DROPSA Vip4chain Operating instructions

Vip4chain
Chain Lubrication & Dispensing
User and Maintenance Manual
Warranty Information
C2047IE - WK 43/02
Manual drawn in accordance with CE
Directive 06/42
CONTENTS
1. INTRODUCTION
2. GENERAL DESCRIPTION
3. MACHINE IDENTIFICATION
4. TECHNICAL CHARACTERISTICS
5. COMPONENTS
6. UNPACKING AND INSTALLING Vip4chain
7. OPERATION
8. TROUBLESHOOTING
9. MAINTENANCE PROCEDURE
10. DISPOSAL
11. ORDERING INFORMATION
12. DIMENSIONS
13. HANDLING AND TRANSPORTATION
14. OPERATING HAZARDS
15. PRECAUTIONS
16. WARRANTY
17. DECLARATION OF COMPLIANCE
18. DISTRIBUTORS
http://www.dropsa.com

2
1. INTRODUCTION
This manual refers to the Vip4chain Lubrication device. You can find additional copies and newer revisions of this
document from out website http://www.dropsa.com. Alternatively contact one of our sales offices.
Please read this manual carefully, as it contains important information on health and safety issues. A copy of this
manual should remain with the user of the product.
2. GENERAL DESCRIPTION
The Vip4chain has been designed to be used for Air/Oil Chain Lubrication, Spray or dispensing applications.
The unit consists of a base module which houses the electronic control and monitoring system. The unit can then be
configured to have one or more (max. 6) dispensing modules which consist of a adjustable micropump (0-30 mm.³)
fitted onto a modular mixing base element. This element both monitors the correct oil injection and mixing the oil into
an air jet that fires it onto the lubrication point.
The system is completly modular and very compact therefore can be quickly and easily installed by following the
instructions in this manual.
3. PRODUCT –MACHINE IDENTIFICATION
The product identification label is located on the front side of the reservoir and contains details of the operating
parameters of the unit including input voltage and required air supply.
4. TECHNICAL CHARACTERISTICS
Vip4chain
Operating Voltage
24 Vdc
110 Vac
Power Consumption
10 W
Air Input Pressure
5 ÷ 8 bar
Remote Alarm Signal
RELAY signal: max 250 V 1 A N.O./N.C.
Operating Temperature
-5 ÷ +55 °C
Max. Working Humidity
90% max
IP Protection Grade
IP-44
Compatible Lubricants
Mineral Oils
Oil Viscosity
32 ÷ 220 cSt
Storage Temperature
-20 ÷ +65 °C
WARNING: do not operate the units outside the parameters indicated.

3
5. COMPONENTS
Main Unit Vip4chain
Vip4chain Electronic Controller : Controls and monitors all the components on the unit, including chain
impulses, air pressure, oil flow, pump activations and oil level.
Pneumatics Circuit: A pressure regulator and filter allows the user to fine tune the air jet to the lubrication
point. An integrated air pressure transducer can monitors min/max air pressures.
A solenoid valve is used to activate the micropumps at the desired intervals.
Oil Reservoir: A Clear 1 litre reservoir.
Pneumatic micropumps.
The micropumps are installed on the air/oil mixing bases. They are adjustable from 0 to 30 mm³ per cycle. To
increase the flow turn the pump adjusting dial clockwise, to decrease counterclockwise.
Modular mixing sub-base with flow sensing.
The modular base has two functions.
Firstly, it monitors that the pumps have correctly injected oil into the unit via a displacement sensor and
secondly, it injects the oil into an air stream to be carried to the lubrication point.
No settings are required as the unit automatically configures itself. A green LED will indicate the correct
operation of the pump module fitted on top of the base unit.
The signals are then sent back to the Main Vip4chain Controller to determine that all the units are
functioning correctly.
When a lubrication cycle is in progress, the LED on the sub base indicates the flow of oil from the micropumps. During
the standby interval the LED will remain off
Item
PART
NUMBER
DESCRIPTION
1
3044335
Reservoir
2
3130139
Filling Cap & Filter
3
3155148
Solenoid 24V DC
4
3155149
Solenoid 110V AC
5
1524408
Modular Mixing Sub-Base
6
3103116
Adjustable pneumatic Micropump
7
1639118
Wiring Box , 24V Version
8
1639119
Wiring Box, 110V Version
1
2
3 o 4
5
6
7 o 8

