VIP5: Lubrication System Controller
Contents
1. General Alarm Output Relay can be a constant signal or generate a coded alarm to allow remote PLC to determine nature of alarm Integrated LCD Display for diagnostic and ease of use Diagnostic and Lubricant Counters for Operation and Alarm conditions All configuration parameters can be set from the Setup menu via the LCD display using the front panel keys No complex internal switches need to be set 3 DESCRIPTION OF OPERATING PROCEDURES The VIP5 controller has three operating modes 1 CYCLE 2 PULSE 3 FLOW CYCLE and PULSE modes are designed for intermittent or continuous lubrication system that require the control of a pump and monitoring of feedback signals to determine when lubrication has successfully completed FLOW is designed as a monitoring only operating mode that allows the user to monitor a pulse signal and determine the actual flow rate This is useful for process control and generally used in re circulating systems 3 1 CYCLE and PULSE Control System operating Principles The VIP5 control system is designed to control intermittent or continuous lubrication system with a variety of control inputs Intermittent operating principle is based on three distinct phases e PRELUBE Phase gt Pre Lubrication that occurs during power up of a system e LUBRICATION Phase Lube Wait stages gt This is when lubricant is provided as above e STANDBY Phase gt The system is inactive awaiting for the next LUB2. 0 16 in STEP 2 Connect power input and pump or control solenoid output to the VIP5 connector strip M1 M1 OUTPUT POWER COMMAND INPUT Further details in section 5 hi For complex connections involving 4 20mA please refer to section 5 If you do not have an end of cycle switch the controller will operate in timer only mode then skip to step 5 i 3 29 STEP 4A If using a Progressive System connect the Dropsa Ultrasensor end of cycle switch to pins 13 14 15 on connector strip M2 STEP 4B If using a 33V Injector System connect the end of cycle pressure switch to pins 14 and 15 on connector strip M2 For any other system please refer to the connection diagrams in section 5 STEP 5 Connect the remote alarm signal relay to your host machine to pins 1 2 3 on connector strip MI 2 ALARM Alarm NO COM Alarm NC 4 29 STEP 6 You can now power on the VIPS and enter setup programming mode When you turn on the device you can check the firmware version loaded rel 3 00 Press and hold the MODE key for 5 seconds to the setup programming menu The VIP5 will display the first parameter and the default value SEP Now configure the parameters STEP 7 Select the type of system SEP TIMER PS DUAL By default the system will be configured a Progressive controller To change the configuration press the MODE key for per 5 seconds and use the arrow
3. Delay time Is how long to wait for the signal to be confirmed and switch off the pump in Pressure switch applications Wait time determines how long to wait in a pump off condition before repeating the cycle This is necessary in injector systems and represents the minimum time required for the injectors to reset In progressive systems for example this can be set to zero 3 1 3 STANDBY Phase During the Standby the VIP5 switches off the pump and waits for the start of another Lubrication Phase The duration of the Standby phase can be determined by a countdown timer or a by an external pulse signal that can be used as a counter The VIP5 also allows a combination of both timer and external pulse signals to determine either the next Lubrication phase or to signal an alarm if external pulse signals are not received within a pre set time 3 2 FLOW MODE OPERATING PRINCIPLES The VIP5 can also be used as a simple Flow monitoring system When Flow mode is selected the unit operates as a flow display and monitors an external signal to calculate the flow based on external impulses The User can additionally set a minimum and maximum Flow limit If the flow is out of these limits the remote alarm contact and the alarm LED on the front panel are both activated 10 29 4 FIXING AND INSTALLATION DETAILS FIXING DIAGRAM The different VIPS models are shown below with fixing dimensions VIPS Plastic Box PN 1639140 16391
4. 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 Flammability The lubricant generally used in lubrication systems is not normally flammable 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 The device does not produce excessive noise less than 70 dB A 25 29 17 WARRANTY 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 Dropsa giving A complete description of the alleged malfunction The part number s Test record number where available format xxxxxx XXxXXXx Date of delivery Date of installation Operating conditions of subject product s AD CON SOUS SC We will subsequently review this information and supply you with either servicing data or shipping instruction and ret
