RelaDyne LubriMist IVT User manual

LubriMist®Model IVT
Oil Mist Generating System
Installation and Operating Manual
(Series 201A)
REVISION 18
OCT 2020
P/N 77740224

LubriMist®Model IVT
Oil Mist Generating System
Installation and Operating Manual
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of 256
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LubriMist®Model IVT
Oil Mist Generating System
Installation and Operating Manual
Page 3
of 256
TABLE OF CONTENTS
INTRODUCTION............................................................................................................................. 8
Manufacturer Contact Information................................................................................................ 9
Explanation Of Graphic Symbols In The Documentation........................................................... 10
UNIT IDENTIFICATION AND LABELING ..................................................................................... 13
LubriMist® Model IVT Model Code Designations....................................................................... 14
Model Code Designation Key.................................................................................................. 15
Tag Detail for NEC Model IVT.................................................................................................... 16
NEC Certificate Of Conformance ............................................................................................... 17
Tag Detail for ATEX Model IVT .................................................................................................. 18
EU Certificate of Conformity....................................................................................................... 19
Operating Conditions – ATEX Constructions ............................................................................. 20
PRODUCT DESCRIPTION ........................................................................................................... 21
Operator Panel ........................................................................................................................... 23
Inlet Air Supply.......................................................................................................................... 24
Inlet Air Supply............................................................................................................................ 25
Mist Outlet Valve Assembly........................................................................................................ 26
Mist Generator Head With Air / Oil Heater ................................................................................. 26
Air Heater Control and Cutout Sensors...................................................................................... 27
Oil Supply Transfer Pump and Control....................................................................................... 28
Main Oil Mist Generator Controller............................................................................................. 29
Inlet Supply Air Pressure Transducer...................................................................................... 30
Ambient Air Temperature Sensor............................................................................................ 30
Regulated Air Pressure Transducer ........................................................................................ 31
Bulk Oil Reservoir Level Transmitter....................................................................................... 32
Mist Pressure Transducer........................................................................................................ 32
Bulk Oil Reservoir Oil Temperature Sensor ............................................................................ 32
Mist Density Sensor................................................................................................................. 33
Oil Supply Pressure Transducer.............................................................................................. 34
Auxiliary Oil Mist Generator........................................................................................................ 35
Optional Equipment.................................................................................................................... 36
Oil Mist Reclamation................................................................................................................ 37
Warm Ambient Option (Cabinet cooling) for NEC constructions............................................. 38
Warm Ambient Option (Cabinet cooling) for ATEX constructions........................................... 39
Air Purge.................................................................................................................................. 40
Cold Ambient Option (Air Preheating and Cabinet Heating) for NEC constructions............... 41
Cold Ambient Option (Air Preheating and Cabinet Heating) for ATEX constructions ............. 43
Auto Bulk Oil Fill....................................................................................................................... 46
INSTALLATION............................................................................................................................. 47
Location / Mounting .................................................................................................................... 48
Mist Distribution System Connection.......................................................................................... 49
Compressed Air Supply.............................................................................................................. 49
Electrical Power Connection....................................................................................................... 51
Power Connections for NEC Cabinet Heater Option............................................................... 53
Grounding................................................................................................................................... 54
Remote Communication And Alarm Connections...................................................................... 55
Remote Alarm Contacts........................................................................................................... 56
Remote Communication Serial Port ........................................................................................ 58
Oil Reclamation Unit................................................................................................................... 60
COMMISSIONING......................................................................................................................... 64
Bulk Oil Supply ........................................................................................................................... 65
Starting The Model IVT Oil Mist Generator ................................................................................ 67
Mist Density Sensor.................................................................................................................... 70
Operation ................................................................................................................................. 70
Location Of The Mist Density Sensor...................................................................................... 70
Sensitivity Adjustments............................................................................................................ 70

