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Lubrication Solutions from iwisGuide for the correct use of iwis lubricants

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SUMMARY

Adequate and effective lubrication of chain joints prolongs the service life of a chain many times over. Selection of the right lubricant and appropriate lubrication method guarantee reduced wear and additional corrosion protection.

Correct relubrication reduces wear and prolongs chain service life

Regular maintenance and lubrication are essential to ensure low wear and longer chain drive service life.

The operating conditions of the system determine maintenance and lubrication intervals. Scheduled maintenance and lubrica-tion must be carried out regularly. Around two thirds of chain failures can be prevented by suitable relubrication, so the choice of a suitable (re)lubricant is the most important factor in ensuring long chain service life, since the individual links of a chain act as bearings while the constantly oscillating chain is in operation.

Inadequate lubrication and additional contamination can cause a reduction of chain performance by as much as 20%, thereby re-ducing service life more than any other influencing factors.

Our lubricants were developed especially for and with iwis, so their ingredients and properties are optimally suited to the product ‘chain’. Thanks to countless trials on specially devel-oped test rigs and our close collaboration with reputable lubri-cant manufacturers, iwis is an expert partner on all aspects of chain lubrication.

Our technical Service-Team will be glad to advise youon chain maintenance and handling. Please get in touch!

Tel: +49 89 76909-1500 | Fax: -1198 E-Mail: sales-muenchen@iwis.com

of chain failures can be prevented by appropriate relubrication.

Did you know?

Relubrication Initial lubrication

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Operation time in h

Chai

n el

onga

tion

in %

0

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The more effective the lubricant,

the greater the permitted bearing

area pressure!

The following abnormalities could be signs of insufficient relubrication:

• Formation of metal dust/rust• Unusual noise level, squeaking• Unusually high chain elongation• Twisted pins• Heavy wear of sprockets• Increased power consumption of drive motor• Heat discoloration/tarnishing

PRACTICAL HINT

Continuous relubrication with a suitable quantity of lubricant is much more effective than long lubrication intervals with large quantities of lu-bricant. To determine the optimum quantity of lubricant, we recommend starting with 3 ml of lubricant per 1 m of chain (for 10B-1) and gradually increasing the dosage until you have found the correct quantity.

As a rule, the lubrication status in the chain joint can be checked by opening a connecting link. The surface of the pins must be covered by a clear, clean layer of lubricant.

1 Dry runningHeavy wear results in rapid destruction of the chain.

2 One-time initial lubricationWear is delayed until the lubricant has been used up.

5 All-round lubricationSignificant wear reduction resulting in chain reliability and long service life.

Our maintenance-free, self-lubricating MEGAlife chains can be fitted as an alter-native.

3 Occasional dry runningwhen relubrication intervals are too long.

4 Partly inadequate lubricationresults in irregular wear – caused by poor-quality, contaminated, unsuitable or insufficiently applied lubricant.

Longer chain service life with the right relubricationIf you find that your chain is insufficiently lubricated, we recom-mend the following action: clean the chain with a very low-vis-cosity oil or suitable wax product to loosen dirt particles and

remove old lubricant and other contaminants from the chain joints. After the chain has been cleaned, relubricate it – follow-ing our practical hints – using a suitable relubricant.

About chain elongation, lubrication conditions and roller chains:The correlation between chain elongation and lubrication

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DriveLoaded half

Driven

Unloaded half

Centre distance

SlackIdealLubrication point

Correct relubrication in practice

1. Preparation

Chain wear most frequently starts in the joint area, so it is essential to en-sure that there is always sufficient lubri-cant around the pins and bushes. Ensure that the chain is thoroughly cleaned be-fore relubrication to guarantee optimum penetration of the lubricant. The best cleaning technique is to use a brush and cleaning spray. In most cases, complete degreasing of the chain is very complex and time-consuming, so it is not recom-mended.

2. Lubricant application

Selecting the most suitable relubricant in combination with the right application technique is the best way to guarantee maximum chain service life.

Regardless of how the relubricant is ap-plied, it must always penetrate the joint (the space between pin and bush). To ensure this, the lubricant is applied be-tween the outer and inner plate. The vis-cosity of the lubricant also plays a major part. The iwis range of relubricant sprays has proved highly successful in day-to-day use.

3. Lubrication point

To ensure that the lubricant penetrates the chain joint, it should be applied di-rectly to the gap between inner and out-er plate and between roller and bush. The ideal application point is positioned on the slack strand, because this gives the lubricant plenty of time to reach the areas of the chain where it is required to act.

