lubrimist ivt manual

LubriMist® Model IVT Oil Mist Generating System

Installation and Operating Manual

REVISION 05 April 2007 P/N 77740224

LubriMist® Model IVT Oil Mist Generator Page 1 of 212


TABLE OF CONTENTS UNIT IDENTIFICATION AND LABELING ....................................................................................... 6 INTRODUCTION ............................................................................................................................. 8

LubriMist® Model IVT Model Code Designations......................................................................... 9 Model Code Designation Key .................................................................................................. 10

Tag Detail for NEC Model IVT .................................................................................................... 11 Certificate Of Conformance ........................................................................................................ 12 Tag Detail for ATEX Model IVT .................................................................................................. 13 EU Certificate of Conformity ....................................................................................................... 14

PRODUCT DESCRIPTION ........................................................................................................... 16 Introduction ................................................................................................................................. 18 Operator Panel ........................................................................................................................... 19 Inlet Air Supply............................................................................................................................ 20 Mist Outlet Valve Assembly........................................................................................................ 21 Mist Generator Head With Air / Oil Heater ................................................................................. 21 Air Heater Control and Cutout Sensors ...................................................................................... 22 Oil Supply Transfer Pump and Control....................................................................................... 23 Main Oil Mist Generator Controller ............................................................................................. 24

Inlet Supply Air Pressure Transducer...................................................................................... 25 Ambient Air Temperature Sensor ............................................................................................ 25 Regulated Air Pressure Transducer ........................................................................................ 26 Bulk Oil Reservoir Level Transmitter ....................................................................................... 27 Mist Pressure Transducer........................................................................................................ 27 Bulk Oil Reservoir Oil Temperature Sensor ............................................................................ 27 Mist Density Sensor................................................................................................................. 28 Oil Supply Pressure Transducer.............................................................................................. 29

Auxiliary Oil Mist Generator ........................................................................................................ 30 Optional Equipment .................................................................................................................... 31

Oil Mist Reclamation................................................................................................................ 32 Warm Ambient Option (Cabinet cooling) for NEC constructions............................................. 33 Warm Ambient Option (Cabinet cooling) for ATEX constructions ........................................... 34 Air Purge .................................................................................................................................. 35 Cold Ambient Option (Air Preheating) for NEC constructions ................................................. 36 Cold Ambient Option (Air Preheating and Cabinet Heating) for ATEX constructions ............. 37 Auto Bulk Oil Fill....................................................................................................................... 39

INSTALLATION ............................................................................................................................. 40 Location / Mounting .................................................................................................................... 42 Mist Distribution System Connection.......................................................................................... 42 Compressed Air Supply .............................................................................................................. 43 Electrical Power Connection....................................................................................................... 44 Remote Communication And Alarm Connections ...................................................................... 46

Remote Alarm Contacts........................................................................................................... 47 Remote Communication Serial Port ........................................................................................ 49

Oil Reclamation Unit ................................................................................................................... 51 COMMISSIONING......................................................................................................................... 54

Bulk Oil Supply ........................................................................................................................... 56 Starting The Model IVT Oil Mist Generator ................................................................................ 58 Mist Density Sensor.................................................................................................................... 61

Operation ................................................................................................................................. 61 Location Of The Mist Density Sensor ...................................................................................... 61 Sensitivity Adjustments............................................................................................................ 61

Commissioning Optional Equipment .......................................................................................... 62 Oil Reclamation Unit ................................................................................................................ 62 Cabinet Cooling ....................................................................................................................... 64 Air Purge .................................................................................................................................. 66 Air Pre-heater........................................................................................................................... 67 Cabinet Heating System - ATEX Constructions ...................................................................... 67 Auto Bulk Oil Fill....................................................................................................................... 68


OPERATING GUIDE ..................................................................................................................... 70 Operating The Control Panel ...................................................................................................... 72

General Control Operation....................................................................................................... 72 Keypad Buttons........................................................................................................................ 72

Setting The Current Date............................................................................................................ 74 Setting The Current Time ........................................................................................................... 75 Reading Unit Operating Conditions ............................................................................................ 76 Reading Alarm And Control Set Points ...................................................................................... 77 Programming User Established Alarm And Control Set Points.................................................. 79 Special Key Pad Sequence Routines......................................................................................... 85 Dip Switch Definition For Hard Program Options. ...................................................................... 85