LubriMist®Model IVT
Oil Mist Generating System
Installation and Operating Manual
Page 4
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Commissioning Optional Equipment .......................................................................................... 72
Oil Reclamation Unit................................................................................................................ 72
Cabinet Cooling ....................................................................................................................... 75
Air Purge.................................................................................................................................. 78
Air Pre-heater........................................................................................................................... 79
Cabinet Heating System.......................................................................................................... 79
Auto Bulk Oil Fill....................................................................................................................... 80
OPERATING GUIDE..................................................................................................................... 81
Operating The Control Panel...................................................................................................... 82
General Control Operation....................................................................................................... 82
Keypad Buttons........................................................................................................................ 82
Setting The Current Date............................................................................................................ 84
Setting The Current Time ........................................................................................................... 85
Reading Unit Operating Conditions............................................................................................ 86
Reading Alarm And Control Set Points ...................................................................................... 87
Programming User Established Alarm And Control Set Points.................................................. 88
Special Key Pad Sequence Routines......................................................................................... 93
Setting Language........................................................................................................................ 93
MODBUS Diagnostic Sub-function Data.................................................................................... 94
Setting Display Contrast............................................................................................................. 95
Communication And Option Feature Set-Up.............................................................................. 96
LOCAL ALARMS, INDICATORS AND READOUT ..................................................................... 100
LED Panel Indicator Lights....................................................................................................... 102
Liquid Crystal Display............................................................................................................... 102
Red And Green External Status Lights..................................................................................... 102
Event Log.................................................................................................................................. 103
Logged Alarm and Fault Messages....................................................................................... 105
Logged Event Messages....................................................................................................... 106
REMOTE COMMUNICATION AND ALARM............................................................................... 107
Remote Alarm Contact ............................................................................................................. 108
Serial Data Port – RS-422/485................................................................................................. 109
Connecting To A Personal Computer (PC) .............................................................................. 110
Data and Event Log.................................................................................................................. 112
Personal Computer Communication Software ......................................................................... 112
MODBUS COMMUNICATION..................................................................................................... 117
Overview................................................................................................................................... 118
Installation................................................................................................................................. 118
Serial Data Port – RS-422........................................................................................................ 118
Connecting To The Host Computer (via 4 wire)....................................................................... 119
Connecting To The Host Computer (via 2 wire)....................................................................... 119
Configuring The IVT Oil Mist Generator ................................................................................... 120
Configuring The Host Computer............................................................................................... 120
Modscan Configuration....................................................................................................... 121
Function Codes......................................................................................................................... 122
Breakdown of each Function Code and it’s HEX Addresses ................................................... 124
Holding Register ....................................................................................................................... 128
Holding Registers Addresses; .................................................................................................. 129
Input Register ........................................................................................................................... 130
Viewing the IVT’s values in real time........................................................................................ 132
General Information.................................................................................................................. 133
BULK OIL SUPPLY RESERVOIR............................................................................................... 135
General Description and Use: .................................................................................................. 136
Commission The Auxiliary Oil Mist Generator.......................................................................... 136
Adding Oil To The Bulk Oil Reservoir....................................................................................... 137
Commission The Main Oil Mist Generator................................................................................ 137

LubriMist®Model IVT
Oil Mist Generating System
Installation and Operating Manual
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AUXILIARY OIL MIST GENERATOR.......................................................................................... 138
General Description and Use: .................................................................................................. 139
Auxiliary Oil Mist Generator Start-Up ....................................................................................... 140
Operation.................................................................................................................................. 142
Air / Oil Heater Operation And Temperature Adjustment......................................................... 143
Controller Operation............................................................................................................... 143
Programming And Changing Set-points................................................................................ 143
Switching From The Auxiliary Oil Mist Generator To The Main Oil Mist Generator................. 145
Mist Outlet Switching Valve...................................................................................................... 145
CONTROLLING THE MIST......................................................................................................... 149
Adjusting Air / Oil Ratio............................................................................................................. 150
Changing The Mist Generating Capacity.................................................................................. 153
ROUTINE MAINTENANCE ......................................................................................................... 154
ROUTINE CHECKS AND MAINTENANCE.............................................................................. 155
CLEANING AND DECONTAMINATION .................................................................................. 157
REMOVAL FROM USE, DISPOSAL AND TRANSPORT........................................................ 159
TROUBLE SHOOTING GUIDE................................................................................................... 161
Main Unit................................................................................................................................... 163
Auxiliary Unit............................................................................................................................. 172
Optional Equipment.................................................................................................................. 173
PARTS LIST / DRAWINGS / SCHEMATICS .............................................................................. 176
Spare Parts Lists ...................................................................................................................... 177
Process & Instrument Diagrams............................................................................................... 179
IVT Oil Mist Generator........................................................................................................... 179
Optional Equipment ............................................................................................................... 180
Electrical Wiring Diagrams And Schematics / IVT – NEC Construction................................... 181
Ladder Diagram / 115 VAC Supply Voltage / IVT – NEC Construction................................ 181
Voltage Panel Wiring Diagram / 115 VAC Supply Voltage / IVT – NEC Construction......... 182
Ladder Diagram / 230 VAC Supply Voltage / IVT – NEC Construction................................ 183
Voltage Panel Wiring Diagram / 230 VAC Supply Voltage / IVT – NEC Construction......... 184
Electrical Wiring Diagrams And Schematics / IVT –ATEX Construction.................................. 185
Ladder Diagram / 115 VAC Supply Voltage / IVT – ATEX Construction.............................. 185
Voltage Panel Wiring Diagram -115 VAC Supply Voltage / IVT – ATEX Construction......... 186
Ladder Diagram / 230 VAC Supply Voltage / IVT – ATEX Construction.............................. 187
Voltage Panel Wiring Diagram -230 VAC Supply Voltage / IVT – ATEX Construction........ 188
Electrical Wiring Schematic / Cold Ambient Option – Cabinet Heating – 115 or 230 VAC -
NEC Construction Only.......................................................................................................... 189
Electrical Wiring Diagram / Cold Ambient Option – Cabinet Heating – 115 or 230 VAC -NEC
Construction Only .................................................................................................................. 190
Voltage Panel Wiring Diagram / Warm Ambient Option – Cabinet Cooling – 115 or 230 VAC -
ATEX Construction Only........................................................................................................ 191
Voltage Panel Wiring Diagram / Cold Ambient Option - Cabinet heating –230 VAC - ATEX
Construction Only .................................................................................................................. 192
Auxiliary Oil Mist Generator Controller Wiring Connection Detail ............................................ 193
Component Power Requirements ............................................................................................ 194
Fuse Ratings and Characteristics............................................................................................. 195
Fuse Location - Main Oil Mist Generator............................................................................... 195
Fuse Legend-115 VAC Main Oil Mist Generator................................................................... 197
Fuse Legend-230 VAC Main Oil Mist Generator................................................................... 199
Fuse Location - Auxiliary Oil Mist Generator......................................................................... 200
Fuse Legend-115 VAC Auxiliary Oil Mist Generator............................................................. 201
Fuse Legend-230 VAC Auxiliary Oil Mist Generator............................................................. 202
Tagging and Labeling............................................................................................................... 203
IVT Front Cabinet Door.......................................................................................................... 204
IVT Operator Access Compartment....................................................................................... 205
IVT Main Oil Mist Generator .................................................................................................. 206