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6. UNPACKING AND INSTALLING Vip4chain
6.1 UNPACKING
Once a suitable location has been found to install the unit remove the unit 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.
6.2 INSTALLING THE UNIT
Allow sufficient space around the unit for ease of maintenance. Install at a suitable level for refilling the oil reservoir.
Do not install in aggressive environments. Fix the unit using the two fixing holes and 6mm screws.
6.3 ELECTRICAL WIRING
Before carrying out any wiring, ensure that the correct power supply is available. Refer to the identification label on
the unit and this instruction manual.
6.4 INSTALLING THE MICROPUMPS ONTO THE BASE MODULE
Normally, you will order a unit already pre-configured with the correct number of micropump and base modules. In
the event these need to be altered or changed, the pumps can be removed by taking out the 2 fixing screws as shown
on the diagram bellow. Ensure to place the three O-Rings correctly when installing a new pump module.
6.5 ADDITING OR REMOVING A SUBBASE.
The bases must always be added or removed from the bottom one first. To add or remove a sub-base from the
Vip4chain unit
1. Disconnect power and air suppl and empty the tank (by removing the unit and pouring out the oil into a
container)
2. Disconnect the solenoid valve on the base of the unit using the three fixing screws.
3. Remove the End-plate by undoing the two fixing screws
4. Add a new sub-base (or remove the existing one) as shown in the diagram below. Ensure the Electrical
connector and O-rings are all in place before closing the sub base against either another sub-base or the end-
plate
5. Add the end-plate and the solenoid valve.
Threaded Insert
O-Seals
Mixing Sub-Base
Fixing Screws
Electrical
Connector
Push-in
Plate
Bleed screw
Bleed screw


Fixing screws
Micropump
O-Rings
Mixing Sub
Base

5
6.5 HYDRAULIC CONENCTIONS
It is suggested to use Ø4 mm tube on the air/oil outlets located on the left hand side of the unit.
6.6 PNEUMATIC CONENCTIONS
Connect the Air inlet to the solenoid inlet on the base of the unit using Ø6 mm nylon tube.
6.7 ELECTRICAL CONNECTIONS
Before carrying out any type of electrical wiring –ensure that all power is removed from the machine.
Ensure also that the voltage you are using matches that which is indicated on the unit. A label next to the connector
also indicates the correct operating voltage of the model you have purchased.
NB:The female connector is purchased separately.
Follow the diagram below to complete the electrical connection.
LEFT HAND SIDE CONNECTOR : Used for input power and remote alarm signal.
BOTTOM CONNECTOR –Located on the rear power box, located on the bottom face . This is used to connect a
remote switch or proximity switch to count impulses from the Chain and time the lubrication cycle.
NB: After all connections have been completed ensure the tubing and cables are protected from impacts and are
suitably secured.
Pin n°
Vers. 24V
Vers. 110V
1
0 V
2
24 Vdc
/
3
/
110 Vac
4
ALARM NC Contact
5
ALARM –Common Signal
6
ALARM –NO Contact
Earth
Pin n°
Signal
1
0 V
2
+ 12 V dc
3
SIGNAL IN.o
4
Not used
5
Not used
6
Not used
Earth
1639115 –Optional connector and 2m cable assembly
3194002 –Connector for signal
Female
Female
Male
Male
1639121
L=2m

