DROPSA VIP4Air Owner's manual

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Lubrication
System
VIP4AirPanel
UserandMaintenanceManual
Originaltexttranslation
C2033IEWK25/19
ManualdrawnupinaccordancewithCEDirective
06/42
www.dropsa.com
1.INTRODUCTION
2.GENERALDESCRIPTION
3.PRODUCTMACHINEIDENTIFICATION
4.TECHNICALSPECIFICATIONS
5.MACHINECOMPONENTS
6.UNPACKINGANDINSTALLINGTHEMACHINE
7.INSTRUCTIONSFORUSE
8.TROUBLESHOOTING
9.MAINTENANCEPROCEDURE
10.DISPOSAL
11.ORDERINGINFORMATION
12.DIMENSIONS
13.HANDLINGANDTRANSPORTATION
14.OPERATINGHAZARDS
15.PRECAUTIONS

TABLEOFCONTENTS
http://www.dropsa.com
ViaBenedettoCroce,1
Vimodrone,MILANO(IT)
t.+3902250791DropsaproductscanbepurchasedfromDropsabranchesandauthorizeddistributors,visit
www.dropsa.com/contactorcontactus[email protected]
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1.INTRODUCTION
ThisuserandmaintenancemanualreferstotheVIP4Airair/oillubricationsystem.
Thismanualshouldbeconservedinsuchawaythatitremainsundamagedovertimeandisreadilyavailabletopersonnel
needingtoconsultit.
Furthercopiesofthismanual,updatesorclarificationscanbeobtainedbydirectlycontactingtheTechnicalSalesOfficeat
Dropsa.
Themanufacturerreservestherighttoupdatetheproductand/ortheuserandmaintenancemanualwithouttheobligationto
revisepreviousversions.Itishowever,possibletocontacttheTechnicalSalesOfficeforthelatestrevisioninuse,ortoconsult
ourwebsiteathttp://www.dropsa.com.
Theuseoftheequipmentreferredtointhismanualmustbeentrustedtoqualifiedpersonnelwithabasicknowledgeof
mechanics,hydraulicsandelectricalsystems.
Itistheresponsibilityoftheinstallertousetubingsuitableforthesystem;theuseofinadequatetubingcancauseproblems
withthepump,injurytopersonsandcreatepollution.
Looseningofconnectionscancauseserioussafetyproblems;carryoutacheckbeforeandafterinstallationand,ifnecessary
retightenthem.
Neverexceedthemaximumworkingpressurevaluespermittedforthepanelandthecomponentsconnectedtoit.
Beforeanymaintenanceorcleaningoperationdisconnectthepowersupply,closeofftheairsupplyanddischargethepressure
frominsidetheequipmentandthetubingconnectedtoit.
Donotsubjectthepanel,theconnections,thetubingorpartsunderpressuretoviolentimpacts;damagedtubingor
connectionsaredangerousandshouldbeimmediatelyreplaced.
Afterlongperiodsofinactivitycheckairtightnessofallpartssubjectedtopressure.
Personnelmustusepersonalprotectionequipment,clothingandtoolsadequateforthelocationandtheuseofthepanelboth
duringitsoperationandduringmaintenanceoperations.
Thepanel,andanyaccessoriesmountedonit,shouldbecarefullycheckedimmediatelyonreceiptandintheeventofany
discrepancyorcomplainttheDropsaSpASalesdepartmentshouldbecontactedwithoutdelay.
DropsaSpAdeclinestoacceptanyresponsibilityforinjuriestopersonsordamagetopropertyintheeventofthenon
observanceoftheinformationpresentedinthismanual.
Anymodificationtocomponentpartsofthesystemorthedifferentdestinationofuseofthissystemoritspartswithoutprior
writtenauthorizationfromDropsaSpAwillabsolvethelatterfromanyresponsibilityforinjurytopersonsand/ordamageto
propertyandwillreleasethemfromallobligationsarisingfromtheguarantee.
2.GENERALDESCRIPTION
TheVIP4Airpanelistobeutilizedfor‘onmandrel’applicationsandmachinetools.
Designedforhighperformanceatalowcost,itisdistinguishedbyitscompactness.
Thesystemiscomposedofacentralunitwhichcontrolsandmanagestheentiresystem.