5. OPERATOR INTERFACE FRONT PANEL 6 1 LAYOUT AND STATUS TABLE OF VIP5 FRONT PANEL Status and Product description Identification Label on side Pump ON LED Pump ON O Pump OFF v 79 Stand by Cycle status LED Shows cycle control input condition ESC Exit from setup menu without saving changes MODE SET Change Value for selected parameter Alarm LED Shows parameter and values during set up or status and counters during normal operation Hardware Reset Button OK Exit from setup menu saving changes BACK Previous Parameter or Setting Decrease displayed value NEXT Next Parameter or Setting Increase displayed value VIP5 Condition PUMP ON LED CYCLE INPUT LED ALARM LED Aam 1 1 OF ON ON Standby Phase OFF 0 0ON OF Lubrication Phase Cycle ON ON OF b tp A 4 X OF X OF AJ 0N 15 29 7 OPERATING MODE VIPS has three different operating modes which are determined during the setup stage described previously These are CYCLE PULSE and FLOW 7 1 CYCLE Mode In Cycle mode a cycle sensor determines the completion of the LUBRICATION PHASE If using timer setting the Lubrication Cycle will complete when the timer expire The Standby phase is determined by a timer or by an external input counter Pump
6. UP and DOWN keys to select the type of system parameter Select LUBE TYPE accounting to the type of system you have select this option for PROGRESSIVE SYSTEM with the end cycle switch eg Dropsa Ultrasensor The VIP5 Controller will activate the pump and compete the cycle when the cycle switch has changeover two times 0 gt 1 gt 0 or 1 gt 0 gt 1 The pump is then switched off until the next lubrication cycle PIU TEE select this option for more complex DUAL LINE SYSTEM You should refer to the advanced setting in section 8 Uli select this option when you have NO CYCLE SENSOR The VIP5 Controller will activate the pup for the duration of the QRUjaagiviag After this the pump is switched off until next lubrication cycle ELM select this option when have a pressure switch configuration in a 33V INJECTOR SYSTEM The VIP5 Controller will switch on the pimp and wait for pressure to be achieved The pup is the switched off until the next lubrication cycle When the correct type of system is selected press OK key to set the next parameter 5 29 STEP 7A If udi mode is selected Set the lube cycle timer value STEP 8 Set the pause time value ZI timer If WOW mode is selected you must determine for how long the pump must run during each lubrication cycle For other operation modes the run time of the pump is automatically determined by the end of cycle monitoring switch Press
7. are only main parameters to manage a lubrication cycle The Quick start guide section placed early this manual describes BASIC MENU programming mode The VIP5 Controller can operate or in stand alone mode default or inserted in a system of overall control which can receive timing signals for starting and stopping of lubrication VIP5 can also operate in exclusive monitoring lubrication mode The Extended Menu allows to set all parameters that guarantee the total control of the system To see the complete list of extended parameters see section 9 3 20 29 9 3 PARAMETERS AND VALUES The following table explains the parameters and possible values of the VIP5 selecting basic or extended menu PARAMETER DEFAULT NAME VALUE DESCRIPTION VALUES RANGE APPLICABILITY MODE CYCLE oem m om m om i SESE STE Se ES eases Timer only Pressure switch Progressive Cycle switch UM D MN gt x lt IMER SELECTS THE CYCLE MONITORING 1OH INOO TYPE Basic ON YX3WIL DUAL dis Dual Line Pressure switches INVE Wait Waiting time for inversion command and ds iy pump Determines Standby Phase Timing Time based Standby Time Counter Which f 2 f PAUSE BY TIMER ichever of above 2 events occurs first Tee eh A set number of external PULSE signals Counter reached an alarm will be given TOUT amp Counter Basic standby phase will be skipped 99h 00m Timeout counter determines how long
8. in Stand by i Pump on ALARM Example 1 Standby and Lubrication determined by ON amp OFF Timer gt E Example 2 Standby determined by a counter D FE Pr LUBRICATION PHASE Example 3 Standby determined by a counter and timer m lt C the first of two events stor gt REPEATED 1 250 Times 1 250 Times Aa 4 Hd on T 0 60 000 cycles Example 4 Standby determined by a counter Alarm signal given if the external counter signals not detected within a set time FE SNC vee MN NUES ee oe 1 min 99 hours 1 60 000 cycles brication Phase can be repeated 7 2 PULSE Mode In Pulse mode the duration of the Standby Phase and the Lubrication Phase are both determined by an external counter The correct operation of the Lubrication Cycle can be monitored using a cycle sensor Pump in Stand b Pump on ALARM LUBRICATION PHASE Example Standby Phase determined by the Pause Counter and lubrication Phase determined by Cycle Counter CYCLE Cnt gt 1 PAUSE Cnt gt 0 The Lubrication Phase is Suspended if no external signals are recieved within a time specified by the suspend Timer SUSPEND T gt 0 X 0 60 000 cycles 1 60 000 cycles SUSPEND 1 60 000 cycles gt 7 3 FLOW Mode Using this mode allows the VIP5 to be used as a simple flow monitoring and display device ALARM Flow control The display shows the current Flow rate being detected i
