ORSCO Lubrication Systems

Transcription

1 Series 170 Lubrication System: Controller Manual Table of Contents: Pg. System eneral operation 1 Customer Controlled 2 Sample Electrical Diagram 3 Timer Controlled 4 Continuous Application 4 Sample Electrical Diagram 5 (Continuous) Pulsed Application 6 Sample Electrical Diagram 7 (Pulsed) Pg. /IC-DC Timer Tech. Data 8 Relay Controlled 9 Sample Electrical Diagram 10 (Continuous Application) Sample Electrical Diagram 11 (Pulsed Application) SC-AC/SC-DC Timer Tech. Data. 12 Series 170 Electrical Spare Parts 13 List System eneral Operation: Inlet air supply flows through a 5 micron filter and is controlled by two integrated solenoid valves. One valve (injector valve) is used to supply air pressure to a positive displacement injector, while the remaining air valve (nozzle valve) feeds a regulator, which in turn provides air to the downstream nozzle assembly. The positive displacement injector has a known volume and when pressurized ( fired ), lubricant is dispensed out of the metering chamber, through the injector check valve and into the downstream nozzle oil line. Each style of nozzle has an integral check valve which maintains pressure within the oil line between the system and the nozzle assembly. Internal porting within the nozzle assembly allows the regulated air supply to mix with the oil supply in a precision mixing chamber downstream of the nozzle check valve. It is at this point the air acts as a transport media, shearing the oil into large droplet formations and carries the oil from the nozzle outlet to the object to be lubricated. The injector valve is cycled on/off with a minimum on time of 0.5 seconds. When the injectors are cycled at a fast rate a thick film of oil is produced on the inner walls of the mixing cavity and nozzle tip. When air is introduced the oil migrates along the inner walls and the result is a thick continuous pattern of oil. When the injectors are cycled at a slow rate the film thickness is reduced resulting in a thinner pattern of oil. The Series 170 lubrication system was designed to function according to two different lubrication applications: Continuous or Pulsed. Continuous Application This is the most common application where the application of lubricant is applied in a continuous fashion. The above mentioned nozzle valve is supplying a constant flow of air to the nozzles while the injectors are cycled at the desired rate, resulting in a continuous pattern of lubricant. Nozzle types used for these applications are of the Swivel style, where the check valve assembly is located within the body of the nozzle assembly (creating a larger mixing chamber). Pulsed Application This application is predominantly used for assembly processes (i.e. engine assembly), but can also be used for lubricating slow moving chains or overhead trolley wheels. For this application the nozzle air valve is cycled at the same rate as the injector valve, where the off time would coincide with the speed of the assembly line or conveyor. This type of application utilizes a Tube-Type nozzle assembly, where the check valve is located at the end of the nozzle tip, resulting in a smaller mixing cavity to immediately transfer the dispensed lubricant to the object Corporate Drive, Shelby Township, MI (586) phone -- (586) fax systems@lincolnindustrial.com

2 The Series 170 Lubrication system is available with three basic control configurations: Customer Controlled Timer Controlled Relay Controlled (All of the above are available with three voltage options: 220 VAC, 120 VAC and 24 VDC.) Definitions: Dwell Time: Duration that the injector valve is activated. Off Time: Duration that the injector valve is deactivated. Injector Cycle Time: Duration of complete cycle (i.e. Cycle Time = Dwell Time + Off Time) Customer Controlled This configuration allows the customer to have complete control of the lubrication system. In this scenario the customer is responsible for the following: 1). Constant power supply for level and pressure switch fault indicator. (Reference system prints for power requirements.) 2). Injector air valve timing signal. Signal should be cycled On/Off according to the timing diagram shown in Fig. 1. (Note: Dwell time should be set for a minimum time of 0.5 seconds.) 3). Nozzle air valve signal. (Dependent upon application, reference Fig. 1). RECOMMENDED DIARAM CUSTOMER CONTROLLED CONTINUOUS SPRAY APPLICATIONS NOZZLE AIR (08SOL, 13SOL) INJECTOR (06SOL, 11SOL) FIXED DWELL TIME = 0.5 SEC. PULSED SPRAY APPLICATIONS NOZZLE AIR (08SOL, 13SOL) INJECTOR (06SOL, 11SOL) "ON" TIME MIN. ~ 0.5 SEC. "ON" TIME MIN. ~ 0.5 SEC. Fig. 1: Customer Controlled Recommended Timing Diagram Form Rev. 3 2

