FLOW MASTER - PRO-CONS
Contents
1. galls min galls min 1523734 1523874 STAINLESS STEEL 0 25 5 ALUMINIUM 0 05 1 1 A 5 1523735 1523875 0 3 1523744 1523884 STAINLESS STEEL 10 0 5 10 1523745 1523885 ALUMINIUM 0 61 0 11 2 2 STAINLESS STEEL 20 4 16 G 1 22 0 22 3 52 ALUMINIUM l l 800 rev min INDUCTIVE SENSOR PART N NPN output PNP output 1523730 1523870 1523754 1523894 1523755 1523895 NOTICE Pre mounted groups are available for flowrates greater than 20 It min 4 4 galls min for example part n 1524475 11 3 Spare parts Connector for pipe Connector for pipe Connector with check valve SC with nut and ring aaa with nut and ring Es with nut and ring Part N Part N for for for for for stainless steel aluminium stainless steel aluminium stainless steel aluminium base base base E a 8 o31 530063 92368 1523343 675230 14093 O2 Base threads UNI ISO completed with motor X1 screws Y ne grub screws pos 1 screws pos 2 O Ring pos 4 12 13 14 E 192903 Base threads UNI ISO completed with grub screws pos 1 screws X and Y screws pos 2 O Ring pos 4 12 13 14 TAPE ee 1 O Ring in Viton 1523352 1523352 3190319 3190318 6 Plug Threads G 1 4 UNI ISO 228 1 3234207 3234206 T7 Screw for metering module A 5 cm 0 3 cu in 14165 14069 4 Screw for metering module B 10 cm 0 61 cu in Screw for metering module C 20 cm 1 22 cu in 8 Sensor 15237389 15232. ed Polydrop S A Av Fabregada 26 Pje Est 2 08907 L Hospitalet de LLobregat Barcelona Spain Tel 34 93 260 22 50 Fax 34 93 260 22 51 E mail sales dropsa it E Dropsa Australia Pty C20 148 Old Pittwater Road Brookvale NSW 2100 Tel 61 299 386 644 Fax 61 299 386 611 E mail sales dropsa com Web site http www dropsa com E mail sales dropsa com 13
3. FLOW MASTER VOLUMETRIC FLOW METER FOR CONTROLLING THE FLOW OF LIQUIDS MANUAL OR MOTORIZED ADJUSTMENT User and Maintenance Manual Warranty information TABLE OF CONTENTS INTRODUCTION GENERAL DESCRIPTION PRODUCT MACHINE IDENTIFICATION TECHNICAL CHARACTERISTICS MACHINE COMPONENTS UNPACKING AND INSTALLING THE MACHINE MACHINE OPERATIONS TROUBLESHOOTING MAINTENANCE PROCEDURE 10 DISPOSAL 11 ORDERING INFORMATION 12 DIMENSIONS 13 HANDLING AND TRANSPORTATION 14 OPERATING HAZARDS 15 PRECAUTIONS 16 WARRANTY INFORMATION 17 DECLARATION OF COMPLIANCE WITH STANDARDS 18 DROPSA LOCATIONS Cease NS Manufacturer _ DropsA SpA FLOWMASTER Manual or motorized Year Certification l l l C2057IE WK 51 02 Manual drafted in compliance with EC Directive 98 37 Annex paragraph 1 7 4 1 INTRODUCTION This manual refers to FLOW MASTER volumetric flow device You can find additional copies and newer revisions of this document from our website http www dropsa com Alternatively contact one of our Sales Offices This User and Maintenance Manual contains important information on health and safety issues for the personnel It is recommended to attentively read this manual and carefully keep it in good condition so that it is always available to personnel requiring to consult it 2 GENERAL DESCRIPTION FLOW MASTER is a volumetric flow meter which constantly monitors lubrication Flow meter precise m
4. If you cannot solve the problem do not attempt to disassemble parts of the machine but contact the Engineering Department of DROPSA S p A pointing out anomaly details ANOMALY PROBABLE CAUSE SOLUTION gt Check sensors and motor for the No signal transmitted by the e Wrong electrical motorized option electrical flow meter connection connections on the control equipment terminal strips Blocked satellite Check and clean the oil output circuit Impure oil in the circuit filtering cartridges Replace them if necessary Abnormal satellite rotation Act on the pumping system electrical Cold oil in the circuit resistance Low pressure Increase pressure Replace the seals see machine parts drawing par 11 3 Oil leakage Worn O ring seals 9 MAINTENANCE PROCEDURE FLOW MASTER has been designed and constructed to require a minimum of maintenance For an easy maintenance it is advised to assemble the machine in an adequate location To facilitate maintenance tasks without interrupting the operation of the machine it is recommended to provide the flow meter with an input ball valve to disconnect parts of the system Periodically check pipe joints to detect possible leaks Always keep the machine unit clear to readily detect possible leaks Periodically once a year or when required replace the refilling filter part n 3130139 The machine does not require any special tool for check or maintenance tasks Howev