9. only be repaired by qualified Dropsa technicians 10 1 ALARM CODE TABLE The following is a list of possible alarms generated by the VIP5 with information for troubleshooting purposes ALARM CODE DESCRIPTION NOTES CHECKS SOLUTIONS ALARM 01 LOW LEVEL The Low level sensor has triggered Replenish the oil reservoir ALARM 02 CYCLE TIMEOUT The cycle switch has not been detected in the specified time Make sure that you have set the timer to a value that allows the cycle to complete ALARM 03 BOOST WARNING The P2 input has been activated and the Boost Function has increased the number of Lubrication Cycles in the Lubrication Phase ALARM 04 THERMAL PROT The Thermal relay trip signal has been detected Verify and repair In PS Cycle mode the pressure switch was already active before the pump was ALARM 05 PS ALREDY ON switched on Check to ensure the venting system is operating correctly In PS Cycle mode the Pressure switch cannot achieve pressure for the duration of the DELAY time parameter ALARM 06 PS AFTER WAIT l Check parameters are correct and the pump is operating correctly and can maintain pressure ALARM 07 NOT IN PRESS No Pressure switch detected within the timeout time Verify pump and pressure switch are operating correctly and there are no leaks In TOUT amp Count Mode no external signal has been receieved for the Timeout ALARM 08 PAUSE TIMEOUT period setting Verify external switch is operating ALARM 09 HI LEVEL MAX level is
10. present in tank ALARM 10 BAD SET 420MA Programming error on the 4 20 mA input modify parameters to have a range MIN MAX gt 4mA ALARM 11 BAD IN 420MA Incorrect wiring on the 4 20 mA signal underrange or overrange ALARM 12 LO FLOW In Flow mode the current flow is below the minimum set level ALARM 13 HI FLOW In Flow mode the current flow is above the maximum set level In Flow mode the current flow is below the minimum set level because no flow ALARM 14 LO FLOWT input signal has been received for the timeout time This generally indicates a broken sensor or that the system being monitored is switched off An unknown Internal error has occurred ALARM 15 UNCODED FAIL Try resetting the unit If the error re occurs the unit must be returned to Dropsa for inspection 10 2 RESTART RESET When an alarm occurs it is displayed on the LCD display with the alarm number and a brief description of the alarm For Example ALARM 11 setup reset By pressing the button located under the Setup label the user can go and modify the parameter values if it is some incorrect parameter that is causing the alarm By pressing the button located under Reset or the hard reset button the VIP5 will restart its programming with the last saved parameters 23 29 10 3 REMOTE CODED ALARM FUNCTION The VIP5 controller has the ability to use a remote pulsed coded alarm contact Every time the VIP5 control enters an alarm condition the remote alarm
11. relay contact is activated Most alarm contacts are simply a NC or NO contact that gives a remote system indication that the local controller is in a fault condition Additionally the VIP5 can trigger the alarm according to the alarm code being generated and allow a remote PLC or even a remote LAMP signal to read the number of the alarm being generated This is done by pulsing the alarm relay in 500ms bursts with a 2000ms gap between each signal burst The timing chart below shows how to interface the logic with your PLC Alarm code number of T1 T2 T1 500ms alarm contact activation time T2 500ms alarm contact deactivation time TWait 2000ms pause time before repetition of same alarm code TWait 2000ms pause time before repetition same alarm code T1 T2 T1 Ti T2 T1 T Wait Ti T2 T1 T1 T2 T1 T Wait 11 TECHNICAL SPECIFICATIONS 12 24 Vdc ac 1639141 OPERATING VOLTAGE 110V 1639142 230V 1639140 Temperature Operating Range 5 C 70 C Permissible Temperature storage range 20 C 80 C Operating Relative Humidity 90 max adequate protection If the cable glands are not sufficient in number for your configuration use a multi O Note To ensure that seal of the casing is guaranteed alone use appropriate cable glands that provide connector solution and a cabling harness that will ensure adequate sealing and avoid torsion and tension on the cable 12 MAINTENANCE PROCEDURES VIPO5 has been designe
12. to wait CYCLE TOUT 30 sec for cycle completion before a timeout alarm is 1s 1h generated a 30 sec In timer Mode how long the pump will run Os 99h LUBE CYCLES 1 Number of Lubrication Cycles to complete a 1 250 Lubrication Phase Determines state at power on START IN Resume Start in Lubrication Phase Lube Resume Resume from power down state A Pulse Coded Alarm signal is given for Coded details see section 10 3 PRELUBE gt lt gt x lt Determines what Alarm conditions should stop the VIP5 Lubrication cycles Never stop the lubrication cycle STOP All alarm conditions On All All but min Level stops the Vip5 All but min Level Only minimum level alarm stops the VIP5 Min level only All but Maximum Level All but Max level Pump output can be constant signal pulsed Continuous PUMP Continuous 7 ie i Pulsed Basic signal or synchronized with control signal see next 3 parameters Synchronized gt PUMP TON Sets the ON value of the pump pulse 0 1 25 0s X gt PUMP TOFF Sets the OFF value of the pump pulse 0 1 25 0s X WAIT TIME 10s Time between two Lubrication Cycles within Null 2 min X the Lubrication Phase In a SEP mode If P2 input is closed the LUBE BOOST CYCLES 1 CYCLES values is increased by this value 1 250 X contained in this setting 21 29 When the pressure switch is made how long to keep the pump running to ensure that the DELAY TIM 5s signal is genuine and not a pressure s