3 Sample Customer Controlled Electrical Diagram 120 VAC, Dual Network System 120 VAC 1PH, 60Hz 0.31 FLA L ND PE N #16 AW RED 0 #16 AW RN #16 AW WHITE FU 4 AMP FUSE OIL LEVEL OK 02FU 02FS AMP FUSE AIR ON SETTIN: 50 PSI 03PS 03LT W LT R 002 POWER ON LIHT SYSTEM FAULT LIHT FU SOL 07LT INJECTOR FU SOL SYSTEM PUMPIN NOZZLE AIR FU SOL 12LT INJECTOR FU SOL SYSTEM PUMPIN NOZZLE AIR Form Rev. 3 3

4 Timer Controlled The Timer Controlled system allows the customer to control the On/Off cycle time of the lubrication system via a PLC or other controller. This type of system has an internal Injector Cycle (IC) Timing Module to control the injector air valve cycle and the nozzle air valve is internally wired according to the application. The customer is responsible for the following: 1). Constant power supply for level and pressure switch fault indicator. (Reference system prints for power requirements.) 2). Supply of Start and Stop signals for lubrication cycle. 3). Internally set IC Timer for desired injector off time, thereby setting injector cycle time. RECOMMENDED DIARAM TIMER CONTROLLED CONTINUOUS SPRAY APPLICATIONS SIL NOZZLE AIR (08SOL, 13SOL) INJECTOR (06SOL, 11SOL) FIXED DWELL TIME = 0.5 SEC. (IC) SWITCH ADJUSTMENT FOR CONTINUOUS APPLICATION TIME DELAY ADJUSTMENT ON A EXAMPLE SETTINS: A: RECYCLIN : 1 SECOND MULTIPLIER TIME DELAY: 26 SECONDS INJECTOR AIR VALVE ON 0.5 SECONDS INJECTOR AIR VALVE OFF 26 SECONDS MODE OF OPERATION SELECTION RECYCLIN A SETTIN TIME RANE SELECTION RANE MULTIPLIER SETTIN 1 TO 255 SECONDS 10 TO 2550 SECONDS x1s x10s Fig. 2 Recommended Timing Diagram: Timer Controlled (Continuous Form Rev. 3 4

5 Sample Timer Controlled Electrical Diagram 120 VAC, Dual Network System, Continuous Application 120 VAC 1PH, 60Hz 0.31 FLA L #16 AW RED 0 ND PE N #16 AW RN #16 AW WHITE FU 4 AMP FUSE OIL LEVEL OK 02FU 02FS AMP FUSE AIR ON SETTIN: 50 PSI 03PS 03LT W LT R 002 POWER ON LIHT SYSTEM FAULT LIHT FU TR 06SOL 07LT 002 INJECTOR SYSTEM PUMPIN 08 08FU SOL NOZZLE AIR FU TR SOL 12LT INJECTOR SYSTEM PUMPIN 13 13FU SOL NOZZLE AIR Form Rev. 3 5

6 Pulsed Spray application: For this configuration the Start/Stop signal is based on an external sensor detecting object presence. The external sensor triggers the IC Timer to begin the cycle. The IC Timer (in Single-Shot mode) will initiate one cycle for both the injector air and nozzle air valves. The duration of this cycle is adjustable, however only one cycle of the injector will be completed regardless of the duration (Reference Fig. 3). For this control scheme both the injector air and nozzle air valve are activated off the same output of the IC timer (Reference sample diagram on Pg. 7). RECOMMENDED DIARAM TIMER CONTROLLED PULSED SPRAY APPLICATIONS SIL FROM EXTERL SENSOR NOZZLE AIR (08SOL, 13SOL) SENSOR SIL "ON" TIME MIN. ~ 0.5 SEC. INJECTOR (06SOL, 11SOL) "ON" TIME MIN. ~ 0.5 SEC. (IC) SWITCH ADJUSTMENT FOR PULSED APPLICATION TIME DELAY ADJUSTMENT ON A EXAMPLE SETTINS: A: SINLE-SHOT : 1 SECOND MULTIPLIER TIME DELAY: 26 SECONDS INJECTOR AIR VALVE ON 26 SECONDS OFF UNTIL NEXT SENSOR INPUT MODE OF OPERATION SELECTION SINLE-SHOT RANE 1 TO 255 SECONDS 10 TO 2550 SECONDS TIME RANE SELECTION MULTIPLIER x1s x10s SETTIN A SETTIN Fig. 3 Recommended Timing Diagram: Timer Controlled (Pulsed) Form Rev. 3 6