LOCAL ALARMS, INDICATORS AND READOUT ....................................................................... 88 LED Panel Indicator Lights ......................................................................................................... 91 Liquid Crystal Display ................................................................................................................. 91 Red And Green External Status Lights....................................................................................... 91 Event Log.................................................................................................................................... 92

REMOTE COMMUNICATION AND ALARM................................................................................. 94 Remote Alarm Contact ............................................................................................................... 96 Serial Data Port – RS-422/485 ................................................................................................... 97 Connecting To A Personal Computer (PC) ................................................................................ 98 Data and Event Log .................................................................................................................... 99 Personal Computer Communication Software ........................................................................... 99

MODBUS COMMUNICATION..................................................................................................... 104 Overview................................................................................................................................... 106 Installation................................................................................................................................. 106 Enable Modbus Communication DIP Switch............................................................................ 106 Serial Data Port – RS-422 ........................................................................................................ 107 Connecting To The Host Computer (via 4 wire) ....................................................................... 107 Connecting To The Host Computer (via 2 wire) ....................................................................... 107 Configuring The IVT Oil Mist Generator ................................................................................... 108 Configuring The Host Computer............................................................................................... 108 Function Codes......................................................................................................................... 110 Breakdown of each Function Code and it’s HEX Addresses ................................................... 112 Holding Register ....................................................................................................................... 115 Holding Registers Addresses; .................................................................................................. 116 Input Register ............................................................................................................................. 117 Viewing the IVT’s values in real time........................................................................................ 119 General Information .................................................................................................................. 120

BULK OIL SUPPLY RESERVOIR............................................................................................... 122 General Description and Use: .................................................................................................. 124 Commission The Auxiliary Oil Mist Generator.......................................................................... 124 Adding Oil To The Bulk Oil Reservoir....................................................................................... 125 Commission The Main Oil Mist Generator................................................................................ 125

AUXILIARY OIL MIST GENERATOR.......................................................................................... 126 General Description and Use: .................................................................................................. 128 Auxiliary Oil Mist Generator Start-Up ....................................................................................... 129 Operation .................................................................................................................................. 130 Air / Oil Heater Operation And Temperature Adjustment. ........................................................ 131

Controller Operation .............................................................................................................. 131 Programming And Changing Set-points ................................................................................ 131

Switching From The Auxiliary Oil Mist Generator To The Main Oil Mist Generator. ................ 133 Mist Outlet Switching Valve ...................................................................................................... 133

CONTROLLING THE MIST......................................................................................................... 136 Adjusting Air / Oil Ratio............................................................................................................. 138 Changing The Mist Generating Capacity.................................................................................. 140

ROUTINE MAINTENANCE ......................................................................................................... 142 TROUBLE SHOOTING GUIDE................................................................................................... 146

Main Unit................................................................................................................................... 149 Auxiliary Unit ............................................................................................................................. 158


Optional Equipment .................................................................................................................. 159 PARTS LIST / DRAWINGS / SCHEMATICS .............................................................................. 162

Spare Parts Lists ...................................................................................................................... 164 Process & Instrument Diagrams............................................................................................... 166

Optional Equipment ............................................................................................................... 167 Electrical Wiring Diagrams And Schematics / IVT – NEC Construction................................... 168

Ladder Diagram / 115 VAC Supply Voltage / IVT – NEC Construction................................ 168 Voltage Panel Wiring Diagram / 115 VAC Supply Voltage / IVT – NEC Construction ......... 169 Ladder Diagram / 230 VAC Supply Voltage / IVT – NEC Construction................................ 170 Voltage Panel Wiring Diagram / 230 VAC Supply Voltage / IVT – NEC Construction ......... 171

Electrical Wiring Diagrams And Schematics / IVT –ATEX Construction.................................. 172 Ladder Diagram / 115 VAC Supply Voltage / IVT – ATEX Construction................................. 173