Thecentralunitregulatesandcontrolsthefunctioningofthemodulardosesandmixers,whicharecomposedofpneumatically
controlledminipumpsandthemixerbases.Theminipumpscanbefittedwithaseriesofspacersinordertovarytheflowrate
soastocoverawiderangeofneeds.Integratedinsidethemixerbaseisaflowcontrol,whichisutilizedbythecentralunitto
verifythecorrectfunctioningoftheequipment.
Themodulardesignofthesystemmakesitextremelyversatile;uptoamaximumof8mixerbasescanbeinstalled.
Thehightechnologyutilizedinthissystempermitsatotalcontrolofthelubricationcombinedwithasimplicityofinstallation
withoutresortingtosuperfluousconnections.
3.IDENTIFICATIONOFTHEMACHINE
Ayellowplateshowingtheproductcode,thesupplyvoltageandthebasiccharacteristicsismountedonthefrontoftheoiltank.
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4.TECHNICALSPECIFICATIONS
CHARACTERISTICSVIP4Airlubricationpanel
Powersupplyvoltage24Vdc
110Vac
Absorbedpower10W
Airsupplypressure5‐ 8bar
Outputsignals Remotealarmcontact:max.250V1ANO/NC
Workingtemperature‐5‐ +55°C
Workinghumidity90%max.
ProtectionclassIP44
AdmissiblelubricantsOil
Oilviscosityatworkingtemp.32‐ 220cSt
Conservationtemperature ‐20‐ +65°C
WARNING:DONOTsupplythemachinewithvoltagesorpressuresotherthanthoseindicatedonthespecificationplate.
5.DESCRIPTIONOFCOMPONENTS
CentralVIP4AirUnit
Thecentralunitofthelubricationsystemiscomposedofthethreeelements:
aTank,madeoftransparentplasticmaterial,compatiblewithlubricantsonthemarket.
anaircontrolsystemcomposedofapressureregulator,appliedlaterally,andasolenoidvalve,whichcanblocktheairflow.
theVIP4Airpanelmanagesandcontrolstheentirelubricationprocess:thetimeintervals,thelubricationflowrate,theair
pressureandtheoillevel.Inadditionitprovidesforprimingcycles(airventing).
PneumaticMinipump
Theminipumpsemployedareparticularlysmallandareinstalledonthemixerbases.Theycanbefittedwitharangeofspacers
whichservetovarytheflowrate.Thefollowingtabledetailshowtorecognizetheseandindicatestherelativepartnumbers.To
changethespacersproceedasfollows:
1. Unscrewandremovethebrasscap(A).
2. Rotateshaft(B)untilthehole(C)alignswiththerelativeslot.
3. InsertaØ2mmtommybarinhole(C).
4. Unscrewhex.nut(D)usinga5,5mmspanner.
5. Slideoffthespacer(E)andreplaceitwiththerequiredone.
6. Replaceandfullytightennut(D),removethetommybarandreplacecap(A).
OFNOTCHESFLOWRATE
(mm3/cycle)
SPACER
PARTNUMBER
1303233188
3153233191
473233193
Notches
4
Mixerbasewithflowratesensor
Inthemixerbasethereisanintegratedlubricationdetectorsystemwithaselfsettingsensor.Thissensordoesnotrequiretobe
regulatedorcalibratedasitautomaticallyadaptstothefunctioningconditionsandthetypeoflubricant.
Thedetectionsystemisinterfaced,bymeansofanelectricalconnectioncompletelyintegratedintothemixerbase,withthe
VIP4Airpanelmountedonthecentralunit.Whereananomalyoccursthisisdetectedbythecentralunit,whichsignalsthe
error.
ThefunctioningisalsoindicatedbyanLEDmountedonthebaseitself.
WhentheVIP4Airstartsalubricationcycle,theLEDlocatedonthemixerbaseilluminates(ON)untiltheendofthelubrication
cycle.DuringthepausetheLEDisnotilluminated(OFF).
Oil filler
cap
Pressure
regulator
Mini-pump
Solenoid valve
Mixer base
Central
unit
Tank
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6.UNPACKINGANDINSTALLINGTHEPUMP
6.1UNPACKING
Onceasuitablelocationhasbeenidentifiedfortheinstallation,openthepackageandremovetheequipment.Checkthatthe
VIP4Airhasnotsustaineddamageduringtransportandstorage.
