VIP4Air - Lube Control
Contents
1. Bie TUBO 4 q a S Condensate vent Screw The panel is designed to accept the mounting of a timer kit optional P N 3132572 Number of elements Height A mm Weight Kg 82 o 97 82 o 57 00 f 3 2 3 7 2 f 9 2 o 6 2 10 15 DIMENSIONS VIP 3 LITER Electric Level Filler plug Delivery Mixer air intake Flow regulating Vent screw screw Al Pump control Condensate vent screw The panel is designed to accept the mounting of a timer kit optional P N 3132572 E 88 5 88 o 93 66 o 6 Eo 8 11 16 GUARANTEE 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 and 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 materials2. The VIP4Air is the most complete and compact Minimal Air Oil Lubrication System available today Air Oil Minimal lubrication is a relatively new technology that has been used successfully to substitute costly Oil Re circulation and non environmentally sound Mist Systems It has provided excellent results both in terms of performance and total system cost It is ideal for use on Bearings High Speed Bearings Gears and also in certain circumstances on Guides It is particularly suited to Spindle Lubrication In the past excessive oil has been used often only to ensure that the system is working This oil generates heat and has to be collected away from the lubrication point Dropsa has taken the minimal lubrication concept one step further with the VIPAAir that can achieve ultra low volume oil discharge and at the same time provide electronic monitoring using a custom designed differential flow sensor integrated into the unit This allows true minimal lubrication by applying micro amounts of lubricants at more frequent intervals whilst giving positive feedback that oil is correctly being injected and mixed into the air stream The VIP4Air System contains all components necessary to achieve and monitor optimum minimal Air Oil Lubrication PRODUCT FEATURES e 1 8 Lubrication Points each with independent monitoring e 0 005 0 030 cm 0 0003 0 0018 cu in of oil per discharge standard settings 7 15 30 mm 0 0004 0
3. Garges Les Gonesse Tel 33 1 3993 003 Fax 33 1 3986 2636 E mail sales dropsa com Dropsa do Brazil Rua Sobralia 175 Santo Amaro Sao Paulo Brazil Tel 55 11 56310007 Fax 55 11 56319408 E mail salesor dropsa com F Poly Dropsa S A Av Fabregada 26 Pje Est 2 08907 L Hospitalet de LLobregat Barcelona Tel 34 9326 022 50 Fax 34 9326 022 51 E mail sales dropsa it 5 Dropsa Australia Pty C20 148 Old Pittwater Road Brookvale NSW 2100 Tel 61 2 9938 66 44 Fax 61 2 9938 66 11 E mail sales dropsa com Lube Control Pty Ltd Providing lubrication solutions t 08 8298 5563 f 08 8298 6253 Web site http www dropsa com E mail sales dropsa com 14
4. ingress of water or dirt EN Frequent lubrication intervals z gm s Me help thermal stability of system am kam f TA jiin Dropsa is a leading international manufacturer of Automatic gt ao 41 Lubrication Systems and can assist with a wide range of technical ally and application advice systems and components Contact one of Ad our offices or distributors for more information DART Web site 7 Control http www dropsa com U S A BRAZIL AUSTRALIA Lube Control Pty Ltd Dropsa Corporation Dropsa Dropsa Australia Ltd mail Providing lubrication solutions t 1 586 566 1 540f 1 586 566 1541 t 55 011 563 10007 t 61 02 9938 6644 les d f 55 011 563 19408 f 61 02 9938 6611 sales dropsa com Unit 5 53 Norfolk Rd U K Marion SA 5043 Dropsa UK Ltd GERMANY FRANCE t 08 8298 5563 t 44 01784 431177 Dropsa Gmbh Dropsa Ame WK 32 03 M or requi f 444 01784 438598 t 49 0211 394 011 t 33 01 3993 0033 e info lubecontrol com au f 449 0211 394 013 C2033PE f 33 01 3986 2636 www lubecontrol com au VIP4Tools LUBRICATION SYSTEM User and Maintenance Manual Warranty Information TABLE OF CONTENTS INTRODUCTION IDENTIFICATION GENERAL DESCRIPTION DESCRIPTION OF COMPONENTS TECHNICALSPECIFICATION HANDLING AND TRANSPORT PRECAUTION IN USE CONTRAINDICATIONS INSTALLATION 10 INSTRUCTIONS FOR USE 11 MAINTENANCE 12 DISPOSAL 13 REPLACEMENT PART LIST 14 DIMENSIONS VIP 1 LITE
5. INDIVIDUAL PUMP Unscrew anticlockwise the red cap at the end of the pump to its stop so completely blocking off the delivery 10 3 REGULATING LUBRICANT DELIVERY FLOW Use the red cap to determine the nominal flow of the individual pump Completely unscrew the pump red regulating cap 0 mm flow turn clockwise for 1 5 turns min flow 5 mm after which every turn corresponds to an increase in flow of 5 mm until reaching 30 mm at the 7 turn see table 0 no pump delivery Completely unscrewed 11 MAINTENANCE The pump has been designed and constructed so as to reduce maintenance to a minimum To simplify maintenance it is recommended that the equipment be mounted in an easily reached location see paragraph 10 2 Periodically check the tubing connections for leaks Always maintain the equipment in a clean condition in order that any leaks will be immediately evident When necessary replace the oil filling filter P N 3130139 Periodically empty the pressure regulator condensate trap by rotating the small red valve located at its base The machine does not require any special tools for carrying out checks and or maintenance tasks It is recommended that suitable tools and personal protection clothing gloves are used in accordance with Legislative Decree 626 94 Safety at Work legislation and that they are in good condition DPR 547 55 in order to avoid injury to persons and damage to the machine Ensure that electrical p