6
7 OPERATION
7.1 COMMISIONING THE Vip4chain
Before using the Vip4chain, the following check list must be observed:
The Unit has not sustained any damage
Electrical and Pneumatic connections are correct
Purge Air from the micropumps by loosening the bleed screw on the micropumps using a 2mm allen key.
Once oil is present, tighten the screw
Power on the unit
Set the operating parameters as described in this manual.
To help purge the air from the unit, set the pumps to maximum output by screwing the regulating dial
clockwise.
7.2 ZERO-OUTPUT:
If you want to temporarily set zero output on a pump module, you can turn the regulating dial anti clockwise until it
stops. Note that if you have sensing enable on the mixing base, you will obtain a pump fault alarm
7.3 SETTING THE OIL OUTPUT ON THE MICROPUMPS
Pump output is set using the red regulating dial.
Turn the dial anti clockwise until it stops. This equals 0 mm3(pump on zero-output as above). Turn the regulating dial
2.5 turns to achieve 10mm3(the output sensor will read this output). Each complete turn will now increase the pump
output by 5mm3, to a maximum of 30mm3. (See following table)
OUTPUT (mm³ / colpo)
TURNS
30
6.5
25
5.5
20
4.5
15
3.5
10
2.5
5
1.5
0= Zero Output
Maximum anti-clockwise
7.4 PROGRAMMING THE CONTROLLER
The controller can operate in two modes :
CHAIN MODE:In this mode, the unit will cycle each time an impulse is received from the remote switch. You can
program the number of cycles in order to lubricate a chain, and then the unit will go into standby mode. You can set
how many impulses from the remote switch have to be detected before returning to cycle mode.
DISPENSE MODE: In this mode, when the unit cycles, it will activate the pumps for a set number of times with an
interval between each activation. Following the dispensing cycle the unit goes into standby mode. As with Chain
mode, it will count a number of impulses from a remote switch (which can even be a single impulse) before it
activates the dispensing cycle again.
The user can set the on time and off time of the pump activation.
Air Pressure regulation.
To set the air mixing pressure hold the down key . The air solenoid will open and the air pressure will be displayed
on the front panel display. Use the regulator to set the desired air pressure.
Normal Operation
When the unit is powered on, it will automatically start in a standby cycle. During the standby cycle the front panel
display will indicate how many more impulses the unit is expecting before commencing a lubrication or dispensing
cycle.
By Pressing the UP Key , you can skip the standby cycle and activate the lubrication cycle immediately.
Alarm
In the event of an failure or alarm, the unit will display an alarm code. This can be cleared by pressing
the button. See the Troubleshooting section of this manual.


Reset

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7.5 SET-UP AND CONFIGURATION OF THE ELECTRONIC CONTROL
SELECT THE OPERATING MODE :
Press and hold the key for at least 2 seconds. The unit will go into its set-up mode.
Select the Operation mode DISEPNSE (‘dISP’) or CHAIN (‘ChA’) by using the UP/DOWN keys and then press to
continue.
According to which is selected the menu will vary. Follow the step-by-step parameter guide below to setup the
unit accordingly. Use to step to the next parameter and UP/DOWN keys to vary the setting on the current
parameter:
CHAIN MODE PARAMETERS
Parameter
Display
Description
Operation
Default
Number of
Lubrication Cycles

Number of times the pumps are activated
during the lubrication cycle. From 0001 a 9999.
Set the value using
the and keys
10
Standby Interval

Determines the length of the Standby intervals
by counting impulses from remote switch.
Set the value using
the and keys
100
Standby
Multiplication
Factor


Multiplies the previous value by 1, 10 , 100 or
1000 to obtain upto 9,999,000 standby
impulses
Set the value using
the and keys
1
Number of Micro-
Pumps
Number of Micropumps installed on the system
with Flow Sensing. Setting this to 0 will disable
flow sensing on all micropumps. If you set less
than the number of micropumps installed than
the nearest ones will be monitored, while the
furthest will remain unmonitored. EG. Setting 5
of a 6 pump system will result in the last pump
not being monitored..
Set the value using
the and keys
Min. 0
Max. 6
Micropump
Activen and Air
On-Time
During the lubrication cycle, the system will
trigger a lubrication shot with each impulse.
This setting determines the length of the
lubrication Shot and how long the air will
remain on for.
Ensure that the duration does not exceed the
time between impulses from the remote switch
for proper operation. 0 a 9,9 sec.
Setting this parameter to 0 will cause the Air
Shot to remain active for the duration of the
impulse from the remote switch
Set the value using
the and keys
1
Min air pressure
Minimum Air Pressure monitoring during cycle.
Setting 0.0 disables minimum air pressure
monitoring. Range 0.0-7.0 bar.
Set the value using
the and keys
0,0
Max air pressure
Maximum Air Pressure parameter during cycle.
Setting 0.0 disables monitoring.Range 0.0-7.0
bar
Set the value using
the and keys
2,5
MODE