Thepackagingmaterialdoesnotrequireanyspecialdisposalprecautions,notbeinginanywaydangerousor.
6.2MOUNTINGTHEVIP4AirPANEL
Provideadequatespacefortheinstallation,leavingaminimumroomof100mmaroundthepanel.MounttheVIP4Airpanelat
shoulderheighttoavoidunnaturalpostureorthepossibilityofobscuringthecontrolpanelorofsustainingimpacts.Donot
installtheVIP4Airinparticularlyaggressiveorexplosive/flammableenvironmentsoroncomponentssubjecttovibration.
Onlyusethesuppliedmountingbracketwith2holesforØ6mmbolts.
6.3MOUNTINGTHEMINIPUMPSONTHEMIXERBASES(forreplacementoraugmenting)
Theminipumpsaremountedonthemixerbasesutilizingtwosecuringscrews.
Particularattentionshouldbepaidtothecorrectpositioningoftheoringsbetweentheminipumpandthemixerbase(see
diagrambelow).
6.4MOUNTINGTHEDOSERASSEMBLYONTHEPUMP(forreplacementoraugmenting)
Toinstallanewmixerunitproceedasfollows:
1. DisconnecttheelectricalpowersupplyfromtheVIP4Airpanelandemptythetankofoil.
2. Disconnecttheairsupplyfromthesolenoidvalveandremovethethreesecuringscrews.
3. Unscrewthescrewswhichsecuretheblankingplate.
4. Connectthenewbase,insertingtheelectricalbridge,payingparticularattentiontothealignment.Securetheunitusingthe
twoscrewssuppliedforthepurpose.
5. Repositiontheblankingplateandtherelativesolenoidvalve.
Securing screws
Mini-pump
Seals
Mixer base
Grub screw
Seals
Base
A
ssembl
y
Securin
g
screws
Electrical
bridge
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6.5HYDRAULICCONNECTIONS
Theonlyconnectiontobeundertakenisthatoftheindividualpumps,providedwithpushinconnections,tothe
lubricationpoint.ThetubingmustbeinØ4mmnylon(obtainablefromDropsa).
6.6PNEUMATICCONNECTIONS
ConnecttheairinputtothepushinconnectorofthesolenoidvalveutilizingØ6mmnylontubing,andprovideastop
valvetopermitshuttingoffthesupply.
6.7ELECTRICALCONNECTIONS
Beforecarryingoutanyoperationcheckthetypeofsupplynecessaryforthemachineasshownonthelabellocated
neartheconnector.
Thepanelistobeinterconnectedwiththeemergencystopswitchofthemachineitisserving.
For110VsupplytheusermustprotecttheinstallationwithamagnetothermicdifferentialINswitchmax.2Amp,
Idn0.03Amp.ForsafetypurposestheAlarmcontact(NO/NC)mustbeconnected.
Fortheelectricalconnectionsrefertothefollowingdiagramrepresentingthelubricationpanelconnections.
Note:Thefemaleconnectorispurchasedseparately(see“Accessories”)
N.B.:Afterallconnectionshavebeencompletedensurethetubingandcablesareprotectedfromimpactsandaresuitably
secured.
7.INSTRUCTIONSFORUSE
7.1STARTINGTHEVIP4AirPANEL
BeforeusingtheVIP4Airpanel,itisnecessarytocarryoutsomepreliminarychecks:
- checktheintegrityoftheequipment
- checkthattheelectricalandpneumaticconnectionshavebeeneffectedcorrectly
- enterthedatainsidetheVIP4AirPanel
7.2METHODOFFUNCTIONING
Stage1InitialfunctionPrimemode
SimultaneouslypresstheMODEandkeysforatleast10seconds.ThepumpgoesintothePrimemode,executing
aseriesoflubricationcycles,with1secondoflubricationand1secondofpause,necessarytoeliminatealltracesof
airfromthesystem,foranoveralldurationof10minutes.
Attheendofthiscycle,thePaneleffectsonelubricationcycleandcarriesoutaverificationofthelubrication.If
therearenoalarmsitproceedstoStage3.
Stage2Initialfunction‐Setup
PresstheMODEkeyfor10secondstoentertheconfigurationmenu.Allthebasicfunctionsnecessaryforthecorrect
functioningoftheequipmentareenteredduringthisSetupfunction.Toregulateseetheparagraphonregulation.