13. 29 The following table lists INPUTS and OUTPUTS for the VIP5 Motor line 1 Output Motor line 2 max 10A 230V Power is supplied via relay from pins 3 and 4 lt Pump Solenoid Connection lt lt IB Power AC DC input 1 12V 24V 110V 230V Power connection for VIP5 Depending on Model Power AC DC input 2 purchased Input lt IB Alarm contact NO lt N Max 2A 30V If ALARM is set to Alarm contact COMMON Remote alarm relay Inverted Value see par 9 3 Pin1 and Pin3 are inverted lt N Output Alarm contact NC lt N Open contact or Input C Minimum Level Sensor PNP NPN NAMUR GND see Note 1 INO10 Input 0 10V Volt analogical input Not used Analog GND iN420 420 mA analogical TTE 0 mA analogical input connection sees Analog GND point Ve see Note 2 Input for external counting device PNP NPN or clean contact Suspend input in CYCLE mode Sais N N Ae Es N NIN lt N o Clean contact PNP NPN NAMUR see Note 1 Input lt N IB lt NO N First Sensor Input for monitoring system Clean contact Eg Pressure switch for injectors or PNP NPN NAMUR Cycle switch for progressive system see Note 1 GND Suspend input in TIMER mode lt N UW Ve see Note 2 Input lt N A lt N Ui lt N Ve see Note 2 Second Input for monitoring system Clean contact Eg
14. 41 1639142 VIPS Steel Box PN 1639144 1639145 1639147 PN 1639150 1639151 1639152 1639153 111 5 mm 111 5 mm Q 3 5 mm 4 4 in 4 4 in 0 13 in O A B 6 in 8 75 in 0 13 in 4 1 UN PACKING Once the installation point has been identified you can unpack the VIP5 from its shipping box Check that the unit has not been subject to any damage during transport Dispose of the packaging in an appropriate manner following local waste regulations 4 2 INSTALLATION The VIP5 must be secured physically to a mounting location and cabled to all the required components of the lubrication system 11 29 The following are general recommendation e Install the unit in an easy to access location so that users can avoid unnatural postures and have good visibility of the display e Leave 100mm or 4 inches around the unit of space to facilitate cabling and maintenance e Do not install the unit in dangerous or excessively aggressive environments with high levels of vibration or in the vicinity of flammable substances e Always use the four fixing points as indicated in the diagram 5 INPUTS OUTPUTS 5 1 ELECTRICAL CONNECTIONS The input and output connections for the lubrication devices and sensors can be achieved via the M1 and M2 terminal strip located on the bottom of the VIP5 box The following are connection information for the M1 and M2 terminal strips TV B8 m n ww o usw A Ser 12
15. MODE key to cycle time Select UP and DOWN arrows to set the value Press OK key to save the value Press UP arrow U function to move onto the next parameter The PAUSE timer is used to set how often the VIP5 will active the pump and run a lubrication cycle By default this is set to every 6 minutes To change the setting press MODE key Then use UP and DOWN arrows to change value Once you have selected your pause time press OK key to save and return to the parameter Menu Press UP arrow W244 to move onto the next parameter 6 29 STEP 9 Set pump Type You must tell the VIP5 if you are using a continuously energized pump system or if it requires to be pulsed to work correctly STEP 10 Complete the Setup eene x The VIPS Controller by default can operate both electric and reciprocating pneumatic pumps that require a continuous command output Example of such pumps are Dragon Series Sumo Cannon Pump Smart Piccola Pneumatic Barrel Pumps These are known as S9 Mte pump type f however you are using a pump that requires a pulsed output the you must selected Uap Examples of such systems would be a Locopump piloted by an 3 2 air solenoid valve To change the setting press MODE button Then use the UP and DOWN arrows to change the value Once you have selected your desired PUMP Type press OK button to save and return to the Parameter Menu At this point the basic parameters have