MODE
MODE
MODE

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DISPENSE MODE PARAMETERS
Parameter
Display
Description
Operation
Default
Number of Pump
Cycles

Number of pump cycles performed
when lubricating/dispensing. From 1 to
9999
Set the value using the
and keys
1
Pump On
The amount of time the pump remains
ON when dispensing.
Range: 0.1s to 9.9s
Set the value using the
and keys
1
Pump Off
The amount of time the pump remains
OFF when dispensing
Range : 0.3 to 9.9 s.
Set the value using the
and keys
1
Number of Micro-
Pumps
Number of Micropumps installed on
the system with Flow Sensing. Setting
this to 0 will disable flow sensing on all
micropumps. If you set less than the
number of micropumps installed than
the nearest ones will be monitored,
while the furthest will remain
unmonitored. EG. Setting 5 of a 6
pump system will result in the last
pump not being monitored..
Set the value using the
and keys
Min. 0
Max. 6
Min air pressure
Minimum Air Pressure monitoring
during cycle. Setting 0.0 disables
minimum air pressure monitoring.
Range 0.0-7.0 bar.
Set the value using the
and keys
0.0
Max Air Pressure
Maximum Air Pressure parameter
during cycle. Setting 0.0 disables
monitoring.Range 0.0-7.0 bar
Set the value using the
and keys
2.5
Standby Impulses


Number of impulses required to
initiate the Lubrication/Dispensing
Cycle.
Settable from 0001 to 9999.
Set the value using the
and keys
3















9
8. TROUBLESHOOTING
The following table highlights some of the most common problems encountered when using the Vip4chain and how to
resolve them.
In the event of doubts or the problem is not listed, do not dismantle the unit but contact a DropsA technical centre for
assistance.
TROUBLESHOOTING TABLE - Vip4chain
FAULT/ALARM
A-PF
Pump Fault
A-AH
Air High
A-AL
Air Low
A-LL
Oil Low
PROBABLE CAUSE
The Flow sensor has not detected
flow to the mixing sub-base. Air
could be trapped in the system.
OR No Oil in system
Air Setting is incorrect or the
delivery tube has become clogged.
Air Setting is incorrect or the
delivery tube has become detached
causing a fall in air pressure
Low oil level in tank or Air Lock.
SOLUTION
Purge Air from the system as described in the
commissioning part of this manual. After cycling the unit,
check to see oil is being dispensed visually.
Check the Oil Level
Hold the DOWN key to see the current air pressure and
ensure that it is lower than the Air High setting in the set
up menu.
Check that the tubes have not become clogged resulting in
an Air High Alarm.
Hold the DOWN key to see the current air pressure and
ensure that it is higher than the Air Low setting in the set
up menu.
Check that the tubes have not become detached resulting
in an pressure loss.
Add Oil to tank. If the alarm does not clear, try purging air
from the hydraulic circuit as described in the comissioning
portion of this manual.
9. MAINTENANCE PROCEDURE
The Vip4chain requires only minimal maintenance. Periodically check that the unit is intact and does not present
leaks.
As required, or at least once a year, clean or substitute the refilling filter (3130139)
The unit does not require any special tooling to operate or maintain it. It is recommended that suitable protective
clothing (including gloves and safety glasses) are worn when maintaining the unit in order to avoid hazards to
equipment or persons.
Be sure that all electrical and pressurized hydraulic components are disconnected prior to any maintenance.

10
10. DISPOSAL
During maintenance or disposal of the machine care should be taken to properly dispose of environmentally sensitive
items such as oils or other lubricants. Refer to local regulations in force in your area.
When disposing of this unit, it is important to ensure that the identification label is also destroyed.
11. ORDERING INFORMATION
VERSIONS
N° Pump units
Vip4chain 24 V DC
Vip4chain 110 V AC
1
3135121
3135131
2
3135122
3135132
3
3135123
3135133
4
3135124
3135134
5
3135125
3135135
6
3135126
3135136
12. DIMENSIONS
Allow 100 mm on each side for easy maintenance.
13. HANDLING AND TRANSPORTATION
Vip4chain Units are packed and dispatched in cardboard containers. During transportation and storage always
maintain the unit the right way up as indicated on the box.
On receipt check that the packaging has not been damaged and store the pump in a dry place.
Pump Elements
A (mm)
Weight (Kg.)
1
331
3,8
2
359
4,3
3
387
4,8
4
415
5,3
5
448
5,8
6
471
6,3