1639115‐ConnectandCableassembly2mt
1639121
L=2m
Pin/Wire 24VVers. 110VVers.
10V
224Vdc/
3/110Vac
4NCAlarm
5Com.Alarm
6
NOAlarm
Ground
7
Stage3Normalfunction
Onswitchingonthecycleisautomaticallyactivated.Duringthepausetimethedisplayshowsalternatelythetime
remainingofthecycleandthemixerairpressure.AtthesametimetheLEDsatthesideofthedisplayare
illuminatedalternately.
Bypressingthekeyitispossibletofreezethedisplayofthemixerairpressurereadinguntilthekeyisreleased.
Bypressingthekeyitispossibletofreezethedisplayofthetimerreadinguntilthekeyisreleased.
Stage4Alarmfunction
Inthealarmmodethedisplaystartsblinkingdisplayingtheerrorcode(seethe“troubleshooting”paragraph).
Whentheconditionshavebeenrestored,theRESETbuttonmustbepressedtoreturntonormalfunctioning.
7.3REGULATION
Toregulatealltheparameters,startthepumpandpresstheMODEkeyfor5seconds.Subsequentlyfollowthe
instructionsgiveninthetablebelow.
PressingtheMODEkeypassesfromoneoptiontothenext.
PARAMETERSDISPLAYDESCRIPTIONOPERATIONDEFAULT
Cyclecontrol
time
Themax.timeissetwithinwhichthedeliveryof
lubricantmustbeconfirmed.Therangeofregulationis
0060seconds
Enterthedesiredvaluesusingthe
↑and↓keys
5s
Pumprecharge
time
Pausetimeforrechargingthepump.Therangeof
regulationis0.09.9seconds.
Enterthedesiredvaluesusingthe
↑and↓keys1.5s
Pausecycle
Intervaloftimebetweenonelubricationcycleandthe
next.Thecountcommenceswhenthedeliveryof
lubricantisconfirmed.Rangeofregulationis
00.0099.59minutes.
Enterthedesiredvaluesusingthe
↑and↓keys
User
discretion
Inversionof
solenoid
command
Relayfunction;1forNC,
0forNO.
Donotalter1
ofcontrol
elements
Numberofelementsinstalledwithflowcontrol.Ifthe
value0isset,beforeenteringinpause(pausetime),all
thetimeouttimemustpass.Rangeofregulation099
elements.
Enterthedesiredvaluesusingthe
↑and↓keys
Min.1
Max.8
Max.air
Max.limitofmixerairpressure.Enteringthevalue0the
alarmisdisabled.Rangeofregulation0.07.0bar
Enterthedesiredvaluesusingthe
↑and↓keys
User
discretion
Min.air
Min.limitofairpressure.Rangeofregulation0.07.0
bar.
Enterthedesiredvaluesusingthe
↑and↓keys
User
discretion
Minimumoil
levelAlarmfunctionforminimumoillevel.
Enteringthevalue0anerroris
displayedbuttheVIP4Air
continuestooperate.
Enteringthevalue1anerroris
signaledandtheequipmentstops.
1
Systemstartpre
cycle
Numberofstartcyclesforsystemprelubrication.Range
ofregulation0060.
Enterthedesiredvaluesusingthe
↑and↓keysbearinginmind
thatthevalueofcyclesentered
mustbedoublethatofthedesired
value.
6
Cyclesoffault Numberofconsecutivefaultcyclesneededforanalarm.Enterthedesiredvaluesusingthe
↑and↓keys.2
AlarmStatus
Settheactiontotakeafteranalarm:
1=stopthelubricationcycles
0=Donotstopthelubricationcycles
Enterthedesiredvaluesusingthe
↑and↓keys.1
Alarmcoded
Settheoptionforalarmoutput:
1=Codedalarm(seePhar.8.1)
0=Standardalarm
Setthevalueby↑and↓buon0
8
7.4OUTLETSCOMBINEDFLOWDATA
8outlets
combinedflow
NylonTube
Ø4x2,5
Airinlet
(bar)
Airflow
Nm3/h
13,0
25,5
38,1
411,3
515,0
618,3
719,2
820,5
8outlets
combinedflow
NylonTubo
Ø6x4
Airinlet
(bar)
Airflow
Nm3/h
13,9
28,2
312,0
416,3
520,3
622,2
722,9
823,4
8outlets
combinedflow
NylonTubo
Ø6x4
Airinlet
(bar)
Airflow
Nm3/h
14,0
28,4
312,2
416,7
520,6
622,6
722,9
823,4
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8.TROUBLESHOOTING
Thefollowingisadiagnostictablegivingthemainanomalies,theprobablecausesandpossiblesolutions.
