DROPSA VIP5 User manual

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
1. INTRODUCTION
2. PRODUCT FEATURES
3. DESCRIPTION OF OPERATING PROCEDURES
4. FIXING AND INSTALLATION DETAILS
5. INPUTS/OUTPUTS
6. OPERATOR INTERFACE FRONT PANEL
7. OPERATING MODE
8. 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
Manual compiled in accordance with Directive C2094IE –WK 20/11
06/42 CE
http://www.dropsa.com

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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.

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STEP 1 –Install and fix VIP5 Controller
The VIP5 Controller should be fixed using the 4 fixing holes.
For further information, refer to Section 4 of this manual.
STEP 2 –Connect power input and pump (or control solenoid) output to the VIP5 connector strip “M1”
Further details in section 5
STEP 3 –Connect the pump low level switch to pin 4 and 5 on connector strip “M2”
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
A
B
C
212 mm
(8.35 in.)
162 mm
(6.4 in.)
Ø 4,2 mm
(Ø 0.16 in.)
OUTPUT
COMMAND
POWER
INPUT

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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
“M2”

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STEP 6 –You can now power on the VIP5 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 LUBE Type
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 SEP Progressive controller.
To change the configuration press the MODE key for per 5 seconds,
and use the arrow UP and DOWN keys to select the type of system parameter.
Select LUBE TYPE accounting to the type of system you have:
SEP :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 -> 1 -> 0, or 1 -> 0 -> 1).
The pump is then switched off until the next lubrication cycle.
DUAL :select this option for more complex DUAL LINE SYSTEM . You should refer to the
advanced setting in section 8.
TIMER :select this option when you have NO CYCLE SENSOR. The VIP5 Controller will
activate the pup for the duration of the LUBE TIME . After this, the pump is switched off
until next lubrication cycle.
PS : 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.

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STEP 7A
If TIMER mode is selected –Set the lube cycle timer value
If TIMER 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 MODE key to SET cycle time
Select UP and DOWN arrows to set the value
Press OK key to save the value
Press UP arrow ( NEXT function) to move onto the next parameter.
STEP 8
Set the pause time value ( PAUSE timer)
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 ( NEXT ) to move onto the next parameter.

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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.
CONTINUOUS : The VIP5 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 CONTINUOUS pump type.
PULSED : If however you are using a pump that requires a pulsed output the you
must selected PULSED.
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.
STEP 10
Complete the Setup
At this point, the basic parameters have 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

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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 -> Control of a sensor device -> Delay time to allow sensor device to
stabilize -> Wait Time before another Cycle Start. 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.
The STANDBY PHASE defines the interval between each LUBRICATION PHASE.
Fig.1 A Lubrication Phase can comprise of many Lubrication Cycles
Cycle
Start
Control
Delay
Wait
Lubrication Phase
Lubrication Cycle
Lubrication Cycle can be repeated up to 250
times.

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2. PRODUCT FEATURES
VIP5 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.
•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).
•Minimum Level Input.
•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).
•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.
PRELUBE Phase -> Pre Lubrication that occurs during power up of a system.
LUBRICATION Phase (Lube –> Wait stages) -> This is when lubricant is provided (as above)
STANDBY Phase -> The system is inactive awaiting for the next LUBRICATION PHASE
Continuous operation is identical but does not have a STANDBY Phase.
Additionally, the VIP5 Control system can also be used as a simple monitoring device in the “FLOW” operating Mode
described later in this manual.

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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 “0” 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.
-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.