6. 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 12 17 DECLARATION OF CONFORMITY Manufacturer DROPSA SpA Company Via B Croce 1 20090 Vimodrone MI Italy Address 39 02 250791 Telephone It is certified that The machin
7. 0009 0 018 cu in e Tamperproof adjustment rings avoids end user modifications Integrated Differential Flow sensor gives positive feedback of Air Oil lubrication e Fully Electronic Controls quick Set up and interfacing to host Integrated Mixing Air Pressure Transducer provides accurate and quick setting of Air Pressure on the electronic display as well as providing alarms for blocked or broken lubrication lines via high low air pressure monitoring e Automated Priming Sequence for quick and easy installation Integrated amp Compact Connections are internal to the unit Air Oil Minimal Lubrication Continuous Air Flow Cyclic micro oil Injection Provides Cooling Reduces friction Provides Transport Medium Minimal quantities avoid churning and heat generation VIP4Air 24 V DC VIP4Air 110 V AC 6 3135076 313507 8 3135002 3135003 Attention connector not included to be ordered separately connector p n 1639115 cable 2 mt Technical Characteristics VIP4Air Lubrication System 24V DC Voltage 110 VAC 5 8 bar 73 5 117 6 psi Remote Alarm relay max 250 V Output Signal 1A NO NC 5 55 C Operating Temperature 23 131 F Humidity Protection Mineral Oils 32 220 cSt 150 1018 SUS Reservoir capacity Reservoir capacity 1 It Air Pressure Inlet Oil Viscosity SS Prevents Contamination and No Excess Oil
8. R 15 DIMENSIONS VIP 3 LITER 16 GARANTEE 17 DECLARATION OF CONFORMITY 18 DISTRIBUTORS 49 o SI on SM ees E DropsA SpA VIPATools Certification Manual drawn up in accordance with CE C2040IE WK 51 02 Directive 98 37 Att paragraph 1 7 4 1 INTRODUCTION This user s and maintenance manual refers to VIP4Tools air oil lubrication system This manual should be conserved in such a way that it remains undamaged over time and is readily available to personnel needing to consult it Further copies of this manual updates or clarifications can be obtained by directly contacting the Technical Sales Office at Dropsa The manufacturer reserves the right to update the product and or the user s and maintenance manual without the obligation to revise previous versions It is however possible to contact the Technical Sales Office for the latest revision in use or to consult our web site at http www dropsa com The use of the equipment referred to in this manual must be entrusted to qualified personnel with a basic knowledge of mechanics hydraulics and electrical systems It is the responsibility of the installer to use tubing suitable for the system the use of inadequate tubing can cause problems with the pump injury to persons and create pollution Loosening of connections can cause serious safety problems carry out a check before and after installation and if necessary retighten them Never exceed the maximum working pre
9. e VIP4 Tools lubrication panel is manufactured in conformity with the DIRECTIVE OF THE COUNCIL OF THE EUROPEAN COMMUNITY concerning the machines 98 37 CE low voltage BT 73 23 CEE is manufactured in accordance with the following standards and harmonised technical specifications EN 292 1 2 EN 1050 EN 982 EN 11200 EN 60947 EN 894 1 2 TECHNICAL DIRECTOR W Divisi Product manager Name DROPSA SpA Company November 2001 Signature Date 13 18 DISTRIBUTORS N B From this manual the only copy valid is the one with the later WK number of week year shown on the front page S Dropsa Corporation 50679 Wing Drive Utica Michigan 48315 USA Tel 1 810 566 1540 Fax 1 810 566 1541 E mail salesusa dropsa com a 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 EE 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 Deutschland Tel 49 0211 394 01 1 Fax 49 0211 394 013 E mail sales dropsa de LUBE gt Control DropsA Unit 5 53 Norfolk Rd Marion SA 5043 www lubecontrol com au X e info lubecontrol com au ii Dropsa Ame Industrie 23 Av des Morillons Z IND des Doucettes 95140
