pressure is limited and signaled by the use of pressure
indicators and atmospheric rupture assemblies. (See page
11). When blockage occurs and oil flow discontinues,
monitoring devices protect the compressor by alarm or
compressor shutdown.
O-Rings
O-Rings
Intermediate Base
Inlet Section
Lube Outlets
End Section
Indicator Port
PlugPiston Enclosure
Plug
Tie Rod
Tie Rod Nuts
Stamping located on the front of the divider block
indicates the quantity of oil discharged by that particular
block with each cycle of the piston. The oil discharged
with each cycle of the piston is expressed in
thousandths of cubic inches (12 = .012 in , 9 = .009 in ,
etc.). Divider blocks are manufactured to require one (1)
or two (2) outlets unless cross port bars are designed
into the system. The number of lube outlets required is
indicated by a stamped letter (S= single, one outlet only,
T= twin, two outlets required). See Figure B. Never block
any outlet that is designed to discharge lubricant.
Notice: Divider block pistons are individually fitted to
each bore to extremely close tolerances and cannot be
turned end for end or interchanged with other pistons.
Dirt or foreign material of any form cannot be tolerated and will cause serious damage or blockage to the lubrication
system components. If contamination does not cause immediate malfunction, it will greatly reduce the expected life of
the divider block system components. Cleaning the divider block and components will only temporarily solve the
problem. The source of contamination must be eliminated. Proper filtration of oil to at least 25 microns before entering
the lube system is essential for trouble free dependable lubrication system operation. All filter elements must be
changed on a periodic basis.
Hard wax or soap like deposits in the divider block system indicate separation of the lubricant thickener out of solution or
the presence of animal fat lubricants. Cleaning the divider block system will only temporarily solve this problem. Consult
you lubricant supplier for alternate lubricants. When changing to a new lubricating oil always inquire if they are
compatible to avoid problems with the lubricator pumps, divider blocks and check valves.
Air cannot be tolerated in lines or components.Although not usually the cause of damage to the lube system, air in the
lube lines and components is often the cause of system locking, lubrication failure or phantom compressor shutdown.
All divider block system components must be full of oil and free of air for proper operation. (See page 14).
3 3
Divider Block
Figure B. Intermediate Base & Divider Block
O-Rings
Piston
Piston Size &
Outlets Required
Indicator Port
Plug
Indicator Port
Piston Enclosure
Plug
Piston Enclosure
Plug
Enclosure Plug
O-Ring Seal
6
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9. LOCATING BLOCKAGE IN DIVIDER BLOCK LUBRICATION SYSTEMS
Blockage in divider block systems is caused by: (1) Crushed Tubing Line (2) Blocked Injection Point
Make a visual inspection of the system and check for crushed tubing lines. Check to ensure all divider blocks required to
discharge oil do not have pipe plugs installed in the base plate outlet. Divider blocks with a letter “T’ stamped on the front
should have (2) two outlets open from the base plate. Divider blocks with a letter “S” stamped on the front should have (1) one
outlet open on the base plate and one outlet plugged. (See page 23 Defining Divider Blocks)
ALL SERVICING MUST BE DONE UNDER THE CLEANEST POSSIBLE CONDITIONS
Dirt, foreign material and air are the worst enemies of all lubrication systems. Always use clean filtered oil
(A): Divider Block Systems with One Divider Valve
Assembly and Reset Pressure Indicator Pins:
Step A1: Connect a manual lubrication system purge gun
to the inlet of the divider block assembly or purge port on
the pressure cross assembly as shown on page 8 Figure
"C" and slowly operate pump. Continue to raise pressure
until an indicator pin pops out. See page 8 Figure "D". If no
indicator pin pops out, blockage is in the divider block
assembly. See Step 4 page 8. If an indicator pin pops out,
the extended pin indicates blockage down the discharge
line common to that pin. Remove the tubing connection
from the check valve at the injection point common to the
divider block with the indicator pin extended out. Slowly
operate the purge pump. If high pressure exists check
tubing and fittings. If the purge pump operates freely and
oil flows from the tubing, connect the purge pump to the
check valve at the injection point. Slowly operate the
purge pump. If high pressure exists the check valve or the
injection point on the cylinder or packing gland is plugged.