16. RICATION PHASE Continuous operation is identical but does not have a STANDBY Phase Additionally the VIPS Control system can also be used as a simple monitoring device in the FLOW operating Mode described later in this manual 9 29 3 1 1 PRELUBE Phase The user can specify a number of lubrication cycles up to 999 which are initiated when the unit is powered on If Prelube is set to zero the VIP5 controller will revert to its pre powerdown status Prelube is activated When the VIP5 system is powered on After the RESET button is pressed After the VIP5 exists from the setup menu As indicated above if Prelube is set to O value the Prelube phase is omitted and when the system is powered on the system will continue from its previous position in the program 3 1 2 LUBE Lubrication Phase The Lubrication Phase is a set of Lubrication Cycles that can be repeated up to 999 times A Lubrication Cycle consists of activating the lubrication pump then Control monitoring a feedback signal from a sensing device if installed There is then Delay period before switching off the pump and a Wait period before the lubrication cycle can be repeated Specifically Cycle time determine how long to wait for the control signal before determining an alarm condition Control Type determines what kind of control signal Single Line Dual Line Injectors Alternatively a Timer only setting means no monitoring will occur
17. a sociedad Dropsa S p a con sede legal en Mil n Via Besana 5 A Dropsa S p A com sede em Milao via Besana n9 5 DICHIARA CERTIFIES CERTIFIE ZERTIFIZIERT DASS DECLARA CERTIFICA che la macchina denominata that the machine named que la machine d nomm e Die Maschine mit der Bezeichnung que la m quina denominada que o equipamento denominado e conforme alle condizioni previste dalle Direttive CEE has been constructed in conformity with the Directives Of The Council Of The European Community on the standardization of the legislations of member states a t construite en conformit avec les Directives Du Conseil Des Communautes Europeennes Entsprechend den Richtlinien des Rates Der Europ ischen Union f r die Standarisierung der Legislative der Mitgliederstaaten konstruiert wurde cumple con las condiciones establecidas por las directivas comunitarias foi constru do em conformidade com as diretivas do Conselho das Comunidades Europeias e 2006 42 Direttiva macchine Machinery Directive 2006 42 Directive machines Maschinenrichtlinien Maquinaria 2006 42 CEE Directiva 2006 42 M quinas e 2006 95 bassa tensione Electrical Safety Low Voltage Directive 2006 95 S curit lectrique Directive Basse Tension Elektrische Sicherheit Niedrigspannungsrichtlinien Seguridad el ctrica 2006 95 Directiva de baja tensi n Seguranga El trica 2006 95 Directiva de Baixa Tens o Vimodrone MI Aprile 2011 CE Tech
18. been set The VIP5 Controller will ask if you wanted to set the advanced options These allow a much more granular control of the lubrication cycle for complex systems and many more control options You can read about the other option in section 9 of the manual Press OK button to save the setting and exit programming mode Setup Completed The VIP5 will now start a lubrication cycle 7 29 1 INTRODUCTION Thank you for purchasing the Dropsa VIP5 Lubrication Controller This is the operating and user manual for the VIP5 Controller used to control and monitor small and medium sized lubrication system such as simple on off systems injector systems progressive divider systems and simple dual line systems It is possible to obtain the latest documentation by visiting our website www dropsa com This manual contains important operating and safety information for users of this product It is essential that you carefully read this manual and conserve a copy with the product so that other users may consult it at any time 1 1 DEFINITION OF LUBRICATION AND STANDBY PHASE LUBRICATION PHASE AND LUBRICATION CYCLE In this manual the LUBRICATION PHASE and LUBRICATION CYCLE refer to the specific instances when the lubrication pump is operating to provide lubrication in a system The LUBRICATION CYCLE is made up of Cycle Start gt Control of a sensor device gt Delay time to allow sensor device to stabilize gt Wait Time before another Cycle S
19. c lubrication parameters 30 In PULSE mode the BOOST CYCLES parameter has been excluded as l redundant In PULSE mode multi cycle possibility using a PS type system has been enabled Change Modify default value for TOT REFILL parameter to 10 hours instead of 2 minutes New FLOW mode feature added Change Alarm relay activation fix for configurations using suspend feature New External pressure switch input alarm added New In DUAL mode secondary solenoid control enabled New feature INVE WAIT parameter added 2 03 24 02 2010 New feature pump control mode SYNCRONIZED added New feature LUBE NO CONTROL value added Operating test added for internal and distributor use only 17 02 2010 Change In SUSPEND parameter added tenths of seconds Change SUSPEND Bug fix 2 04 01 12 2010 2 02 27 29 19 DECLARATION OF CONFORMITY DropsA Dropsa Spa Via Benedetto Croce 1 20090 Vimodrone MI Italy 39 02 250 79 1 39 02 250 79 767 sales dropsa it www dropsa com AN ISO 9001 APPROVED COMPANY DICHIARAZIONE C pi CONFORMIT DECLARATION OF COMPLIANCE WITH STANDARDS DECLARATION DE CONFORMITE KONFORMITATSERKLARUNG DES STANDARDS DECLARACI N DE CONFORMIDAD DECLARA O DE CONFORMIDADE La societ Dropsa S p A con sede legale in Milano Via Besana 5 Dropsa S p A registered office in Milan Via Besana 5 Dropsa S p A au Si ge Social Milan Via Besana 5 Dropsa S p A Sitz in Milano Via Besana 5 L