Relubrication Initial lubrication

VP6 SuperPlus SprayVP6 Kombi SuperPlus Spray is a fully synthetic, high-adhesion, high-temperature chain oil. Suitable for all industrial chain applications.

Highlights:

• Temperature range from 0 °C to 250 °C• Wide range of applications• Easy to apply• High-performance lubricant developed

especially for chain applications• Optimum penetration• Silicone-free

VP6 SuperPlus is suitable for use as a relubri-cant with the following iwis initial lubricants:1

• JWIS : IP2, IP3, IPW, IP4, IP9, IP14• ELITE : EL-1, EL-3, EL-4, EL-6, EL-8, EL-9

NEW VP8 FoodPlus SprayVP8 FoodPlus Spray is a relubricant for chains in food applications. Thanks to its outstanding wear protection properties, combined with a wide temperature range and corresponding food safety certificates, it can be used in a wide range of ap-plications in the food industry.

Highlights:

• NSF H1 food-grade approval (No. 157999)• MOSH/MOAH-free• Precise, economic application possible• Optimum penetration of chain joint• Temperature range from -35 °C to +135 °C• Free of animal products and ethanol• Silicone-free

VP8 FoodPlus is suitable for use as a relubricant with the following iwis initial lubricants:2

• JWIS: IP16, also compatible with IP0• ELITE: EL-2, iwiDUR

VP8 FoodPlus can also be used in applications with temperatures below 0 °C.

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Recommended relubricantsSelecting an effective lubricant and the right relubrication technique are essential to ensure efficient relubrication. We offer the following range:

1 Application-specific conditions such as ambient temperature must be taken into account.2 On request, compatibility of our relubricant sprays with other iwis lubricants not listed here can be considered, taking the respective application into account.

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The iwis lubricant portfolio offers the right initial lubricant for a wide range of different applications. Choosing the right initial lubricant with care is vital, as it plays a crucial role in ensuring controlled running-in elongation and a long chain service life. Besides the lubricant itself, the right lubricant application tech-nique is also decisive for subsequent chain performance in con-tinuous operation.

The drip time can be adjusted according to customer require-ments, guaranteeing that there will always be sufficient lubri-cant in the chain joint and the outside of the chain covered only with a thin film of lubricant. This will, for instance, reduce the risk of oil dripping or spinning off in sensitive environments.

Temperatures in the application Frequency and method of cleaning

Contamination (type and quantity) Compatibility with the relubricant

Moisture Drive chain speeds

Substances that may come into contact with the chain

Various aspects are crucial when choosing an initial lubricant:

We will be glad to help you to choose suitable lubricants.

The right initial lubricant

Initial lubrication

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Relubrication

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Our recommendation for the right initial lubricant, depending on application and chain type used

Application/environment Requirement(s) Chain type JWIS lubricant ELITE lubricant

Standard drives Standard roller chain IP2 EL4

High loads JWIS SL nickel-plated roller chain

IP2 EL4 eliDUR+

High loads + no contamination by lubricant JWIS MEGAlife – –

Damp/corrosive environment

JWIS CFELITE CF

Dry, iwiDUR*

Dry, eliDUR+*, iwiDUR*

Maintenance-free JWIS b.dry Dry, iwiDUR* –

Medium loads JWIS CR Dry, IP3* –

High loads Nickel-plated roller chain IP2, IP9 eliDUR+, EL3

Dusty environment Standard roller chain IPW iwiDUR

Maintenance-free JWIS MEGAlife IPW –

Sensitive environment

No contamination by lubricant JWIS MEGAlife Dry, IPW* –

No contamination by lubricant +Drive chain speed > 3m/s

JWIS MEGAlife II Dry, IPW* –

High temperatures < 70 °C JWIS SL JWIS MEGAlifeJWIS CRNickel-plated roller chain

IP3/IP4 EL4, eliDUR+

> 70 °C JWIS SL JWIS CRNickel-plated roller chain

IP3/IP4 EL1, EL4, EL5

High standards of hygiene

JWIS MEGAlife Nickel-plated roller chain

Dry, IPW* Dry, iwiDUR*

Corrosive environment JWIS CR Dry, IP3* –

Corrosive environment + maintenance-free JWIS b.dry Dry, iwiDUR* –

Food processing IP16 iwiDUR, EL2

Corrosive environment JWIS b.dry Dry, iwiDUR* –

Corrosive environment + high loads JWIS CR Dry, IP3* –

* if possible

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IP2

Standard lubricant with good lubricating effect and outstand-ing corrosion protection for all applications.