Voltage Panel Wiring Diagram -115 VAC Supply Voltage / IVT – ATEX Construction ........ 173 Ladder Diagram / 230 VAC Supply Voltage / IVT – ATEX Construction.............................. 174 Voltage Panel Wiring Diagram -230 VAC Supply Voltage / IVT – ATEX Construction ........ 175 Voltage Panel Wiring Diagram / Warm Ambient Option – Cabinet Cooling – 115 or 230 VAC - ATEX Construction Only........................................................................................................ 176 Voltage Panel Wiring Diagram / Cold Ambient Option - Cabinet heating – 230 VAC - ATEX Construction Only .................................................................................................................. 177

Auxiliary Oil Mist Generator Controller Wiring Connection Detail ............................................ 178 Component Power Requirements And Identification................................................................ 179 Component Identification.......................................................................................................... 180 IVT Low Voltage Controller Layout........................................................................................... 181

Main Board Analog Input Terminal Strip................................................................................ 182 Main Board Digital Input Terminal Strip................................................................................. 183 Main Board Digital Output Terminal Strip .............................................................................. 184 Expansion Board Analog Input Terminal Strip....................................................................... 185 RS-422/485 Data Communication Terminal Strip ................................................................. 186

Bill Of Materials – IVT / NEC Construction. .............................................................................. 187 General Arrangement Drawings – IVT / NEC Construction ..................................................... 188

Operator Panel....................................................................................................................... 188 Main Oil Mist Generator Access, (left door)........................................................................... 189 Auxiliary Oil Mist Generator Access, (right door)................................................................... 190 Top View................................................................................................................................ 191 Electrical Power Switches...................................................................................................... 192 Oil Transfer Pump / Oil Mist Discharge ................................................................................. 193 Air Supply Components ......................................................................................................... 194 Electrical Control Components .............................................................................................. 195

General Arrangement Drawings – IVT / ATEX Construction.................................................... 197 Operator Panel....................................................................................................................... 197 Main Oil Mist Generator Access, (left door)........................................................................... 198 Auxiliary Oil Mist Generator Access, (right door)................................................................... 199 Top View................................................................................................................................ 200 Electrical Power Switches...................................................................................................... 201 Oil Transfer Pump / Oil Mist Discharge ................................................................................. 202 Air Supply Components ......................................................................................................... 203 Electrical Control Components .............................................................................................. 204

Optional Equipment .................................................................................................................. 205 Cold Ambient Option - Air Preheating - NEC and ATEX Constructions ................................ 205 Cold Ambient Option - Cabinet heating – ATEX only ............................................................ 206 Air Purge Option .................................................................................................................... 207 Warm Ambient Option – Cabinet Cooling – NEC Construction............................................. 208 Warm Ambient Option – Cabinet Cooling – ATEX Construction........................................... 209 Optional Demisting Unit ......................................................................................................... 210 Optional Auto Bulk Oil Fill ...................................................................................................... 211


UNIT IDENTIFICATION AND LABELING


INTRODUCTION 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 Lubrication Systems Company office nearest you, or check out the LSC Webster at www.lsc.com. For questions regarding this publication or if you have specific questions regarding the installation of the Model IVT Mist Generator, contact. Lubrication Systems Company 1740 Stebbins Dr. Houston, Texas 77043 USA Ph 713.464.6266 Fx 713.464.7375 Email [email protected]


LubriMist® Model IVT Model Code Designations • Electrical Standard:

The LubriMist® Model IVT Oil Mist Generator is available in models designed to comply with either North American or European electrical standards. The first entry of the IVT model code designates the electrical standard used. a) Equipment designed to the North American standards is compliant with Article 501 and

505 of the National Electrical Code (NEC) and has been evaluated by Underwriters Laboratories. The NEC version of the LubriMist® Model IVT has a UL/CUL Listing to Class I, Division 2, Groups B, C, D temperature code T4 and alternately Class I, Zone 2, Group IIB + H2, T4

b) Where electrical installations require European standards, the LubriMist® Model IVT Oil Mist Generator is available to ATEX II 3G EEx nC IIC T4.

• Inlet Power: The LubriMist® Model is available for connection to either 115 or 230 VAC single-phase power. The purchaser specifies supply voltage. Refer to the model code sheets for options available for specific voltages and construction.

• Labeling: Designates the language used in the operator interface to display messages.