LubriMist®Model IVT
Oil Mist Generating System
Installation and Operating Manual
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IVT Auxiliary Oil Mist Generator ............................................................................................ 207
IVT Cabinet Rear................................................................................................................... 208
ATEX Cabinet Cooling Option ............................................................................................... 209
ATEX Cold Weather Option................................................................................................... 210
Tag Details............................................................................................................................. 211
77500601 Warning Label.................................................................................................... 211
77500603 Remote Alarm Contact Rating Label................................................................. 211
77780286 Fuse Legend – 115 VAC (Aux Unit) .................................................................. 212
77780287 Fuse Legend – 230 VAC (Aux Unit) .................................................................. 212
77780288 Fuse Legend – 115 VAC (Main Unit)................................................................. 213
77780289 Fuse Legend – 230 VAC (Main Unit)................................................................. 213
77780290 NEC NAMEPLATE............................................................................................. 214
77780291 ATEX Nameplate............................................................................................... 214
77780293 Warning Label.................................................................................................... 215
77780294 Fuse Warning Label........................................................................................... 215
77780388 Air Supply Label................................................................................................. 215
77780432 Overfill Warning Label ....................................................................................... 216
77780436 LSO Test Label.................................................................................................. 216
77780437 Aux Unit Start-Up Instruction Sheet................................................................... 217
77780434 Instruction Sheet - Accessing The Alarm / Event Log....................................... 218
77780474 ATEX Cabinet Heating Label............................................................................. 219
77780475 ATEX Cabinet Cooling Option Label ................................................................. 219
77780476 Static Discharge Warning Label ........................................................................ 220
77780477 Warning Label.................................................................................................... 220
77780536 Heat / Hot Surface Warning Label..................................................................... 220
Sensitive Electronic Devices Caution Label ....................................................................... 220
IVT Low Voltage Controller Layout........................................................................................... 221
Component Identification....................................................................................................... 222
Thermocouple Input / Output Terminal Strip (TB1 & TB2) .................................................... 223
4-20 mA Input / Output Terminal Strip (TB3 & TB4............................................................... 224
Digital Inputs / Outputs Terminal Strip (TB5 & TB6).............................................................. 225
IVT Controller Power Input Terminal ..................................................................................... 227
RS-422/485 Data Communication Terminal Strip ................................................................. 228
Bill Of Materials – IVT / NEC Construction............................................................................... 229
General Arrangement Drawings – IVT / NEC Construction ..................................................... 230
Operator Panel....................................................................................................................... 230
Main Oil Mist Generator Access, (left door)........................................................................... 231
Auxiliary Oil Mist Generator Access, (right door)................................................................... 232
Top View................................................................................................................................ 233
Electrical Power Switches...................................................................................................... 234
Oil Transfer Pump / Oil Mist Discharge ................................................................................. 235
Air Supply Components......................................................................................................... 236
Electrical Control Components.............................................................................................. 237
Bill Of Materials – IVT / ATEX Construction............................................................................. 238
General Arrangement Drawings – IVT / ATEX Construction.................................................... 239
Operator Panel....................................................................................................................... 239
Auxiliary Oil Mist Generator Access, (right door)................................................................... 241
Top View................................................................................................................................ 242
Electrical Power Switches...................................................................................................... 243
Oil Transfer Pump / Oil Mist Discharge ................................................................................. 244
Air Supply Components......................................................................................................... 245
Electrical Control Components .............................................................................................. 246
Optional Equipment.................................................................................................................. 247
Cold Ambient Option - Air Preheating - NEC and ATEX Constructions................................ 247
Cold Ambient Option - Cabinet heating – ATEX only............................................................ 250
Air Purge Option .................................................................................................................... 251