Correct as necessary. Always test the check valve for
reverse leakage by pumping oil into the outlet side. If oil
leaks through the check valve replace it immediately.
(B): Divider Block Systems with One Divider Valve
Assembly without Reset Pressure Indicator Pins:
Step B1: With manual purge gun connected to the divider
block or purge port on the pressure cross assembly as in
StepA1, remove each indicator port plug one at a time and
slowly operate the pump. Do not exceed 1,000 PSI. If
pressure on the gauge holds replace the indicator port
plug. Remove and replace each indicator port plug one at
a time until pressure drops on the pressure gauge and the
divider block cycles freely when operating the purge
pump. If the pressure gauge drops after removing an
indicator port plug and the divider valve cycles freely the
blockage is downstream of that individual divider block.
Replace the indicator port plug and remove the tubing
connection from the check valve at the injection point.
Slowly operate the purge pump. If high pressure exists
check tubing and fittings. If the purge pump operates
freely and oil flows from the tubing connect the purge
pump to the check valve at the injection point. Slowly
operate the purge pump. If high pressure exists the check
valve or the injection point on the cylinder or packing gland
is plugged. Correct as necessary. Always test the check
valve for reverse leakage by pumping oil into the outlet
side of the check valve. If oil leaks through the check valve
replace it immediately. If all indicator port plugs are
removed and the divider block will not cycle, blockage is in
the divider block assembly. See Step 4 page 8.
(C):Divider Block Systems with Master and
Secondary Divider Blocks with Pressure Indicator
Pins installed:
Step C1: Connect a manual lubrication system purge gun
as shown on page 9 Figure "E" to the inlet of the master
divider block assembly or purge port on the pressure cross
assembly and slowly operate pump. Continue to raise
pressure until an indicator pin pops out. See page 8 Figure
"D". The pin indicates blockage down the discharge line
common to that pin. If an indicator pin pops out, see Step 2.
If no indicator pin pops out, blockage is in the master
divider block assembly. See Step 4 page 8.
(D): Divider Blocks Without Pressure Indicator Pins:
Step D1: With manual purge gun connected to the master
divider block or purge port on the pressure cross assembly
remove each indicator port plug one at a time and operate
the pump. Do not exceed 1,000 PSI. If pressure on the
gauge drops and the divider block cycles freely after an
indicator plug is removed, the blockage is downstream of
that individual divider block. See Step 2. If all indicator port
plugs are removed and the master divider block will not
cycle, blockage is in this divider block assembly. See Step
4 page 8.
Step 2: Testing indicates blockage is located downstream
of the Master divider block. If installed remove the
indicator pin, or indicator port plug and connect the purge
gun to the indicator port on the front of the master divider
block that feeds the blocked line. See page 9 Figure "F".
Remove all indicator port plugs in the secondary divider
block assembly. If oil can be easily pumped through all
indicator ports, the blockage is not in the tubing line or the
divider valve. See Step 3. If oil does not flow freely through
the indicator ports the blockage is in the secondary divider
block or its supply line. Disconnect the tubing line from the
inlet of the secondary divider block assembly and pump
the purge gun to verify blockage is not in the tubing line. If
blockage is in the divider block assembly, see Step 4 page
8.
Step 3: Remove indicator port plugs or indicator pins from
the secondary divider blocks. Connect purge gun to each
indicator port of the secondary divider blocks one at a time
and slowly operate pump. See page 9 figure "G". If high
pressure exists in any port tested blockage has been
located. Check tube, fittings, check valves, packing gland
and cylinder injection points by pumping oil into each.