• Oil Reclamation: For installations using the patented LubriMist® Closed Loop Oil Mist Systems. The oil reclamation option includes equipment to reclaim the oil from the return mist header when closed loop technologies are used. The Oil Mist Reclamation option includes a motor driven centrifugal coalescer to strip the oil from the return mist stream. A pneumatic driven pump returns the collected oil into the IVT Oil Mist Generator bulk supply reservoir. A high-level alarm switch is provided. For a complete description see Optional Equipment under the PRODUCT DESCRIPTION section of this manual. • Cabinet Accessories: Several accessories are available when certain environmental and ambient conditions can be expected. These options are recommended where aggressive or extreme site conditions exist. The options are designed to improve operational reliability and reduce long term maintenance. Cold and warm ambient options are available for locations where extremely hot or cold ambient temperature may be encountered. Air purging is recommended where extremely corrosive atmospheres may be encountered. For a complete description see Optional Equipment under the PRODUCT DESCRIPTION section of this manual.

EXPLOSION HAZARD – Substitution of components may impair suitability for Class I, Division 2. WARNING

EXPLOSION HAZARD – Substitution of components may impair suitability for II 3G EEx nC IIC T4 WARNING


Model Code Designation Key LubriMist® Model IVT

Oil Mist Generator

Option Description Option Code Description

C ATEX II 3G EEx nC IIC T4. Electrical Standard

N NEC CLASS 1 DIV 2 GROUP B/C/D T4 (Class I, Zone 2, Group IIB = H2)

A 115 VAC 50/60 HZ SINGLE PHASE & IMPERIAL MEASURING UNITS (3)

S 230 VAC 50/60 HZ SINGLE PHASE & IMPERIAL MEASURING UNITS

M 115 VAC 50/60 HZ SINGLE PHASE & METRIC MEASURING UNITS (3)

Inlet Power

B 230 VAC 50/60 HZ SINGLE PHASE & METRIC MEASURING UNITS

E ENGLISH and SPANISH Labeling

X NOT LISTED - CONSULT FACTORY FOR AVAILABILITY

X NONE

A EXPLOSION PROOF CLASS 1 DIV. 2 GROUP C/D T2C ONLY, 115 VAC 50/60 HZ SINGLE PHASE; (1)

B NEMA MOTOR: 230/460 VAC 50/60 HZ 3 PHASE; EXPLOSION PROOF CLASS 1 DIV. 2 GROUP C/D T3C (1)

C ATEX MOTOR: 230VAC 50 HZ 1 PHASE;

EEX DE IIC T4 IP56 - ZONE 2 (2)

D ATEX MOTOR: 380/400/415 VAC 50HZ

3 PHASE; EEX DE IIC T4 IP56 - ZONE 2 (2)

E NEMA MOTOR: 575 VAC 50/60 HZ 3 PHASE; EXPLOSION PROOF CLASS 1 DIV. 2 GROUP C/D T3C (1)

Oil Mist Reclamation

F NEMA MOTOR: 250 VAC 50 HZ 1 PHASE; EXPLOSION PROOF CLASS 1 DIV. 2 GROUP C/D T3C (1)

X NONE

C NEC - WARM AMBIENT OPTION (CABINET COOLING) (5)

P NEC & ATEX - AIR PURGING (ROTOMETER) (7)

H NEC - COLD AMBIENT - AIR PRE-HEATING (6)

J NEC - BOTH WARM & COLD AMBIENTS

W ATEX - WARM AMBIENT - CABINET COOLING (5)

Q ATEX - COLD AMBIENT - AIR PRE-HEATING & CABINET HEATING (6)

Cabinet Accessories

K ATEX - BOTH WARM & COLD AMBIENT OPTIONS

NON-REQUIRED FIELD.

CONSULT FACTORY IF FIELD INCLUDES ENTRY

Special

1 AUTO BULK FILL

2 SS T304 SUNSHADE

MODEL CODE IVT _ _ _ _ _ NOTES: 1) FOR NEC CONSTRUCTION ONLY. 2) FOR ATEX CONSTRUCTION ONLY 3) AIR PRE-HEATING OPTION IS NOT AVAILABLE WITH 115VAC ATEX CONSTRUCTION 4) IF OIL MIST RECLAMATION OPTION IS SELECTED, IVT WILL ONLY BE SUITABLE FOR CLASS 1 DIV. 2

GROUP C/D. TEMPERATURE CODE RATING ON THE MOTOR WILL DICTATE THE TEMPERATURE CODE RATING FOR THE IVT.