IP3

Long-term lubricant for high-speed drives, absolutely non-drip and non-splash.

IPW

High-performance lubricating wax with good adhesion and outstand-ing wear protection, permitting significantly longer relubrication intervals. Can be used without problems in dusty or powdery environments.

IP4

Thermally stable high-tempera-ture lubricant that provides good protection against wear and corrosion.

IP9

Corrosion protection for preser-vation with minimal lubricating effect.

IP14

Dry lubricant for slow-running chain drives and low to medium loads.

IP16

Food-grade lubricant with good wear and corrosion resistance. Meets the stringent requirements of USDA-H1 and LMBG (NSF No. 154891).

IP0

Low-temperature lubricant with optimum lubricating effect. Free-flowing across entire tem-perature range.

Initial lubricants Overview of temperature ranges

+280

+260

+240

+220

+200

+180

+160

+140

+120

+100

+80

+60

+40

+20

0

-20

-40

-60

-80

IP2

IPW

IP4

IP9

IP14

IP16

IP0

°C

IP3

IMPORTANT

Choosing the right initial lubricant for the application in question plays a crucial role in ensuring controlled running-in elonga-tion and a long chain service life. Besides the lubricant itself, the right lubricant application technique is also decisive for sub-sequent chain performance in operation.

Relubrication Initial lubrication

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EL1

High-performance lubricant for operating temperatures up to 250 °C.

EL2

FDA H1-rated food-grade lubri-cant.

EL3

Long-term, mineral oil-based lubricant with special additives to improve adhesion and corrosion protection.

eliDUR+

Lubrication and corrosion protec-tion, specially designed for use on roller chains.

EL4

Synthetic high-temperature lubri-cant with maximised operating temperature range.

EL5

Synthetic Teflon long-term lubricant for high-temperature applications.

iwiDUR

New generation of food-grade wax lubricant with FDA-H1 classifica-tion (NSF No. 154890).

+280

+260

+240

+220

+200

+180

+160

+140

+120

+100

+80

+60

+40

+20

0

-20

-40

-60

-80

°C

EL1

EL3

EL5

EL2

EL4

Initial lubricants Overview of temperature ranges

Highlights eliDUR+

is an outstanding lubricant and anti-corrosive agent that was specially developed for roller chains. It contains additives that provide protection against extreme pressure, wear and corrosion. It has excellent wear values and improves the perfor-mance of ELITE roller chains on wear test benches by up to 300 %.

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Maintenance-free roller chains: When relubrication is not possible

The purpose of correct (re-)lubrication is to minimise friction in the chain joint i.e. between pin and bush. The more friction oc-curs, the greater the incidence of wear.

However, some applications do not permit the use of “liquid” oil as an initial lubricant or relubricant. In order to achieve the longest possible chain service life in such cases, a chain can be treated with grease or wax as an initial lubricant. This can complicate relubrication at a later date, however.

There are other ways of protecting the chain joint against wear by treating the surfaces of pins and bushes, the “partner components” subject to the most friction. What are known as “maintenance-free” versions have also proved to be a practical solution. These include chains with bushes made from sintered material which permit the long-term “storage” of lubricant in the chain joint, so that the outside of the chain stays dry but the joint area is well lubricated. This iwis range of maintenance-free chains is marketed under the JWIS-MEGAlife brand.

Another way of reducing friction is to use bushes made from special high-performance plastic, which takes over the friction reduction task normally performed by lubricant and allows the chain to run completely without lubrication. The leading prod-ucts in this field are JWIS-b.dry chains made from CF stainless steel – ideal for use in sensitive environments!

The same rule applies to maintenance-free chains as to other versions: relubrication is recommended as soon as it possible/permissible, as this can significantly prolong the service life of the chain.

Please feel free to contact us if you need help or advice in rela-tion to concrete application cases.

Relubrication Maintenance-free

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Maintenance-free iwis chains for added value

MEGAlifeMEGAlife maintenance-free roller chains feature chemically nick-el-plated individual components for corrosion protection, and can be used in a temperature range from -40 ° to +150 °C.

Special oil-impregnated sintered bushes are a highlight in terms of wear resistance and prolonged service life, as they provide long-term self-lubrication of the chain bearing – no additional lu-bricants are required.