7
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10. LOCATING BLOCKAGE IN DIVIDER BLOCK LUBRICATION SYSTEMS (cont'd.)8
Step 4: When testing indicates blockage is in the divider block, before disassembly, remove all piston enclosure plugs.
See page 6 Figure A. Without removing the pistons use a brass rod and finger pressure only to move each piston back
and forth. If all pistons are moveable, replace the enclosure plugs and retest the assembly by pumping oil into the inlet.
(Blockage may have been dislodged and the assembly may be in working condition without further service.)
If piston is jammed or wax like substance or dirt is found in the piston bore, the divider block must be disassembled and
cleaned. Before removing, make a note of divider block positions on the base from top to bottom. See Figure C.
(Example 9T-12T-24T). Working with one block at a time, remove the piston with a brass rod. If the piston is stuck, try
removing it in the opposite direction. The piston may have to be forced out by lightly tapping it with a brass rod only. Do
not use any type of hard metal object to remove the piston. After removal, thoroughly wash the piston and divider block
with a clean suitable solvent. Blow out all ports in the divider block and use a small piece of wire to clean out all
passages. Inspect divider block bore and piston for scratches or score marks. If either of these are damaged a new
divider block must be installed. The final step is to thoroughly clean the base sections and blow out all ports with
compressed air.
Caution: DO NOT use emery cloth, bearing cloth or any type of abrasive substance to clean or smooth any
piston or bore. To do so will cause the divider block to bypass and can cause extensive damage to compressor
components. Pistons are precision fitted to each bore to extremely close tolerances and cannot be turned end
for end or interchanged with other pistons.
After entire divider block assembly has been cleaned, inspected and all blocks and pistons appear in good condition,
lubricate and reassemble, positioning the divider blocks on the base in their original order as per notes. Make sure all
pistons slide smoothly and fit snugly in divider block bores. After assembly, test for proper operation and purge the
system with a purge gun using oil common to the system. To insure proper operation of the divider block system, it
is absolutely necessary that all tubing and components be filled with clean oil common to the system. All air
must be purged from tubing and components before start-up. (See page 14 Purging Divider Block Systems)
S.S. Tubing
Purge Port Connection
Purge Here before Start-up
Divider Block
Assembly
Discharge Side
of Lube Pump 200 00 051
25
0
0
0
0
01
30
0
0
0
0
5
T
C
C
0
500
1000
501
0
00
25
3000
2000
Check Valves
24T
9 T
12T
Reset Pressure
Indicator Pins
or Port Plugs
Divider Block
Inlet Purge here
Figure "D".
Figure "C". Lubrication System with One Divider Block Assembly
INDICATOR
PIN OUT
Divider Block Side View
Manual Purge Gun
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11. LOCATING BLOCKAGE IN DIVIDER BLOCK LUBRICATION SYSTEMS (cont'd) 9
Master Divider Block Inlet
24S
12S
12T
24T
12T
12T12T
24T
12S
Manual Purge Gun
Check Valves
Cross Port Bar
Indicator
Port Plug
Pressure Indicator Pin
0
500
1000
0
15
0
25
00
003
0
02 00
Secondary
Divider Block
Inlet
Secondary Divider Blocks
Figure "D".