If,afterconsultingthisdiagnostictable,theproblemremainsunresolved,donotattempttodisassemblethemachinelooking
forfaults,butcontacttheEngineeringDepartmentatDropsawithanasfullydetaileddescriptionaspossibleoftheanomaly.
DIAGNOSTICTABLEFORTHEVIP4AIRPANEL
ALARMSIGNAL
APF
Pumpcycle
AAH
Airhigh
AAL
Airlow
ALL
Oillevel
APE
Precycle
DESCRIPTIONOFDEFECT
o Theflowsensorhasnot
detectedthecorrectdose.
o Airpressuretoohigh
(couldbepluggedair/oilline)
o Airpressuretoolow
(couldbebrokenair/oilline)
o Lowoillevel
o Noprecyclereading

CAUSE/INTERVENTION
o Presenceofairinthecircuitcausingincorrectdelivery.Carryout
Primingcycle.
o Pumpdefective.CarryoutPrimingverifyingthedeliveryoflubricantat
theoutlet.
o Flowsensordefective.Checkthesensorelectricalconnectionsor
replaceit.
o Checktheoillevelinthetank.
o Checkthepressureonthedisplayandregulateitontheexternal
reducer.Tofacilitatetheoperationpressandholddownthekeyto
freezetheairpressuredisplay.Thealarmdependsonthevalue
enteredduringsetup.
o Checkthepressureonthedisplayandregulateitontheexternal
reducer.Tofacilitatetheoperationpressandholddownthekeyto
freezetheairpressuredisplay.Thealarmdependsonthevalue
enteredduringsetup.
o Addoiltothetank.Warning:ifthelowoillevelalarmfunctionisnot
enabled,therewillbeanalarmsignalbuttheequipmentwillnotbe
stopped.
o Presenceofairinthecircuitcausingincorrectdelivery.Carryout
Primingcycle.
o Pumpdefective.CarryoutPrimingverifyingthedeliveryoflubricantat
theoutlet.
o Flowsensordefective.Checkthesensorelectricalconnectionsor
replaceit.
o
Checktheoillevelinthetank.
8.1CODEDALARM
TheVIP4airisabletosendawarningcodedtohighlightthetypegeneratedalarm.Youdoitswitchingthealarmrelaywith
1spulsesand5spauseparameters.Followingtableshowthecodealarmlistofcodedalarm(AC=1).
CODETYPEALARMSIGNAL
ALARM01 LOWLEVELALL
ALARM02 CYCLETIMEOUT AAH
ALARM03 BOOSTWARNING AAL
ALARM04 THERMALPROT. APE
ALARM05 PSALREDYONAPF
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9.MAINTENANCEPROCEDURE
Thepumphasbeendesignedandconstructedsoastoreducemaintenancetoaminimum.
Tosimplifymaintenanceitisrecommendedthattheequipmentbemountedinaneasilyreachedlocation(seeparagraph7.2).
Periodicallycheckthetubingconnectionsforleaks.Alwaysmaintaintheequipmentinacleanconditioninorderthatanyleaks
willbeimmediatelyevident.
WhennecessaryreplacetheoilfillingfilterP/N3130139.
Periodicallyemptythepressureregulatorcondensatetrapbyrotatingthesmallredvalvelocatedatitsbase.
Themachinedoesnotrequireanyspecialtoolsforcarryingoutchecksand/ormaintenancetasks.Itisrecommendedthat
suitabletoolsandpersonalprotectionclothing(gloves)areusedinaccordancewithLegislativeDecree81/2008(SafetyatWork
legislation),andthattheyareingoodconditioninordertoavoidinjurytopersonsanddamagetothemachine.
Ensurethatelectrical,pneumaticandhydraulicsuppliesaredisconnectedbeforeundertakinganymaintenancetasks.