Highlights• Seamless sintered bush 1 made of a material developed spe-

cifically for this application, hardened and treated to optimize its tribological properties

• Pin 2 with wear-resistant, friction-optimized coating• Seamless roller 3 with corrosion-resistant coating

and optimized geom-etry for the sintered bush

b.dry roller chains are made from rust- and maintenance-free CF stainless steel, and their optimized link design is a high-preci-sion highlight. The secret of the b.dry range: “steel-on-steel” is a thing of the past!

Our b.dry bushes are made from a special high-performance poly-mer and are completely lubricant-free. To date, the properties of this material are unrivalled and unique.

Highlights• High-performance polymer bush

1 made from FDA-compliant material

• Thin-walled seamless stainless steel bush 2 , ball-drifted

• Base chain: JWIS CF stainless steel chain 3

dry

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For more information, see our product flyer or online at www.iwis.com/bdry

For more information, see our product flyer or online at www.iwis.com/megalife

Technische Highlights • Optimal aufeinander abgestimmte Einzelteileigenschaften ver-

ringern den Verschleiß der Ketten und erhöhen die Lebensdau-er markant. b.dry-Ketten sind extrem zuverlässig, dynamisch hochbelastbar und korrosionsbeständig.

• b.dry-Ketten laufen komplett trocken, eine Schmierung ist nicht notwendig dank Hochleistungskunststoff gleitlager im Gelenk.

• Hochleistungspolymer-Hülsen sind FDA-konform, hochbe-lastbar und reibungseffi zient. Kontakt mit Lebensmitteln oder hygienischen Artikeln ist unbedenklich.

• Edelstahlträgerhülsen: dünnwandig, nahtlos und kugelkalib-riert. b.dry-Ketten erreichen dadurch eine höhere Festigkeit sowie eine erheblich größere Verschleißbeständigkeit.

• CF-Grundkette ist aus austenitischem Edelstahl.

• Sehr hohe Medienbeständigkeit. Informationen zur chemi-schen Beständigkeit der b.dry-Kette und -Hülse auf Anfrage.

• Längentoleranzen nach ISO 606.

• Temperaturbereich: -100 °C bis +200 °C.

• Keine Nachschmierung erforderlich.

• Auch in Ausführungen als Rollenketten mit Anbauteilen oder verlängerten Bolzen sowie als kundenindividuelle Entwicklung möglich. ANSI-Ketten auf Anfrage.

Anwendungsgebiete• In aggressiven Umgebungen• In Umgebungen mit Wasser- oder Dampfapplikationen

und strengen Reinigungsvorschriften wie z.B.:• Pharmaindustrie• Lackierstraßen• Lebensmittelindustrie• Reinraumanwendungen

Hochleistungspolymer-Hülse aus FDA-konformem Werkstoff

Edelstahlträgerhülse dünnwandig, nahtlos und kugelkalibriert

Grundkette: JWIS CF-Edelstahlkette

dry1

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Verschleißlebensdauer Kette initialgeschmiert

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4x besser als der Wettbewerb

LABS-frei LABS-freiIm trockenen Zustand

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Standard-Ketten

iwis Standard-Ketten

wartungsfreie Ketten

Versuchsläufe ohne Nachschmierung bei hohen Geschwindigkeiten.Grafische Darstellung entspricht iwis Testergebnis

MEGAlife

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MEGAlife I und MEGAlife IIDie wartungsfreien iwis Ketten

PROBLEM/AUSGANGSLAGE

• Nachschmierung nicht oder nur bedingt möglich

• reine und trockene Umgebungs-bedingungen

• erschwerter Zugang für Wartungsarbeiten• Verschmutzung der Anlage und des

Fördergutes durch Kettenschmierstoff.