20. d not to require any regular maintenance We recommend to occasionally clean the unit with a damp cloth not using solvents The battery life is approximately 10 years In the event that the battery needs to be replaced you should note that there are two possible battery types a A Soldered type battery that must be removed and re soldered This type of battery can be obtain from Panasonic PART NUMBER BT CR2032 H easily purchased all over the world b The replaceable type battery can be simply removed and replaced This type of battery can be obtain from Panasonic PART NUMBER CR2032 easily purchased all over the world 24 29 13 DISPOSAL PROCEDURES The unit does not contain any harmful substances and should be disposed of following local regulations including any recycling information indicated on the components themselves 14 ORDING INFORMATION VIP5 15 MOVING AND SHIPPING Use suitable padded packaging when shipping the VIP5 controller and ensure that no damage has been sustained before reinstallation 16 OPERATING PRECAUTIONS ATTENTION It is necessary to carefully read about the instructions and the risks involved in the use of lubrication machines The operator should make sure he fully understands the operating and safety procedures of the VIP5 controller and any connected machinery or devices Power supply Any type of intervention must not be carried out before the unplugging of the machine from power supply
21. http www dr psa com VIP5 Lubrication System Controller Control system for small and medium size Lubrication Systems Software Version 3 0 Quickstart Guide User Operating and Maintenance Manual Original text translation Warranty Information CONTENT INTRODUCTION PRODUCT FEATURES DESCRIPTION OF OPERATING PROCEDURES FIXING AND INSTALLATION DETAILS INPUTS OUTPUTS OPERATOR INTERFACE FRONT PANEL OPERATING MODE CYCLE MONITORING 9 SETUP PROGRAMMING 10 PROBLEMS AND SOLUTIONS 11 TECHNICAL SPECIFICATIONS 12 MAINTENANCE PROCEDURES 13 DISPOSAL PROCEDURES 14 ORDERING INFORMATION 15 MOVING AND SHIPPING 16 OPERATING PRECAUTIONS 17 WARRANTY 18 REVISIONS 19 DECLARATION OF COMPLIANCE 20 DISTRIBUTORS poo b aS SY eqs Manual compiled in accordance with Directive C2094IE WK 42 11 06 42 CE Quickstart Guide 10 STEPS TO SETUP YOUR VIP5 Controller This section provides summary instruction for programming the VIP5 controller BASIC Menu and functionality The features in the basic menu can be used to control and monitor a majority of simple TIMER BASED PROGRESSIVE AND 33V INJECTOR lubrication systems allowing to get your system up and operational in minimal amount of time 2 29 STEP 1 Install and fix VIPS Controller The VIP5 Controller should be fixed using the 4 fixing holes For further information refer to Section 4 of this manual L ae 162 mm 4 2 mm 6 4 in
22. low level if you use 4 20mA input m MEHEEENEIEESNEM gt LO LEVEL MA gt HI LEVEL MA 8 2 Setting a high level if you use 4 20mA input 4 0 20 0 When resetting a low level alarm grace period 5s i i Os 5s before monitoring level inputs 1 19 4 0 MININPUT X DELAY Enable or Disable the Real Time clock Enable DATETIME Disable functions Note be sure battery is connected Disable x SHouR o onetime Hoursening foa hh x eT pestro rcromoeursermnes ves no x 3 9 4 SPECIAL FUNCTIONS 1 LCD CONTRAST ADJUSTMENT by Pressing ESC or OK during power on or immediately after a reset you access the menu for adjusting the contrast of LCD hold down OK the contrast decreases with ESC increases 2 FLOW TOTALIZER DATA VISUALIZATION with the VIP5 in standby mode pressing the OK key will allow you to scroll through the current average flow rate or the total volume dispense in the last DAY HOUR or TOTAL since last reset 3 RESETTING THE FLOW TOTALIZER during the visualization of the above parameters the flow can be reset by holding the DOWN key 4 TIME AND DATE during standby it is possible to view time and date by using the ESC key only if DATETIME parameter is set on enable 5 EVENT LOG VIEWER n by holding the Up or Down key for five seconds it is possible to scroll through the Event Log available in version FW 2 xx onwards 22 29 10 PROBLEMS AND SOLUTIONS AN ATTENTION The VIP5 should
23. n the system It is also possible to scroll through menus to see totalizing flow counter Flow Out of Range 16 29 7 4 PRELUBE The Prelube cycle is a pre lubrication cycle that is triggered when the system is powered on or reset If the pre lube cycle value is set to 1 or greater the VIP5 will perform the set number of Lubrication Phases Note that if Each Lubrication Phase comprises two or more Lubrication Cycles then the total cycles performed will be equal to the Lubrication Cycles multiplied by the Prelube Cycles POWER ON OR RESET PRELUBE 21 RUN n LUBE Cycle NORMAL OPERATION 17 29 8 CYCLE MONITORING 8 1 MONITORING OPTIONS There are four possible Cycle Monitoring Options explained below 1 TIMER TIME ONLY RESET BUTTON The Lubrication cycle is simply operated according to a preset Timer value R MOTOR PUMP ak ea Therefore no input is monitored to confirm MINIMUM LEVEL the correct completion of the lubrication cycle l l i l i l I l I l i I i I L 2 PS PRESSURE SWITCH Pressure switch monitoring is typically used in injector system The VIP5 will monitor input P1 to verify that it is an OPEN contact at the start of the cycle The pump is activated and the pressure switch must CLOSE within a timeout period otherwise a cycle alarm is generated Once the P1 contact is closed a DELAY timer checks that the switch is not broken PRESSURE SWITCH for a se