10. ew base tightening the two securing screws supplied paying particular attention to the alignment and positioning of the seals 4 Reattach the connections to the new base 9 5 HYDRAULIC CONNECTIONS The only connection to be undertaken is that of the individual pumps provided with push in connections to the lubrication point The tubing must be in 24 mm nylon obtainable from Dropsa 9 6 PNEUMATIC CONNECTIONS Connect the air input to the push in connector utilizing 406 mm nylon tubing both for the pump and the mixer and provide a stop valve to permit shutting off the supply 9 7 ELECTRICAL CONNECTIONS The only electrical connection required is that of the Samba level see paragraph 6 Technical opecifications N B After all connecting up has been completed ensure the tubing and cables are protected from impacts and are suitably secured 10 INSTRUCTIONS FOR USE 10 1 STARTING THE VIP4Tools PANEL Before using the VIP4Tools panel it is necessary to carry out some preliminary checks check the integrity of the equipment check that the electrical and pneumatic connections have been effected correctly vent the residual air from the pump using the vent screw located at the center of the securing screws until lubricant exits retighten the vent screw without using excessive force to facilitate the venting regulate the pumps to maximum flow and operate for some cycles 10 2 EXCLUDING LUBRICANT DELIVERY FROM AN
11. ltage 220 V ac WARNING DO NOT supply the machine with voltages or pressures other than those indicated on the specification plate 6 HANDLING AND TRANSPORT Prior to dispatch VIPATools lubrication panels are carefully packed in a cardboard carton During transportation and storage maintain the equipment the right way up as indicated on the carton On receipt check that the packaging is not damaged and store the equipment in a dry place 7 PRECAUTIONS IN USE It is necessary to carefully read the warnings and the risks involved in using the lubrication panel The operator must understand the functioning of the unit by studying the user s manual Electric currents No intervention must be attempted on the equipment without first having disconnected the electrical power supply electric level and ensuring that it cannot be reconnected during the intervention All installed equipment electrical electronic tank and base structure must be connected to the ground line see paragraph 10 7 Flammability The oil employed in the lubrication circuit is not normally flammable It is nonetheless indispensable to take every precaution against the oil coming into contact with very hot parts or open flames Pressure Prior to any intervention on the equipment ensure that pressure is released from all branches of the lubrication circuit Failure to do this could result in oil being discharged under pressure where connections or components a
12. neumatic and hydraulic supplies are disconnected before undertaking any maintenance tasks 12 DISPOSAL During the maintenance of the machine or in the event of its being scrapped do not discard polluting components in the environment Refer to local regulations for their correct disposal At the time of final disposal of the machine it is necessary to destroy the identification plate and all other documentation 13 REPLACEMENT PARTS LIST VERSIONS 6 AJ 31350906 A J 91385116 v 8 J LJ 31508 J J J 9S3135138 9 COMPONENTS ACCESSORIES APPROXIMATE CONSUMPTION FOR LRT OILS 3226661 3226662 USAGE Grams per lubrication nozzle in 8 hours operating time ALUMINIUM LEADED STEEL ALLOY STEEL Wege asd LEADED BRASS SOFT STEEL STAINLESS STEEL ALLOYS Saw cutting Turning Shearing Cutting off Boring Drilling Milling Slotting Threading Tapping Planing Shaving Threading blind tapping Moulding and standard drawing Broaching Toothing Bending 35 40 40 50 f t B t ot 90 100 50 50 70 70 14 DIMENSIONS VIP 1 LITER Electric Level Filler plug TT T i te zip b hy Air mixer ra Regulator E53 acd ru om 2 ELE ai Lee ie U A LU Mi d P E m E SEE EN l 1 NM y LL A P TINI I Deli iid Flow regulating Mixer air intake screw Vent screw Pump control h Y E ee JL
13. re disassembled see paragraph 10 6 Noise The VIP4Tools lubrication panel does not emit excessive noise remaining below 70dB A WARNING before carrying out the replacement of the mini pumps empty the tank of lubricant AIR CHARACTERISTICS Characteristic Pressure at point of connection Max quantity of particles in suspension 15 mg Nmc Max diameter of particles Dew point Max quantity of oil in suspension 5 mg Nmc Whenever not utilizing natural base oils compatible with existing health regulations it is necessary to adjust the mixer pressure so as to avoid the formation and dispersion of oil mist into the environment The mixing pressure is indicatively between 1 and 2 5 Bar 8 CONTRAINDICATIONS The VIP4Tools panel does not have any particular contraindications except for the following points e he operator coming into contact with fluid due to breakage opening of supply tubing e he operator must be furnished with suitable personal protection clothing equipment part VIII 626 Safety at Work legislation Abnormal posture Take note of the indications shown in paragraph 10 2 Contact with oil during filling maintenance The operator must be furnished with suitable personal protection clothing equipment part VIII 626 Safety at Work legislation e Use of unsuitable lubricants Main inadmissible fluids Fud X Danger Lubricants with abrasive additives High wear ra