INDICATOR
PIN OUT
Divider Block Side View
Figure "E"
Lubrication System with Master and Secondary Divider Blocks
Figure "F"
Locating Blockage Down Stream
of Master Divider Block
Figure "G"
Locating Blockage Down Stream
of Secondary Divider Block
Manual Purge Gun
Manual Purge Gun
Secondary
Divider Block
Secondary
Indicator Port
Plug or
Indicator pin
Secondary
Indicator Port
Plug Removed
Indicator Port
Master Divider Block
Indicator Port
Secondary
Divider Block
24S
12S
12S
0
050
1000
1500
250003
00
0
20
0
12T
12T
24T
Check valves
12T
12T
24T
Check valves
Secondary
Divider Block
Secondary
Indicator Port
Plug or
Indicator pin
24S
12S
12S
12T
24T
12T
12T
24T
Check valves
0
500
1000
1500
250003
00
0
20
0
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NeoMag
Cycle Indicator

12. Pressure Testing
Divider Blocks
For By-Passing
DESCRIPTION
All divider blocks are metal to metal sealing surfaces and the possibility of oil passing around the piston to a point of least
resistence is always present. By-passing can be a result of excessive clearance between the piston and bore of a new
divider block or from millions of cycles each year causing wear between the piston and bore. For this reason it is
necessary to test each individual divider block before installation and/or after continued use. This will confirm the piston
to bore tolerances are close enough to build adequate pressure to force oil into the injection point. Note: Never assume
tolerances between the piston and bore are acceptable even if the divider block is new and the piston is cycling
properly. Pressure test all divider blocks in low to medium service at least every two years. When high injection
pressures are present or there is no filtration of the oil before the lubrication system the divider blocks should be
pressure tested or replaced every 12 months. Divider blocks are much less expensive to replace than compressor
cylinders, rods or packing, not to mention the cost of labor and lost revenue from down time.
Procedure for Testing Divider Blocks For By-Passing
To test divider blocks for by-passing, a manual purge gun equipped with a pressure gauge and capable of developing
5000 PSI is necessary. For pressure testing the divider block use a 10-weight oil at room temperature to simulate hot oil.
Test each divider block assembly complete with pin indicators installed.Test only one divider block at a time..
A. Place the divider block assembly in an open container with all base outlets open. Connect the purge gun to the inlet of
the divider block assembly. Operate the purge gun to cycle the divider block several times to purge air from the assembly
and verify that oil will flow freely from all outlets. Divider blocks should cycle at less than 300 PSI. (See “A”)
Divider blocks stamped with a “T” should have only one outlet on the base plugged during testing of that side of the
piston. Each outlet of the divider block stamped with a “T” must be plugged and tested one side at a time (See “B”).
Individual testing of each outlet ensures both sides of the piston will build adequate pressure.All divider blocks stamped
with an “S” on the front should have both outlets on the base plugged to test for by-passing (See Figure “C”) This will test
both sides of the piston at the same time. (See page 23 Defining Divider Block Identification)
B. Plug the outlet on the base under the divider block being tested with a 1/8” pipe plug. If a tubing fitting is installed in the
base, plug the fitting with a tubing plug. Leave all other outlets open. Operate the purge gun until the pressure gauge
indicates 3000 PSI. The block may cycle once or twice, but should pressure to 3500 PSI immediately. Stop pumping oil
into the divider valve at 3500 PSI. Check the plug in the discharge outlet to confirm there are no external leaks. The
pressure gauge should not lose more than 1000 PSI during a 30-second test. Note: Testing the divider blocks at
higher pressures is necessary if the application dictates higher system operation.
If the pressure gauge on the purge gun drops suddenly and oil squirts from the other outlets, a by-pass condition exists.
The piston is worn and is allowing oil to by-pass. This is not acceptable and the divider block must be replaced. If the
tested block does not lose more than 1000 PSI in 30 seconds, relieve the pressure, move the plug to the next outlet and
repeat the same test. After all divider blocks have been pressure tested with this recommended procedure, the divider
blocks should be reassembled, purged with oil and put back in service.
Divider Block
Inlet
24T
24T 24T
12S
12S 12S
12T
12T 12T
Manual Purge Gun
Divider Block
With “S”
Base
Outlets Open
Oil Flowing
Freely
Plugged
to Test One Side
of the “T” Twin Block
All Other
Outlets Open
Both Sides
Plugged
to Test “S”
Single Block
All Other
Outlets Open
0
50
0
1000
5 0
1 0
25000
30
0
20
00
0
50
0
1000
15
00
2005
000
3
2000
0
50
0
1000
15
00
2005
003
0
2000
“A" Divider Block All Outlets Open “B” Testing “T” Divider Block “C” Testing “S” Divider Block
10
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