DROPSA FACT Operating instructions

FACT
Controller
S/W Ver. 1.50
User and Maintenance Manual
Original text translation
Warranty Information
TABLE OF CONTENTS
1. INTRODUCTION
2. GENERAL DESCRIPTION
3. MACHINE IDENTIFICATION
4. TECHNICAL CHARACTERISTICS
5. EQUIPMENT
6. FLOWMASTER
7. UNPACKING AND INSTALLALLING THE EQUIPMENT
8. OPERATING INSTRUCTIONS
9. TROUBLESHOOTING
10. MAINTENANCE PROCEDURE
11. DISPOSAL
12. ORDERING INFORMATION
13. DIMENSIONS
14. HANDLING AND TRANSPORTATION
15. PRECAUTIONS
16. WARRANTY INFOMATION
17. DECLARATION OF COMPLIANCE
18. DISTRIBUTORS
The manual has been prepared in compliance with Directive
CE 06/42 C2209IE WK 30/16
http://www.dropsa.com
Via Benedetto Croce, 1
Vimodrone, MILANO (IT)
t. [phone]
Dropsa products can be purchased from Dropsa branches and authorized distributors, visit
www.dropsa.com/contact or contact us [e-mail]

2
Fig. 1
1. INTRODUCTION
This User and Maintenance Manual refers to FACT controller. You can find additional copies and newer revisions of this
document from our website http://www.dropsa.com.Alternatively contact one of our Sale Offices.
Please read this manual carefully, as it contains important information on health safety issues: a copy of this manual should
remain with the user of the product.
2. GENERAL DESCRIPTION
2.1 GENERAL CHARACTERISTICS
In medium/large lubrication systems it is often necessary to independently monitor and control the flow of each of the
lubrication points. FACT CONTROLLER has been designed to monitor and control (via motorized Flowmasters) lubricant flow.
This controller is particularly suitable for medium/large lubrication systems. Each FACT can monitor and control up to 16
Flowmasters. Its modular structure allows expansion of the lubrication system without having to change the controller.
2.2 ACCESSORIES
You can expand the number of flow monitored by the FACT by connecting to FACT EXPANDER that can manages an
additional 16 flow meters. Up to seven FACT REMOTE EXPADNER MODULES can be connected to a single FACT enabling the
control of up to 128 Flow switches.
With an interface board it is also possible to connect FACT with the previous generation of FACT REMOTE EXPANDER
MODULE.In this case maximum number of controllable flow switches is 128. The interface board can be housed inside the
FACT EXPANDER box.
New Fact
New Fact Expander

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2.3 CONNECTION EXAMPLE
Below is an example of connection explained before.
FACT \ FACT EXPANDER CONNECTION
2.4 BASIC APPLICATIONS
FACT is used to manage flowmaster flow measurment and regulation devices (see DROPSA "Flowmaster" product) used
primarily in oil recirculating systems. The FACT and Flowmaster products can be used in any applications that requires acurate
point-for-point montiroing and control of lubricant flow in oil-recirculation systems
3. MACHINE IDENTIFICATION
Product identification label is located on the side of the controller and contains product serial number, voltage and basic
technical characteristics.
4. TECHNICAL CHARACTERISTICS
PARAMETER
FACT
&
FACT EXPANDER
Power supply
Automatic range : 85÷260 VAC – 50/60 Hz
Power absorption
30 W
Input signals
Flow meters 24 V DC TIPO NPN/PNP
Output signals ⇒Remote alarm 250 V 1A (switch)
Max Distance between FACT and FACT-Expander and between FACT and
FACT-EXPANDER
100 m (328 ft)
Operating temperature
- 5°C ÷ + 55°C (-41°F ÷ +131°F)
Storage temperature
-20°C ÷ +65°C (-68°F ÷ +149°F)
Operating humidity
90% max
Mechanic protection grade
IP64
ATTENTION: All electrical equipment must be installed by adequately qualified personnel and in compliance
with above specifications and good electrical practice.
Serial line RS-485 –
maximum length
100 m (328 ft)
Insert end of line
terminator
You can connect up to 7 expansion
units each controller, to control up
to 128 flow masters.
NEW FACT
EXPANDER
NEW FACT
EXPANDER
NEW
FACT

4
Fig. 2
5. EQUIPMENT
FACT has a touch screen LCD display that allows users to interface and set the operations of controller. A tree structure Sub-
menu allows access to all the parameters. You will see the pages linked from the main display menu listed on in par.9.
The panel is installed in a sealed IP64 box seal. Inside the box the controller contains a control PCB where the terminal strip is
located to allow for all necessary connections (see par.8.3).
The cables come into the device through cable glands.
6. FLOWMASTER
FLOWMASTER is a volumetric flow meter that allows flow measurement of lubricant independently of temperature and
viscosity.
It's equipped by a common base manifold for all types of flowmaster modules. Different modules provide different flow
range.
The following table summarizes the flow rates measurable using three types of module available.
The metering module monitors flow with reliability thanks to a satellite, pushed by the lubricant and rotating with an orbital
movement and an inductive sensor which can be connected to FACT-2000. As satellite rotation speed increases or decreases
depending on flow, sensor sends a signal to the controller at each satellite revolution.
The measuring module is connected to the base by four screws, so that any kind of intervention can be carried out without
disassembling main or branch piping.
Key advantages of the system:
-System modularity ;
-Flow visual monitoring via transparent cover;
-Flow delivery always guaranteed (even if satellite stops, flow goes on);
-Accurate monitoring of the flow;
-Easy maintenance.
METERING MODULE SIZE CAPACITY
cm³/rev
cu.in./rev
lt/min.
gals/min.
5
0,30
0,20 ÷ 5
0,044 ÷ 1,1
10
0,61
0,50 ÷ 10
0,11 ÷ 2,2
20
1,22
1 ÷ 20
0,22 ÷ 4,4
FACT Cottroller