HIGHLIGHTS MEGALIFE II

• Die Lösung bei schnell laufenden Kettentrieben, v > 3m/s und/oder hohen Belastungen

• Deutlich verbesserte Verschleiß bestän-digkeit durch ein spezielles thermoche-misches Verfahren der Bolzen, die zu einer sehr hohen Oberflächenhärte und optimalen Haftfestigkeit führt

• Deutlich längere Lebensdauer• Bolzen und Sinterhülsen sind optimal

aufeinander abgestimmt• Nicht geeignet in Umgebungen,

wo Korrosion auftreten kann• Haupteinsatz der ML II ist als

Antriebskette• Für anspruchsvolle Anwendungen

HIGHLIGHTS MEGALIFE I

• Hervorragend geeignet für normale Kettenanwendungen ohne Nach-schmierung bei Geschwindigkeiten bis max. 3m/s

• unter bestimmten Bedingungen dauer-haft wartungsfrei

• Sehr leicht zerlegbar – easy break• Auch in korrosiven Umgebungen einsetz-

bar; empfehlenswert mit Schmierung, wenn möglich

• 100 % Kompatibilität mit iwis Standard-Förderketten durch Verwendung der gleichen iwis Original-Anbauteilen

• MEGAlife I Rollenketten mit verlängerten Bolzen sind chemisch vernickelt

• Alle Rollenketten mit abgesetzten Bolzen• Umweltfreundlich durch Entfall der

Schmierung• Auch als Transferkette oder Stauförder-

kette oder Gripkette verfügbar – die wartungsfreie iwis – Lösung für neue Anwendungen in der Fördertechnik

UNSERE LÖSUNG

Wartungsfreie iwis Hochleistungsketten mit spezieller Gelenkausführung. Innovative technische Details führen zu einer bisher unübertroffenen Lebensdauer auch ohne Nachschmierung.

www.iwis.com

b.dry wartungsfreie Edelstahlketten

Edelstahl weiter gedacht: extrem verschleißbeständig, rostfrei und absolut trocken!Überall dort, wo Nachschmierung unerwünscht oder unmöglich ist, zeigen b.dry-Ketten ihr volles Potenzial: Hygienisch und ohne Einsatz jeglichen Schmiermittels scheuen sie in Bezug auf Perfor-mance keinen Vergleich. Ihre Verschleißlebensdauer ist deutlich länger als vergleichbare Ketten: Im trocke nen Zustand zweimal besser, mit Initialschmierung, sogar vierfach.

b.dry-Ketten bestehen aus rost- und wartungsfreiem CF-Edelstahl mit einem optimierten Gelenk: Letzteres ist ein Highlight in Sachen Präzision und Geheimnis der b.dry-Serie: „Stahl auf Stahl“ ist Vergangenheit! Schmiermittelfreiheit ist ein Verdienst unserer b.dry-Hülsen, die aus einem speziellen Hochleistungspolymer bestehen. Das Material ist bislang unbestreitbar einzigartig in seinen Fähig-keiten: b.dry-Produkte laufen komplett trocken und dabei trotzdem verschleißfester, korrosions-beständiger, bruchfester und mit deutlich längerer Lebensdauer als vergleichbare Ketten.

dry

NEU von iwis

iwis.com/MEGAlife

MEGAlife I und MEGAlife II Die wartungsfreien iwis Ketten

MEGAlife wartungsfreie Rollen- und Förderketten können überall dort eingesetzt werden, wo eine Nachschmierung nicht oder nur bedingt möglich ist. Dazu gehören trockene Umgebungsbedingungen und Anwendungen mit erschwer-ten Zugang für Wartungsarbeiten. MEGAlife Ketten sind durch vernickelte Einzelteile korrosionsgeschützt und in einem Temperaturbereich von –40° bis +160°C einsetzbar.

Die wartungsfreien JWIS Rollenketten MEGAlife verfügen über eine extrem hohe Dauer- und Bruchfestigkeit, die dem Kunden eine zusätzliche Sicherheit in der Anwendung bietet. Die überdurch-schnittlich hohe Verschleißlebensdauer ohne Nachschmierung führt zu weniger Stillstandszeiten und geringerem Instand-haltungsaufwand. Je nach Einsatz werden die wartungsfreien Ketten trocken oder mit zusätzlicher Spezialschmierung geliefert.

MEGAlife Highlights:

1 Nahtlose Sinterhülse aus speziell für diese Anwendung entwickelten Werkstoff , gehärtet und für optimale tribologische Eigenschaften behandelt

2 Bolzen mit verschleißfester und reibungsoptimierter Oberfl ächenbeschichtung

3 Nahtlose Rolle mit korrosionsgeschützter Oberfläche und auf die Sinterhülse optimierte Geometrie

1

3

2

MEHRWERT

Benefits of our maintenance-free roller chains:Optimized wear properties, very high fatigue strength and breaking strength, high-quality long-lasting corrosion protection, reduced downtime and maintenance costs for machines and plant, reduced risk

of product or production facility contamination.

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