LubriMist®Model IVT
Oil Mist Generating System
Installation and Operating Manual
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Warm Ambient Option – Cabinet Cooling – NEC Construction............................................. 252
Warm Ambient Option – Cabinet Cooling – ATEX Construction........................................... 253
Optional Demisting Unit......................................................................................................... 254
Optional Auto Bulk Oil Fill...................................................................................................... 255

LubriMist®Model IVT
Oil Mist Generating System
Installation and Operating Manual
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INTRODUCTION

LubriMist®Model IVT
Oil Mist Generating System
Installation and Operating Manual
Page 9
of 256
Manufacturer Contact Information
A LubriMist® Oil Mist System is a centralized lubrication system that generates, conveys, and
automatically delivers lubricant to bearings, gearboxes, chains, and sliding surfaces in various
industrial machinery and equipment. This publication provides instruction and information for the
LubriMist® Oil Mist Generator Unit “IVT”. Design, application and distribution of LubriMist® Oil
Mist is covered in other publications. For additional information contact the manufacturing office
nearest you or check our website.
For questions regarding this publication or if you have specific questions regarding the installation
of the Model IVT Mist Generator, contact.
Manufacturer
5615 W Fuqua St. B-201
Houston, Texas 77085
USA
Ph 1.713.464.6266
Fx 1.713.464.7375
Manufacturer
CLARUS | COT-PURITECH | LUBRITECH | SICELUB |
Read and understand this operating manual
before attempting to install, commission, or use
this equipment. Failure to understand these
instructions could result in serious personal
injury and or loss of property.
WARNING

LubriMist®Model IVT
Oil Mist Generating System
Installation and Operating Manual
Page 10
of 256
Explanation Of Graphic Symbols In The Documentation
The following graphic symbols are used in this publication to communicate specific detailed
information necessary for the safe operation of this product. These graphic symbols are used to
create “Safety Alerts” within the documentation to alert the users of potential hazards, instruction
on how to avoid injury and instruction notices for safe operation. When interfacing with this
product it is important these safeguards are observed.
It is important for safety alerts to have the appropriate choice of signal word because this word
and its colored background communicate the severity of the hazard. The signal word calls
attention to the warning and designates a degree or level of hazard seriousness. The signal
words for product safety alerts as used in this manual are “DANGER”, "WARNING", "CAUTION",
and "NOTICE".
SYMBOL SYMBOL DESCRIPTION AND USE
This symbol is used to identify a “SAFETY ALERT” associated with either a
“WARNING” or “CAUTION” severity hazard. The alert is accompanied with
instruction necessary to avoid a hazard or personally injurious situation. The
“SAFETY ALERT” symbol is accompanied with other graphics to further
identify the type of hazard or personal injury risk involved.
This symbol is used to identify a “DANGER” level of hazard seriousness.
“DANGER” indicates a hazardous situation which, if not avoided, will result
in death or serious injury
WARNING
This symbol is used to identify a “WARNING” level of hazard seriousness.
“WARNING” indicates a hazardous situation which, if not avoided, could
result in death or serious injury
This symbol is used to identify a “CAUTION” level of hazard seriousness.
“CAUTION” indicates a hazardous situation which, if not avoided, could
result in minor or moderate injury
This symbol is used to identify “NOTICE” instructions and is used where a
"SAFETY ALERT" designation is too severe. A “NOTICE” label is used for
instruction or issuing a reminder about a condition which is more procedural
in nature rather than related to an immediate risk of personal injury.
This symbol is used to warn against risk of creating an “EXPLOSION”. This
symbol can be used in conjunction with a “SAFETY ALERT” symbol with
either a “DANGER”, or “WARNING” or “CAUTION” severity level.
This symbol is used to warn against “ELECTRIC SHOCK”. This symbol can
be used in conjunction with a “SAFETY ALERT” symbol with either a
“DANGER”, or “WARNING” or “CAUTION” severity level.