7 Sample Timer Controlled Electrical Diagram 120 VAC, Dual Network System, Pulsed Application 120 VAC 1PH, 60Hz 0.31 FLA L #16 AW RED 0 ND PE N #16 AW RN #16 AW WHITE FU 4 AMP FUSE OIL LEVEL OK 02FU FS AMP FUSE AIR ON SETTIN: 50 PSI 03PS 03LT W LT R 002 POWER ON LIHT SYSTEM FAULT LIHT CR CUSTOMER PRX CUSTOMER PRX FU TR 1 10TR 14CR FU FU SOL 07LT 08SOL INJECTOR NOZZLE AIR 13SOL 13FU 131 NOZZLE AIR 14CR SENSOR INTERFACE CR 12LT SOL SYSTEM PUMPIN SENSOR INTERFACE 07 INJECTOR SYSTEM PUMPIN Form Rev. 3 7

8 /IC-DC TIMER MODULE MAX..69 Mode of Operation: Single Shot or Recycling mode, dip switch selectable adjustable ON and OFF times. ( ON time first). Time Delay: Type: Microcomputer based with ceramic resonator and watchdog circuitry. Adjustment Range: ). ON Time: Factory preset at 0.5 seconds. 2). OFF Time: 8 switches adjust the OFF time delay Range: One switch selects 1 of 2 multipliers X1S = 1 to 255 seconds in 1 second increments. X10S = 10 to 2550 seconds in 10 second increments Repeat accuracy: ±0.1% or ±16 milliseconds, whichever is greater. Setting accuracy: ±2% or ±50 milliseconds, whichever is greater. Recycle Time: 300 milliseconds maximum. Initiate Time: 32 milliseconds maximum. Time Delay vs. Temperature and Voltage: ±2% or ±50 milliseconds, whichever is greater. Input: (# ): 24 VAC to 240 VAC, -20% to +10%, 50/60Hz. IC-DC (# ): 9 VDC to 135 VDC Outputs: Type: Solid State Form: Normally open Rating: 0.7A steady state, 10 Amp inrush Voltage Drop: (AC) 2.5V 0.7A (DC) 2.5V 0.7A Protection: IEEE 587 Level A Dielectric breakdown: 2000 Volts RMS 60 Hz. Mechanical: Mounting: Snap on to 32mm DIN1 & 35mm DIN 3 rail Termination: Push on terminal blocks for up to 14 AW wire. Environmental: Operating temperature: -40 C to +60 C (-100 F to +140 F) Storage temperature: -40 C to +85 C (-100 F to +140 F) Humidity: 95% relative, non-condensing DIN RAIL MOUNT ADAPTOR 35mm DIN 3 32mm DIN 1 Form Rev. 3 8

9 Relay Controlled The Relay system allows the customer to control the On/Off time of the lubrication system via an internal timer. This type of system has an internal System Cycle (SC) Timing Module to control On/Off cycle time of the lubrication system. The customer is responsible for the following: 1). Constant power supply for level and pressure switch fault indicator. (Reference system prints for power requirements.) 2). Internally set IC Timer for desired injector off time, thereby setting injector cycle time. 3). Internally set SC Timer for desired system cycle time. Continuous/Pulsed Spray applications: For this configuration the applications are controlled internally in the same manner as the Timer controlled systems. Reference Fig. 4. RECOMMENDED DIARAM CONTROLLED CONTINUOUS SPRAY APPLICATIONS "ON/OFF TIME FROM SC TIMER (OUTPUT 18) "ON" TIME "OFF" TIME NOZZLE AIR (08SOL, 13SOL) INJECTOR (06SOL, 11SOL) FIXED DWELL TIME = 0.5 SEC. PULSED SPRAY APPLICATIONS "ON/OFF TIME FROM SC TIMER (OUTPUT 18) "ON" TIME "OFF" TIME SIL FROM EXTERL SENSOR NOZZLE AIR (08SOL, 13SOL) INJECTOR (06SOL, 11SOL) "ON" TIME MIN. ~ 0.5 SEC. SYSTEM CYCLE (SC) TIME DELAY ADJUSTMENT ON A ON TIME ADJUSTMENT } OFF TIME ADJUSTMENT } EXAMPLE SETTINS: A: X1M MULTIPLIER : X10M MULTIPLIER SYSTEM CYCLE TIME ON TIME: 10 MINUTES OFF TIME: 10 MINUTES ON TIME RANE SELECTION RANE MULTIPLIER SETTIN 1 TO 15 MINUTES 10 TO 150 MINUTES OFF TIME RANE SELECTION RANE MULTIPLIER SETTIN 10 TO 150 MINUTES 1 TO 15 HOURS x1m x10m x10m x1h A A Fig. 4 Recommended Timing Diagram: Relay Controlled Form Rev. 3 9