5) REQUIRED WHEN MAXIMUM AMBIENT TEMPERATURE EXCEEDS 104F (40C). 6) REQUIRED WHEN MINIMUM AMBIENT TEMPERATURE FALLS BELOW 15F (-10C). 7) REQUIRED FOR HIGHLY CORROSIVE OR HUMID OPERATING CONDITIONS


Tag Detail for NEC Model IVT LubriMist® IVT Oil Mist Generators manufactured compliant with Underwriters Laboratories UL/CUL Listing to Class I, Division 2, Groups B, C, D temperature code T4 and alternately, Class I, Zone 2, Group IIB + H2, T4. Equipment is labeled as follows. Note that temperature codes may vary with certain model numbers.

Data Ref. Description Example Model Code

Per Cust. P.O. & LSC Job Order See ” LubriMist® Model IVT Model Code Designation Key”

IVT-NAEXX

Serial No.

Unique Serial Numbers are to be issued to each machinery item. The LSC Sales Order Number is used as serial number prefix, and is followed with a designation for mist flow capacity specific to the machine being manufactured. The last designation differentiates multiple machinery’s sold under the same sales order Sales Order Number Mist Generating Capacity 060 = 60 Bearing Inch 213 = 213 Bearing Inch 475 = 475 Bearing Inch 933 = 933 Bearing Inch Item X of Y quantity produced on S.O.

!!!!!! - !!! - !!

Series No.

Indicates Model Series that the machinery is manufactured. Series numbers are maintained through revision log. When an Engineering Change is made to the product, those changes are recorded as a change in Series Number. New equipment enters market as Series 101 A______

101 A

Volts AC

Machinery is available for connection to either 115 VAC or 230 VAC electrical power. Purchaser specifies the electrical power requirement. Reference ”LubriMist® Model IVT Model Code Designations” For 115 VAC power____________________________ For 230 VAC power____________________________ κ NOTE: Ratings do not include electric motor drivers for “Oil Mist Reclamation” option.

115 230

Amps

Maximum operating power requirement at the specified voltage with the power switch for both the “MAIN” and “Auxiliary” oil mist generator in the ON position. Machinery for use at 115 VAC___________________ Machinery for use at 230 VAC___________________ “AIR PREHEATER” option is available with 115 and 230 VAC models. Amperage is with the power switch for both the “MAIN” and “Auxiliary” oil mist generator in the ON position. Reference ”LubriMist® Model IVT Model Code Designations” Machinery with “AIR PREHEATER” option: Machinery for use at 115 VAC___________ Machinery for use at 230 VAC___________ κ NOTE: Ratings do not include electric motor drivers for “Oil Mist Reclamation” option.

15.5 7.8 22.9 11.5

UL

LubriMist®

C ® US

Model NoSerial No.

Max Inlet Air Pressure; 150 PSIG / 10.3 BarOperating Temperature -40°C < T amb < +60°C

Class I Division 2 Groups B, C, D - TListed Oil Mist Generator for Hazardous LocationsVolts AC 50 / 60 Hz Amps

Series No.

LISTED

713/464-6266l e-mail [email protected] Fax 713/464-Lubrication Systems Co. Houston Texas

S

23 PNClass I, Zone 2, Group IIB + H2, T


Certificate Of Conformance NEC Construction

The Manufacturer: Lubrication Systems Company 1740 Stebbins Dr. Houston, Texas 77043 USA Hereby declares that The product: Model IVT - _ _ _ _ _ -_ Oil Mist Generator With product code position 1 = N With product code position 2 = A or B or M or S With product code position 3 = E or X With product code position 4 = X or A or B or E or F With product code position 5 = X or C or P or H or J With product code position 6 = Blank or 1 or 2 Has been evaluated to the requirements of the following standards: UL 508 Standard for Industrial Control Equipment C22.2 No. 14 Canadian Standard for Industrial Control Equipment UL 1604 Electrical Equipment for use in Class I and Class II, Div. 2 and Class III

Hazardous (Classified) Locations C22.2 No. 213-M1987 Non-Incendive Electrical Equipment for use in Class I, Div. 2 Hazardous

Locations And is Listed by Underwriter Laboratories Inc. BAYZ.E204253 as approved for: USL, CSL Model IVT Oil Mist Generator for Use in Class I, Division 2, Groups B, C, and D

hazardous locations USL, CSL Model IVT Oil Mist Generator with oil reclamation unit for Use in Class I, Division

2, Groups B, C, and D hazardous locations, provided with Listed Class I, Div. 1, Group C and D motor, or Listed Class I, Div. 2, Groups B, C, and D motor.