10.DISPOSAL
Duringthemaintenanceofthemachine,orintheeventofitsbeingscrapped,donotdiscardpollutingcomponentsinthe
environment.Refertolocalregulationsfortheircorrectdisposal.Atthetimeoffinaldisposalofthemachineitisnecessaryto
destroytheidentificationplateandallotherdocumentation.
11.ORDERINGINFORMATION
VERSIONS
ofDosers VIP4Air‐24VdcVIP4Air‐110Vac
131350643135065
23135055 3135056
331350673135068
431350703135071
531350733135074
631350763135077
731350793135080
831350823135083
ACCESSORIES
PARTNUMBERDESCRIPTION
3044335Tankcomplete
3130139Filter,filling,oil
3155148Solenoidvalve24Vdc
3155149Solenoidvalve110Vac
1524408Mixerbasewithflowcontrol
3103115CMinipump,pneumatic,completewithsetofwashers+2screws 14067
3233193Washerfor7mm3
3233191Washerfor15mm3
3233188Washerfor30mm3
5717300Tube,flexibleØ4
5717301Tube,flexibleØ6
1639111Box,connection,powersupply24Vdc
1639112Box,connection,powersupply110Vac
1639115Connector+connectioncable(2m)
3194003Connector
3133283Kitfor3103115
3103116minipumps
11
15.DIMENSIONS
NumberofelementsHeightA(mm)Weight(Kg.)
13313.8
23594.3
33874.8
44155.3
54485.8
64716.3
74996.8
85277.3
Tube
Tube Ø 6
A
ir inpu
t
12
13.HANDLINGANDTRANSPORT
PriortodispatchVIP4Airlubricationpanelsarecarefullypackedinacardboardcarton.Duringtransportationandstorage
maintaintheequipmenttherightwayupasindicatedonthecarton.
Onreceipt,checkthatthepackagingisnotdamagedandstoretheequipmentinadryplace.
Giventhelightnessoftheunit,liftingdevicesarenotrequiredforitshandling.Theboxisfittedwithsuitablehandlingdevices.
14.PRECAUTIONSINUSE
Itisnecessarytocarefullyreadthewarningsandtherisksinvolvedinusingthelubricationpanel.Theoperatormustunderstand
thefunctioningoftheunitbystudyingtheuser’smanual.
Electriccurrents
Nointerventionmustbeattemptedontheequipmentwithoutfirsthavingdisconnectedtheelectricalpowersupplyand
ensuringthatitcannotbereconnectedduringtheintervention.
Allinstalledequipment,electrical,electronic,tankandbasestructure,mustbeconnectedtothegroundlineutilizingthe
terminalsfittedtoeachcomponent.
Flammability
Theoilemployedinthelubricationcircuitisnotnormallyflammable.Itisnonethelessindispensabletotakeeveryprecaution
againsttheoilcomingintocontactwithveryhotpartsoropenflames.
Pressure
Priortoanyinterventionontheequipmentensurethatpressureisreleasedfromallbranchesofthelubricationcircuit.Failure
todothiscouldresultinoilbeingdischargedunderpressurewhereconnectionsorcomponentsaredisassembled.
Noise
TheVIP4Airlubricationpaneldoesnotemitexcessivenoise,remainingbelow70dB(A).
WARNING:beforecarryingoutthereplacementoftheminipumps,emptythetankoflubricant.
15.CONTRAINDICATIONS
TheVIP4Airpaneldoesnothaveanyparticularcontraindicationsexceptforthefollowingpoints:
Theoperatorcomingintocontactwithfluidduetobreakage/openingofsupplytubing.
Theoperatormustbefurnishedwithsuitablepersonalprotectionclothing/equipment.
Abnormalposture.
Takenoteoftheindicationsshowninparagraph10.2.
Contactwithoilduringfilling/maintenance.
Useofunsuitablelubricants.
Maininadmissiblefluids.
Fluid Danger
Lubricantswithabrasiveadditives Highwearrateofcontactedparts
LubricantswithsiliconbasedadditivesSeizureofthepump
Petrol
solvents
flammableliquidsFire
explosion
damagetoseals
CorrosiveproductsCorrosionofthepump
injurytopersons
WaterOxidationofthepump
FoodsubstancesContaminationofthesubstancesthemselves
/