5. Community Directive in line with the member states legislations relating to machine safety EMC 89 336 CEE and BT 73 23 CEE and subsequent revisions of the aforementioned standards Has been manufactured in conformance with the following technical harmonised standards and specification EN 292 1 2 EN 1050 EN 982 EN 11200 EN 60947 EN 894 1 2 Technical Director W Divisi Product Manager Name DROPSA S p A Company lee DECEMBER 2002 Signature Date 12 18 DROPSA LOCATIONS Dropsa USA Inc 50679 Wing Drive Utica Michigan 48315 USA Tel 1 586 566 1540 Fax 1 586 566 1541 E mail salesusa dropsa com EIS Dropsa UK Ltd Unit 6 Egham Business Village Egham Surrey TW20 8RB Tel 44 01784 431177 Fax 44 01784 438598 E mail salesuk dropsa com E BR Dropsa S p A Via B Croce 1 20090 Vimodrone MI Italy Tel 39 02 250 79 1 Fax 39 02 250 79 767 E mail sales dropsa it Export E mail vendite dropsa it National Dropsa Gmbh Volmerswerther Strasse 80 40221 Dusseldorf 1 Germany Tel 49 0211 39 40 11 Fax 49 0211 39 40 13 E mail sales dropsa de L J Dropsa France 23 Av des Morillons Z des Doucettes 91140 Garges Les Gonesse Tel 33 01 39 93 00 33 Fax 33 01 39 86 26 36 E mail sales dropsa com Fea Dropsa do Brazil Rua Sobralia 171 Santo Amaro Sao Paulo Brazil Tel 55 011 5631 0007 Fax 55 011 5631 9408 E mail salesor dropsa com
6. a proper support surface free from impediments which could interfere with machine well functioning WARNING All the electric electronic components reservoirs and base structure must be grounded The stainless steel option makes the FLOW MASTER suitable for applications in harsh damp or corrosive environments Connect inlet par 11 3 fig 1 pos J and outlet par 11 3 fig 1 pos K piping Connect the inductive sensor cables and the motor cables for the motorized option to the electronic control and monitoring equipment terminal strip see FACT 2000 User and Maintenance Manual To assemble flow meters in batteries follow the instructions below 1 Unscrew the two grub screws par 11 3 fig 1 pos 1 of the next flow meter 2 Tighten the two screws par 11 3 fig 1 pos 2 to the previous flow meter Pay attention to the O Ring correct position to prevent damages during assembling 3 Screw again the grub screws par 11 3 fig 1 pos 1 to the previous flow meter The above operations must be carried out for all the flow meters being assembled 4 6 3 TECHNICAL INDICATIONS It is recommended to use Structural steel piping of proper dimensions Grip ring pipe fittings To assembly block pipe fittings and tighten pipes using a vice An inlet filter with a proper filter grade not over 90u Dropsa part N 3130309 If the machine is operated for the first time 1 Decrease oil pumping unit pressure and
7. ensure that all the connections are correct and there are no leaks 2 Increase pressure progressively to suit individual flow requirements 7 PUMP OPERATIONS 7 1 MANUAL OPTION Output adjusting of the manual FLOWMASTER is easy through the use of two needle valves the output adjustment can be coarsely par 11 3 fig 1 pos X or finely adjusted par 11 3 fig 1 pos Y To coarsely adjust 1 Unlock the locknut of the needle valve 2 Close the fine adjustment valve par 11 3 fig 1 pos Y by turning clockwise with a M3 allen spanner 3 Increase or decrease the output by turning counterclockwise or clockwise with a M5 allen spanner the coarse adjustment valve par 11 3 fig 1 pos X It is advisable to make the fine adjustment only after the coarse adjustment as follows 1 Increase or decrease the output by turning counterclockwise or clockwise with a M3 allen spanner the fine adjustment valve par 11 3 fig 1 pos Y to suit individual flow requirements The fine adjustment valve par 11 3 fig 1 pos Y only is used for the size A module 7 2 MOTORIZED OPTION To adjust motorized FLOWMASTER output Close the fine adjustment valve par 11 3 fig 1 pos Y and let the electronic control equipment start automatically in line with the setting data 8 TROUBLESHOOTING The following diagnostic table indicates the main anomalies which may be encountered the probable causes and possible solutions