24. nical Director Maurizio Greco 8900000088885 C 89808b 0005069 Legal representative Milena Gavazzi 28 29 20 DISTRIBUTORS p A 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 EA 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 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 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 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 salesfr dropsa com Ed Dropsa do Brazil Rua Sobralia 171 Santo Amaro Sao Paulo Brazil Tel 55 011 5631 0007 Fax 55 011 5631 9408 E mail salesbr dropsa com En Dropsa China Dropsa Lubrication Systems Shanghai Co Ltd Tel 86 021 67740275 Fax 86 021 67740205 E mail china dropsa com ll Dropsa Australia Ltd C20 148 Old Pittwater Road Brookvale NSW 2100 Tel 61 0 2 9938 6644 Fax 61 0 2 9938 6611 E mail salesau dropsa com Web site http www dropsa com E mail sales drop
25. o zero Therefore it is recommended that after inserting the battery jumper the date and time is OQ Note Every time the battery jumper is removed and reinserted causes the DATE TIME function to be 14 29 5 4 PRECAUTIONS TO BE USED WHEN CARRING OUT WIRING There are no specific safety risks associated with this device Use general precautions that you would use when operating an electrical device All wiring should be carried out by a qualified electrician e Before wiring the panel ensure correct voltage as indicated on the product label e Only perform wiring operations once you are sure power is off and cannot be accidentally switched on e A circuit breaker that is easy accessible must be used in the wiring of the pump Ensure the break contact has a contact distance of at least 3 mm e When using the 12 24V AC device the power must come from a transformer in compliance with prescription of IEC 62558 2 6 e n case of connection to 230 V or 110 V the connections on M1 power and pump must have reinforced isolation up to the terminal connections The cable must be routed to avoid damage to the outer isolation sheaf e t is advisable to use a fuse or a differential isolation to protect the device The device should have a recommended value of 0 03 Ampere with 1 milllisecond maximum activation time isolation capability 2 10kV and nominal In 6A e t is good practice to use cable ties that can help prevent cables being torn 6
26. pike Os 2min X X must exist before being reported When the suspend signal is given to the controller we can have following values Never Do not stop Never Never In Pause Stop at the end of lubrication SUSPEND phase In Pause In Cycle Stop during lubrication phase In Cycle Always Always Stop when a signal is received SUSPEND T Neuer In Pulse Mode will suspend the Lubrication Null 2min Phase if a signal is not received In Cycle Mode set number of pulses during Null 250 PAUSE CNT pause phase This mode can be used with cycle mode Basic If pause is zero will be based on pause time Null 6000 setting PULSE mode The ratio that can be applied for pause count setting to allow the user to obtain a higher counting breaks eg if pause is 52 1 10 100 and the multiplier is 100 the value will be PAUSE MULTIP 5200 The Duration of the Lubrication cycle in 1 X CYCLE CNT 1 PULSE Mode 60000 FLOW VALUE 10 Informational value of now much lubricant is 0 0 1000 dispensed per Lubrication Cycle f Counts Information Unit for the flow value parameter Cubic Liters Pints X UNITS Counts used for display purposes only Gallons KilosGrams FLOW MIN 10 0 Minimum Flow Setting 0 0 6000 Totally excludes flow alarm if null FLOW MAX 100 0 Maximum Flow Setting 0 0 6000 MIN LEV Configuration for the input signal of minimum NC INPUT ine NO 4 20mA Setting a
27. sa com 29 29
28. second pressure switch on a dual PNP NPN NAMUR Line System see Note 1 Input lt IB N lt GND IB oo Note 1 If using NAMUR wire sensors a 1 5kQ to 2 5kO resistor should be installed between Signal and GND see paragraph 6 1 for wiring diagram Note 2 for active sensors the maximum current available is 100mA in total on Ve e When using clean contacts the VIP5 will use 12 or 24V to monitor the contact 13 29 5 2 WIRING EXAMPLES ACTIVE SENSOR NAMUR SENSOR MICROSWITCH DESCRIPTION 18 2K JHM A pa Input PS2 for DUAL Line wen e K 22 Mode P ol x Input BOOST for SEP Mode JPN Input PS1 for DUAL line or Mode Input CONTROL for SEP Mode SIGNAL er Uf Input SUSPEND for TIMER 3 i Mode Count input in Mode PULSE or FLOW Input PAUSE Cnt SERDUAL PS TIMER SIGNAL Minimum level analog Input Future expansion not used cdi Minimum level TO 1639161 E s SIGNAL 1639138 1639139 4 AID II Relay NO 3 Relay COM Alarm Out SN oe BATTERY gt AG amp Ww NS JUMPER Bridge pins to activate battery D By inserting the Jumper into the bridging pins the battery function is activated and this allows the VIP5 to operate with the Date time and status save function when the power is removed set t