USL Indicates Listing to U.S. Standards CNL Indicates Listing to Canadian Standards

Signed By: Charles Ehlert Title: Director of Quality and New Product Development Date: August 2004


Tag Detail for ATEX Model IVT LubriMist® IVT Oil Mist Generators manufactured compliant with the ATEX Directive

LubriMist

e-mail [email protected]

50 / 60 Hz

Operating Temperature Max Inlet Air Pressure; 150 PSIG / 10.3 Bar

Lubrication Systems Co. Houston Texas USA

Oil Mist Generator for Hazardous Locations3 G EEx nC IIC T

713/464-6266 l

EPSILON 03 ATEX 1272DEMKO ** ATEX ******Y.O.M.

Serial No.Volts AC

Model No. IVT-

Fax 713/464-9871l

C < T amb < °C°

Amps

®

1 PH

Data Ref. Description Example Model Code

Per Cust. P.O. & LSC Job Order See ” LubriMist® Model IVT Model Code Designation Key”_____________________________

IVT-CBEXX

Serial No.

Unique Serial Numbers are to be issued to each machinery item. The LSC Sales Order Number is used as serial number prefix, and is followed with a designation for mist flow capacity specific to the machine being manufactured. The last designation differentiates multiple machinery’s sold under the same sales order Sales Order Number Mist Generating Capacity 060 = 60 Bearing Inch 213 = 213 Bearing Inch 475 = 475 Bearing Inch 933 = 933 Bearing Inch Item X of Y quantity produced on S.O.

!!!!!! - !!! - !!

Series No.

Indicates Model Series that the machinery is manufactured. Series numbers are maintained through revision log. When an Engineering Change is made to the product, those changes are recorded as a change in Series Number. New equipment enters market as Series 101 A______

101 A

Volts AC

Machinery is available for connection to either 115 VAC or 230 VAC electrical power. Purchaser specifies the electrical power requirement. Reference ”LubriMist® Model IVT Model Code Designations” For 115 VAC power___________________________ For 230 VAC power___________________________ κ NOTE: Ratings do not include electric motor drivers for “Oil Mist Reclamation” option.

115 230

Amps

Maximum operating power requirement at the specified voltage with the power selector switch in the “MAIN” oil mist generator position. (The selector switch allows only the “MAIN” or “SPARE” oil mist generator to be energized at any given time. Machinery for use at 115 VAC___________________ Machinery for use at 230 VAC___________________ “AIR PREHEATER and CABINET RADIATORS” option is available for 230 VAC models only. Reference ”LubriMist® Model IVT Model Code Designations” Machinery with “AIR PREHEATER and CABINET RADIATORS” option - 230 VAC_________________ 9.0

κ NOTE: Ratings do not include electric motor drivers for “Oil Mist Reclamation” option.

8.1 4.1


EU Certificate of Conformity The Manufacturer: Lubrication Systems Company 1740 Stebbins Dr. Houston, Texas 77043 USA Hereby declares that The product: LubriMist® Model IVT Oil Mist Generator Is in conformity with the following Directives:

European Directive 94/9/EC CAT 3 ATEX European Directive 73/23/EEC as amended by European Directive 93/68/EEC “Low Voltage Directive” European Directive 89/336/EEC as Amended by European Directive 93/68/EEC “EMC Directive”

The Manufacturer declares that the machine described above is protected for use in potentially explosive atmosphere. The apparatus marking shall include the following code:

3 G EEx nC IIC T4 Epsilon Compliance, UK. Certificate Number EPSILON 03ATEX1272X The following Harmonized European Standards have been applied: EN 62326: 1997: 1997 + Amendments A1 & A2 Electrical Equipment For Measurement, Control And Laboratory Use - EMC Directive (Emissions Only, Immunity covered by component CE test) EN 61010-1: 2001 Safety Requirements Electrical Equipment For Measurement, Control And Laboratory Use. EN 50021: 1999 Electrical Apparatus for Potentially Explosive Atmospheres – Type of Protection “n”.