8. 739 9 Metering module B completed with screw pos 7 Sa Metering module C completed with screw pos 7 Metering module A completed with screw pos 7 1523734 1523735 O Ring in Viton for metering module ana 383 a O Ring in Viton for fine adjustment valve 1523354 1523354 O Ring in Viton for coarse adjustment valve motorized 1523397 1523397 Output adjustment unit with ratiomotor 1523692 1523691 O Ring is built in for 9 9a 10 modules O Ring Pos 4 must be mounted only between base and base Screws Pos 11 Gasket Pos 5 and Plug Pos 6 must be ordered separately 12 DIMENSIONS 12 1 Manual FLOW MASTER GAS OUTLET SA UNI ISO 288 1 BASE NY 1523630 PATENTPENDING ADJUSTMENT m INLET FINE je ADJUSTMENT e BASE LUBRICANT INLET 55 5 mm 2 18 in 12 2 Motorized FLOW MASTER GAS OUTLET Ap 4 UNI ISO 2268 7 LUBRICANT INLET if BASE LUBRICANT FINE INLET REGULATION 43 mm 1 7 in 55 5 mm 2 18 in Depth X Module metering AL D0 LL BY 67 5 2 pC 82 F6 mm 3 in GAS INLET 1 2 UNI ISO 228 1 METERING MODULE 1 96 in 450 mm 25 mm 1 37 in 27 5 mm 0 85 in d ES a ar ey E 9 E er S si et e t ps eegen METERING Ce SEA MODULE ja Vid E E GA GA i GEAR MOTOR FOR OUTPUT ADJUSTMENT 13 HANDLING AND TRANSPORTATION Given the low weight and small dimensions of the machin
9. R does not produce excessive noise less than 70 dB A 15 PRECAUTIONS No particular operating hazards characterize the FLOW MASTER except for the following precautions e Operator s contact with lubricant during maintenance tasks The operator must be provided with suitable personal protective clothing and devices tit VIII 626 e Use of incompatible lubricant MAIN NO COMPATIBLE FLUIDS Lubricants containing silicon Pump failure Pump oxidization Food Products Contamination of the product 10 16 WARRANTY INFORMATION All products manufactured and marketed by Dropsa are warranted to be free of defects in material or workmanship for a period of at least 12 months from date of delivery Extended warranty coverage applies as follows Complete system installation by Dropsa 24 Months All other components 12 months from date of installation if installed 6 months or more after ship date warranty shall be maximum of 18 months from ship date If a fault develops notify us giving a complete description of the alleged malfunction Include the part number s test record number where available format xxxxxx xxxxxx date of delivery date of installation and operating conditions of subject product s We will subsequently review this information and at our option supply you with either servicing data or shipping instruction and returned materials authorization RMA which will have instructions on how to prepare the pr
10. e it is not necessary the use of material handling equipment Prior to shipping the machine is carefully packed in cardboard packing During transportation and storage pay attention to the side on the cardboard packing On receipt check that the packing is not damaged and then storage the machine in a dry location CAUTION During storage machine components can withstand temperatures 20 C 60 C 4 F 140 F However in order to avoid damages machine starting should occur at a minimum temperature of 5 C 41 F 14 OPERATING HAZARDS It is necessary to read carefully about the instructions and the risks involved in the use of lubrication components The operator must know machine functioning and dangers through the user manual Power supply Any type of intervention must not be carried out before the unplugging of the machine from the power supply Make sure that no one can start it up again during the intervention All the installed electric and electronic equipment reservoirs and basic components must be grounded Inflammability The lubricant generally used in lubrication systems is not normally inflammable However it is advised to avoid contact with extremely hot substances or naked flames Pressure Prior to any intervention check the absence of residual pressure in any branch of the lubricant circuit as it may cause oil sprays when disassembling components or fittings Noise and vibrations FLOW MASTE
11. er it is recommended the use only of appropriate and in good conditions tooling protective devices gloves and clothing 626 94 and DPR 547 55 to avoid injury to persons or damage to machine parts WARNING Before any maintenance procedure be sure that power hydraulic and pneumatic supplies are off 10 DISPOSAL During maintenance or disposal of the machine care should be taken to properly dispose of environmentally sensitive items Refer to local regulations in force in your area When disposing of this unit it is important to ensure that the identification label and all the other relative documents are also destroyed 11 ORDERING INFORMATION 11 1 Assembly base metering module inductive sensor Manual option METERING Motorized option MODULE SERIAL N MATERIAL NPN output PNP output SERIAL N MODEL 1523730 1523870 1523950 1523740 1523880 1523060 B STAINLESS STEEL 1523750 1523890 1523970 1523732 1523872 1523952 1523742 1523882 1523962 ALUMINIUM A 1523752 1523892 1523972 11 2 Components PART N THREADS MATERIAL Manual option Motorized option Inlet Outlet 1523330 1523630 STAINLESS STEEL G 2 UNI ISO G 3 8 UNI ISO 1523332 1523632 ALUMINIUM METERING MODULE PART N FLOWRATE MIN FLOWRATE MAX FLOWRATE NPN output PNP output MODEL MATERIAL cm3min St B rev min at 1000 min cu in min litres min litres min