29. stem directional valves the pressure itself causes the valve to perform the line inversion However if using an electrically operated directional valve then a signal must be given to power the solenoid that causes the valve to invert The VIP5 already has this control capability but you must fit the equipment that included the Terminal Wiring board in order to have the output present to power the solenoids For further information contact the Dropsa technical sales office 19 29 9 SETUP PROGRAMMING The following section explains how to navigate the VIPS setup menus and contains detailed explanation of each parameter and possible values 9 1 Navigating around the setup menu The navigation map below shows how to navigate around the setup menu OPERATING SETUP PARAMETERS VALUES SETUP MODE OR set value 3 Pave saved parameters OR value no save not saved parameters OR set value Save parameters no save not saved parameters value To enter the SETUP menu from the OPERATING Mode hold the roco Mode button for 5 seconds The 4 Up and Down keys allow scrolling through the parameters By pressing the Mode button again the indicated parameter value can be modified by using the Up and Down keys To exit use the ox 0 key or e Esc if you with to exit without saving 9 2 BASIC EXTENDED MENU When turn on Vip5 Controller show a BASIC menu that allows user a quickly setup there
30. t time before switching off the pump This ensures that pressure spikes at the start of a lubrication cycles on long lines are filtered out A WAIT timer can be set to allow the injectors to reset when using multi cycle configuration 18 29 3 SEP SERIES PROGRESSIVE Series progressive Operating mode is used for Cycle switch monitoring typically on progressive systems The Pump is switched on and P1 input is monitored and must change state twice within the timeout period otherwise a timeout alarm will be generated Once P1 changes state twice the pump is switched off and VIP5 goes to standby or the Lubrication Cycle is repeated for the desired number of times There is no WAIT time in this mode as progressive systems do not need venting time 4 DL DUAL LINE Dual Line cycles generally use two pressure switches connected to P1 and P2 The VIP5 starts the pump and must see that P1 switch is closed within the timeout time After this the Lubrication lines are inverted by use of a directional valve The P2 switch must also then be made within the timeout timer setting A user configurable DELAY timer can be set to filter pressure spikes as in the PS operating mode EXPANDER POWER MOTOR PUMP P MINIM MLIVEL uu INVERTER 8 2 NOTES ON CONTROLLING A DIRECTIONAL VALVE IN A DUAL LINE SYSTEM ares d 1 OEE AH BESS tae RT EUR When using hydraulic dual line sy
31. tart This sub cycle can be repeated as many times as required and the completion of this repetition is considered the LUBRICATION PHASE Fig 1 Illustrates this graphically Lubrication Phase Lubrication Cycle can be repeated up to 250 Fig 1 A Lubrication Phase can comprise of many Lubrication Cycles The STANDBY PHASE defines the interval between each LUBRICATION PHASE 8 29 2 PRODUCT FEATURES VIPS is an advanced lubrication control that offers many operating possibilities and features in a single compact package It is an ideal product for small and medium systems as it offers considerable advantages over using a much bigger expensive PLC system to achieve the same result Some of the key features are Three separate inputs to monitor Dual line pressure switches progressive cycle switch injector pressure switch and external signals to use as a counter for standby or lubrication phase Signal Inputs can be NPN PNP or a Clean Contact or Namur style switching Time or counter based determination of both Lubrication and Standby Phase e Counter based Lubrication phase can be used independently while monitoring correct function of a cycle switch ideal for use in impulse piloted system e g chain and conveyor lubrication e Minimum Level Input e 4 20ma Input for analog measurement of Reservoir Level Ability to configure pump output for Electrical or pneumatic pump pump On Pump Off values can be set individually
32. urned materials authorization RMA which will have instructions on how to prepare the product 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 to 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 states 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 26 29 18 REVISIONS The following is a list of key changes between software releases REV FW DATA MODIFICHE New menu layout and QUICKSTART mode to allow simple for basi
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