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More detailed information related to this product are described in the product manual that can be downloaded from our
website http://www.dropsa.com.
7. UNPACKING AND INSTALLALLING
7.1 UNPACKING
Once a suitable location has been found to install the unit remove the equipment from the packaging. No particular disposal
procedures are necessary; however packing should be disposed of in accordance with regulations that may be in force in your
area or state.
7.2 INSTALLING
Provide adequate space for the installation, leaving minimum 100 mm (3.93 in.) around the controller. Mount the controller
at comfortable height to avoid unnatural posture or the possibility of sustaining impacts. For the installation use the four
fixing holes (see dimensions in ch. 14). Do not install the controller in particularly aggressive or explosive/flammable
environments, if not preventively disposed by the manufacturer.
Fig. 3

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7.3 ELECTRIC CONNECTIONS
7.3.1 FACT CPU BOARD
Connect power supply to Terminal X1 (A ferrite must be tightened around the power supply cable).
Connect the flowmaster devices on terminals 1 to 16.
For remote alarm connections various voltage-free contact relays can be used.
Use the following connection for monitoring.
Remote Low Flow Alarm can be connected to Terminal Strip C.
Remote Alarm – user settable based on operating parameter Use Terminal Strip B.
ATTENTION: Before opening the equipment disconnects power and wait 5 minutes.
Fig. 4
Terminal supply X1
Touch screen
Power Supply
Dip-switches
Touch screen
connection
RS485 OUT
Flowmaster
terminal 1-8
Flowmaster
terminal 9-
16
Terminal Strip C
Terminal Strip B

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Fig. 5
Set the DIP switches as follows depending on if you are using NPN or PNP inputs:
•1-2-3 off / 4-5-6 ON to set input signals as ”N” signals (for NPN inputs)
•1-2-3-4-5-6 OFF to set input signals as ”P” signals (for PNP inputs)
•
7.3.2 SOFTWARE VERSION
The software version of FACT can be checked on “CHANGE PARAMETERS” menu and it is visible only after logging in with a user
with minimum level 4 access rights.
7.3.3 FACT EXPANDER
The EXPANDER is the same of FACT. Therefore the electrical connections are identical to FACT (section 7.3.1). There are only
two settings more to do: the setting of RS485 terminating tensile strength (through a termination jumper) and the position of
dip-switches.
To set terminating tensile strength you must put the jumper between pins 2-3. The jumper is placed between pins 1-2. If the
board in question is not the last of the line and you are linking a series of more fact expander.
The dip-switches is divided into 2 parts: from 1 to 3 sets the number of FACT EXPANDER, and from 4 to 6 sets if the
Flowmaster signal is "P" or "N".

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Fig. 6
To set the FACT-EXPANDER number, that must be included from 1 to 7 and in sequential order, use the following table.
N° FACT EXPANDER
DIP-SWITCH 1
DIP-SWITCH 2
DIP-SWITCH 3
1
ON
OFF
OFF
2
OFF
ON
OFF
3
ON
ON
OFF
4
OFF
OFF
ON
5
ON
OFF
ON
6
OFF
ON
ON
7
ON
ON
ON
To set the signals from Flowmaster you must set the 3 dip-switches from 4 to 6 ON to configure input signals as signals "P", or
set OFF to configure the input signals as signals "N".
8. OPERATING INSTRUCTIONS
Before operating the system:
⇒Verify the unit is intact.
⇒Check electrical connections have been correctly carried out.
When the system is started for the first time:
⇒Set the main operating parameters of FACT (see par. 8.6 CONFIGURATION and par. 8.7 SYSTEM CONFIGURATION).
The following paragraphs contain information on system configuration, flow settings, default parameters, monitoring and
controlling lubrication system. In case the system is modified (type/ number of flowmasters), all parameters must be set
again.
3
2
1
TERMINAL JUMPER
DIP-SWITCH

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8.1 MONITOR
When turned on, the display shows the Flowmaster status. On the screen displays the nominal value of flow rate setted and
value measured for each Flowmaster installed.
A light indicates that flow behaviour in relation to min and max thresholds, high and low settable (see par.8.3) precisely:
• Green = measured value between low value and high value
• Yellow = measured value between the minimum value and low value, or between high value and maximum
• Red = value lower than minimum value or value greater than maximum value,
• No colour = no pulses from Flowmaster
See chap. 8.2
Alarm present
Measured value
Light indicating the status of the flow
Nominal Value
See chap. 8.8

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8.2 MENU
From the main page by going to the menu screen appears as in the image below. From this dynamic page (the keys appear
depending on the type of access that has) can access the various configurations of the FACT. For the password contact
Dropsa offices.
Customizable text
See chap. 8.5
See chap. 8.4
See chap. 8.3
See chap. 8.1
See chap. 8.6