11
14. OPERATING HAZARDS
It is necessary to read and understand the possible hazards and risks involved when using a lubrication pump. The
operator must fully understand the hazards explained in this manual.
Electrical Power
No maintenance must be performed on the unit without having detached and isolated the power supply and ensuring
that it cannot be reconnected for the duration of the maintenance task. Always remember to ensure that equipment
is properly earthed.
Flammable substances.
Mineral oils generally used in lubrication systems are not normally flammable. However, it is desirable to avoid
contact with extremely hot substances or naked flames. Ensure that the machine that the lubrication system is
installed onto contains the necessary fire extinguishing devices.
Pneumatic & Hydraulic Pressure
Before any maintenance or connection task, ensure that all pressure has been properly bled from the system. Residual
pneumatic or hydraulic pressure can cause the release of undesired spurts of liquid, which may hit the operator.
Always wear safety glasses and glove when working with pneumatic and hydraulic systems.
Noise and Vibration
The Pump does not produce excessive vibration or noise (less than 70 dB(Non si deve effettuare alcun intervento sulla
macchina prima di aver scollegato la stessa dall’alimentazione elettrica ed accertato che nessuno possa ricollegarla
durante l’intervento.
15. PRECAUTIONS
Contact with Oil. The operator should wear protective clothing to avoid contact with the lubricant.
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 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 pressure values permitted for the panel and the components connected to
it.
Before any maintenance, cleaning or other 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
Incompatible fluids may cause danger
Examples of incompatible/non-permissible Fluids.
Fluid
Danger
Lubricants containing abrasive components.
Premature wear of pump
Lubricants containing silicon.
Pump failure
Petrol, Solvents, flammable liquids
Fire, explosion, seal damage.
Corrosive products
Pump damage, danger to persons.
Water
Pump oxidization
Food Products
Contamination of product

12
16. 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 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 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 & 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.

13
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: CHAIN LUBRICATION & DISPENSING Vip4chain
oHas been manufacturer in conformance with the European Community Directive relating to the harmonised
standards of the member states relating to machine safety, EMC (89/336/CEE) and BT (73/23/CEE) and
subsequent revisions of the aforementioned standards
TECHNICAL DIRECTOR Walter Divisi
Name
DROPSA SpA - Vimodrone (Mi) - Italy
Company
Signature Date
April 2002

14
18. DROPSA LOCATIONS
Web site: http://www.dropsa.com - E-mail: [e-mail]
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: [email protected] (Export)
E-mail: [email protected] (National)
Dropsa Ame
23, Av.des.Morillons
Z.I. des Doucettes 91140
Garges Les Gonesse, France
Tel: [phone]
Fax: [phone]
E-mail: [email protected]
Dropsa (UK) Ltd
Unit 6, Egham Business Village,
Egham,Surrey,TW20 8RB
Tel: [phone] - 431177
Fax: [phone] - 438598
E-mail: [email protected]
Dropsa do Brazil Ind. E Com. Ltda
Rua Sobralia 175,
Sao Paulo, Brazil
Tel: [phone]
Fax: [phone]
E-mail: [email protected]
Dropsa USA Inc.
6645 Burroughs Ave
48314-2132 Srerling Hts,Mi Us -USA
Tel: [phone]
Fax: [phone]
E-mail: [email protected]om
Dropsa Lubrication Systems
Nr 8 Dongxing Road,
Songjiang Industrial Zone
(Shanghai) Co., Ltd
Tel: [phone]
Fax: [phone]
E-mail: [email protected]
Dropsa Gmbh
Volmerswerther Strasse 80
40221 Dusseldorf 1, Deutschland
Tel: [phone]
Fax:[phone]
E-mail: [email protected]
Dropsa Australia Pty.
C20/148 Old Pittwater Road
Brookvale, NSW 2100
Tel: [phone]
Fax: [phone]
E-mail: [email protected]