12. mittent working maximum operating time 1 hour 6 bar 88 2 psi 20 bar 294 psi GENEE Inlet G 1 2 UNI ISO 228 1 Outlet G 3 8 UNI ISO 228 1 Seals O Ring in Viton Stainless steel AISI 316 Bases and metering modules or aluminium Transparent polyamide Maximum distance between a flow meter and the Electronic 15 metres 16 4 yard Control Equipment It is advisable the use of a shielded cable Motor for output adjustment 392 1 Max torque 3 Kg cm 6 61 b cm Reviminwithoutload Je Rev min with max torque Je 15 mA Proximity Inductive Sensor 200 mA 10 30V D C 200 Hz lt 18 mA NPN or PNP 25 C 70 C 13 F 158 F O gt N Proximity Inductor Sensor Electric Diagram PROXIMITY SWITCH m BROWN PROXIMITY SWITCH BROWN 229 2 TON E TE BLACK NPN NO C BLUE PNP NO C BWE 70 SO d c a MILANO 10 30 V d c EN MILANO T Stan 4 DOS ITALY i l 200 mA af ITALY j 5 MACHINE COMPONENTS BASE j pg 1 i METERING MODULE GEAR MOTOR FOR OUTPUT ADJUSTMENT e INDUCTIVE SENSOR 6 UNPACKING AND INSTALLING THE MACHINE 6 1 UNPACKING Once a suitable location has been found to install the unit remove the machine from the packaging Check the device has not been damaged during transportation or storage No particular disposal procedures are necessary aS packaging materials are not dangerous or polluting 6 2 INSTALLING Install the flow meter on
13. oduct for return Upon prepaid receipt of subject product to an authorized Dropsa Sales amp Service location we will then either repair or replace such product s at out option and if determined to be a warranted defect we will perform such necessary product repairs or replace such product s at our expense Dropsa reserves the right to charge an administration fee if the product s returned are found to be not defective This limited warranty does not cover any products damages or injuries resulting from misuse neglect normal expected wear chemically caused corrosion improper installation or operation contrary to factory recommendation Nor does it cover equipment that has been modified tampered with or altered without authorization Consumables and perishable products are excluded from this or any other warranty No other extended liabilities are stated or implied and this warranty in no event covers incidental or consequential damages injuries or costs resulting from any such defective product s The use of Dropsa product s implies the acceptance of our warranty conditions Modifications to our standard warranty must be in made in writing and approved by Dropsa 11 17 DECLARATION OF COMPLIANCE WITH CE STANDARDS Manufacturer DROPSA SpA Via B Croce 1 20090 Vimodrone MI Address 02 250 791 Telephone Certifies that The machine FLOW MASTER Has been manufacturer in conformance with the European
14. onitoring without calibrations or adjustments is due to volumetric measurements not dependent on lubricant temperature or viscosity FLOWMASTER is a modular system consisting of two elements e Base e Metering module MODULAR SYSTEM The base is common to all size modules which are also interchangeable The modular construction makes it possible to built assys base and metering module of 20 modules or more OPERATING PRINCIPLE A satellite which rotates with a fixed orbital movement is operated by the liquid passage through the metering module An inductive sensor picks up each orbital movement and transmits a signal to an electronic reader The operator can read the output of the metering module in litres min or in rev min directly from the FACT 2000 device display or from a PC monitor VISUAL INDICATION OF THE FLOW OF LIQUID A satellite built in the module body rotating with an orbital movement indicates the fluid velocity The flow output is neither reduced nor interrupted even if the satellite stops 3 PRODUCT MACHINE IDENTIFICATION Machine identification red label is located on the front side of the unit and contains machine serial number 4 TECHNICAL CHARACTERISTICS Base and metering module Fluid maximum viscosity at lubricant operating temperature 1000 cSt 4628 SUS Operating temperature 20 C 60 C 4 F 140 F Minimum pressure continuous working Maximum pressure inter
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