10 Sample Relay Controlled Electrical Diagram 120 VAC, Dual Network System, Continuous Application 120 VAC 1PH, 60Hz 0.31 FLA L #16 AW RED 0 ND PE N #16 AW RN #16 AW WHITE FU 4 AMP FUSE 1 03LT 02FU 021 OIL LEVEL OK 02FS AMP FUSE AIR ON 1 SETTIN: 50 PSI 03PS 022 XXXCR 041 SC-AC 1 04TR XXXCR 091 SC-AC 1 09TR W FU TR 1 10TR 1 08FU 03LT R FU SOL 07LT 08SOL LT 13SOL 13FU SYSTEM FAULT LIHT SOL POWER ON LIHT SPRAY CYCLE INJECTOR SYSTEM PUMPIN NOZZLE AIR SPRAY CYCLE INJECTOR SYSTEM PUMPIN NOZZLE AIR Form Rev. 3 10

11 Sample Relay Controlled Electrical Diagram 120 VAC, Dual Network System, Pulsed Application 120 VAC 1PH, 60Hz 0.31 FLA L #16 AW RED 0 ND PE N #16 AW RN #16 AW WHITE FU 4 AMP FUSE 1 03LT 02FU 021 OIL LEVEL OK 02FS AMP FUSE AIR ON 1 SETTIN: 50 PSI 03PS SC-AC 14CR 16CR CUSTOMER PRX A1 1 04TR A2 SC-AC 09TR 071 W 1 05TR 08FU 03LT FU FU TR R 06SOL 07LT 08SOL LT 13SOL 13FU CR SYSTEM FAULT LIHT SOL POWER ON LIHT SPRAY CYCLE INJECTOR SYSTEM PUMPIN NOZZLE AIR SPRAY CYCLE INJECTOR SYSTEM PUMPIN NOZZLE AIR SENSOR INTERFACE CUSTOMER PRX CR 002 SENSOR INTERFACE 12 Form Rev. 3 11

12 SC-AC/SC-DC TIMER MODULE MAX..69 Mode of Operation: Recycling mode, dip switch selectable adjustable ON and OFF times. ( ON time first). Time Delay: Type: Microcomputer based with ceramic resonator and watchdog circuitry. Adjustment Range: 1). ON Time: 4 switches adjust the ON time delay Range: One switch selects 1 of 2 multipliers X1M = 1 to 15 minutes in 1 minute increments. X10M = 10 to 150 minutes in 10 min. increments 2). OFF Time: 4 switches adjust the OFF time delay Range: One switch selects 1 of 2 multipliers X10M = 10 to 150 minutes in 10 min. increments X1H = 1 to 15 hours in 1 hour increments Repeat accuracy: ±0.1% or ±16 milliseconds, whichever is greater. Setting accuracy: ±2% or ±50 milliseconds, whichever is greater. Recycle Time: 300 milliseconds maximum. Initiate Time: 32 milliseconds maximum. Time Delay vs. Temperature and Voltage: ±2% or ±50 milliseconds, whichever is greater. Input: SC-AC (# ): 24 VAC to 240 VAC, -20% to +10%, 50/60Hz. SC-DC (# ): 9 VDC to 135 VDC Outputs: Type: Solid State Form: Normally open Rating: 0.7A steady state, 10 Amp inrush Voltage Drop: (AC) 2.5V 0.7A (DC) 2.5V 0.7A Protection: IEEE 587 Level A Dielectric breakdown: 2000 Volts RMS 60 Hz. Mechanical: Mounting: Snap on to 32mm DIN1 & 35mm DIN 3 rail Termination: Push on terminal blocks for up to 14 AW wire. Environmental: Operating temperature: -40 C to +60 C (-100 F to +140 F) Storage temperature: -40 C to +85 C (-100 F to +140 F) Humidity: 95% relative, non-condensing DIN RAIL MOUNT ADAPTOR 35mm DIN 3 32mm DIN 1 Form Rev. 3 12

13 Series 170 Electrical Spare Parts List Description: Orsco Item Number: 120 VAC reen Pilot Light VAC Red Pilot Light VAC White Pilot Light VDC reen Pilot Light VDC Red Pilot Light VDC White Pilot Light VAC reen Pilot Light VAC Red Pilot Light VAC White Pilot Light Injector Timer Module IC-DC Injector Timer Module SC-AC System Timer Module SC-DC System Timer Module /4 Amp Fuse Amp Fuse Amp Fuse Amp Fuse Amp Disconnect Switch Form Rev. 3 13

14 50650 Corporate Drive, Shelby Township, MI (586) phone -- (586) fax