14. ssure values permitted for the panel and the components connected to it Before any maintenance or cleaning operation disconnect the power supply close off the air supply and discharge the pressure from inside the equipment and the tubing connected to it Do not subject the panel the connections the tubing or parts under pressure to violent impacts damaged tubing or connections are dangerous and should be immediately replaced After long periods of inactivity check air tightness of all parts subjected to pressure Personnel must use personal protection equipment clothing and tools adequate for the location and the use of the panel both during its operation and during maintenance operations The panel and any accessories mounted on it should be carefully checked immediately on receipt and in the event of any discrepancy or complaint the Dropsa SpA Sales department should be contacted without delay Dropsa SpA declines to accept any responsibility for injuries to persons or damage to property in the event of the non observance of the information presented in this manual Any modification to component parts of the system or the different destination of use of this system or its parts without prior written authorization from Dropsa SpA will absolve the latter from any responsibility for injury to persons and or damage to property and will release them from all obligations arising from the guarantee 2 IDENTIFICATION OF THE MACHINE A yellow pla
15. te of contacted parts Lubricants with silicon based additives Seizure of the pump Petrol solvents flammable liquids 9 INSTALLATION 9 1 UNPACKING Once a suitable location has been identified for the installation open the package and remove the equipment Check that the VIP4Tools has not sustained damage during transport and storage The packaging material does not require any special disposal precautions not being in any way dangerous or polluting 9 2 MOUNTING THE VIP4Tools PANEL Provide adequate space for the installation leaving a minimum room of 100 mm around the panel Mount the VIP4Tools panel at shoulder height to avoid unnatural posture or the possibility of sustaining impacts Do not install the VIP4Tools in particularly aggressive or explosive flammable environments or on components subject to vibration Only use the supplied mounting bracket with N 2 holes for 06 mm bolts 9 3 MOUNTING THE MINI PUMPS ON THE MIXER BASES for replacement or augmenting The mini pumps are mounted on the mixer bases utilizing two securing screws Particular attention should be paid to the correct positioning of the o rings between the mini pump and the mixer base see diagram below 9 4 MOUNTING OF THE MIXER ASSEMBLY ON THE VIP4TOOLS for replacement or augmenting To install a new unit proceed as follows 1 Empty the tank of oil 2 Disconnect the air supply and unscrew the connections on the base 3 Connect the n
16. te showing the product code and the basic characteristics is mounted on the front of the oil tank 3 GENERAL DESCRIPTION The VIP4Tools panel is to be utilized for on mandrel applications without controls on the machine for the lubrication of tooling and chains Designed for high performance at a low cost it is distinguished by its compactness The system comprises a pneumatically controlled mini pump and the mixer base The mini pump can be manually regulated to cover a wide range of needs 0 30 mm The modular design of the system makes it extremely versatile up to a maximum of 8 mixer bases can be installed The system can be timed by adding the pneumatic impulse generator kit P N 3132572 or by controlling it from the machine PLC 4 DESCRIPTION OF COMPONENTS Central VIP4Tools Unit The central unit of the lubrication system is composed of the following items a Tank made of transparent plastic material compatible with lubricants on the market a System for the regulation of the mixer air a modular Subframe a Samba type Minimum level indicator an adjustable Mini pump 1 Liter tank 3 Liter tank ES version complete with timer kit 5 TECHNICAL SPECIFICATIONS Permitted lubricants Mineral synthetic Oil viscosity at working 32 320 cSt temperature Conservation temperature 20 65 C Temperature 10 C 80 C Maximum switching power 50W 5V Maximum current 1A Maximum vo
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