Signed By: Charles Ehlert Title: Director of Quality and New Product Development Date: August 2004


Operating Conditions – ATEX Constructions

• Indoor/outdoor Use • Ambient temperature range

o -20°C to +40°C (-4°F to +104°F) Standard Construction o Minimum allowable ambient with Cold Ambient Option (air pre-heater with cabinet

heater) to -40°C o Maximum allowable ambient with Warm Ambient Option (cabinet cooling - ATEX) to

+45°C

• Altitude to 2000m • Relative humidity not exceeding 95% without Air Purge Option

Relative humidity to 100% with Air Purge Option

• Power supply fluctuations not to exceed ±10% rated voltage. • Over voltage category II IEC 60364-4-443 • Pollution degree 2


PRODUCT DESCRIPTION


Introduction The LubriMist® Model IVT is a self-contained oil mist generation package, designed to provide reliable uninterrupted service. This section of the manual is designed to familiarize the user with the machine and its various components and features. The features included as standard equipment is identified and discussed, then optional equipment is described at the end of this section. The OPERATOR PANEL is designed to help the equipment operator monitored the Model IVT on a routine daily basis. From this location local readout for normal operating and system fault conditions can be reviewed. Adjustments to heater control and, alarm set points are made from this location. The INLET AIR SUPPLY, MIST GENERATOR HEAD, OIL SUPPLY, INSTRUMENTATION AND ELECTRICAL and the AUXILIARY OIL MIST GENERATOR are all contained in the mechanical compartment located behind the operator panel.

Use the plan view below for locating each IVT Oil Mist Generator feature as they are described.

Feature Section Page No. Operator Panel B-B 19 Inlet Air Supply G-G, H-H, 20 Mist Outlet Valve Assembly F-F 21 Mist Generator Head w/ Air/Oil Heater A-A, I-I, 21 Air Heater Control And Cutout Sensors A-A 22 Oil Supply Transfer Pump and Control A-A, G-G 23 Main Oil Mist Generator Controller A-A 24 Inlet Air Supply Pressure Transducer G-G 25 Ambient Air Temperature Sensor G-G 25 Regulated Air Pressure Transducer A-A 26 Bulk Oil Reservoir Level Transmitter D-D 27 Mist Pressure Transducer E-E 27 Bulk Oil Reservoir Oil Temperature Sensor E-E 27 Mist Density Sensor E-E 28 Oil Pressure Transducer C-C 29 Auxiliary Oil Mist Generator H-H 30

IVT Plan View


Operator Panel The IVT Oil Mist Generator provides controlled equipment operator interface via an operator control panel located at the front enclosure door. The operator accessible features are: 1. The main oil mist generator operator interface control keypad and display. The keypad allows

the operator to display operating values of all monitored variables and program set points and alarm values by pressing the associated keypad button. Values are displayed on a local LCD display. Each variable has a local status indicator (LED) that indicates its status. A green LED is illuminated for normal operation and a red indicates that a fault condition exists. The keypad allows local setting of certain user programmable limits and set points.

2. The operator handles of the air supply ball valves to the main oil mist generator, the oil supply pump, and the auxiliary oil mist generator.3

3. The manual adjustment knobs of the air pressure regulators that control the supply air pressure to the main oil mist generator, the oil supply pump, and the auxiliary oil mist generator.

4. The air heater controller for the auxiliary oil mist generator air/oil heater. 5. Power switches for the main oil mist generator and the auxiliary oil mist generator. 6. Manual toggle valves for manually filling the main and auxiliary oil mist generator reservoirs. 7. Mist pressure gauge for monitoring mist header pressure when the auxiliary oil mist generator

is in operation. 8. Separate oil level indicators for the main oil mist generator reservoir, the auxiliary oil mist

generator reservoir, and the bulk oil supply reservoir. Each reservoir compartments is also equipped with a plugged drain valve.

9. As the oil supply is transferred from the bulk oil supply reservoir, it passes through a 10-micron spin on type oil filter. A threaded fill nozzle and cap provides the user with a fill point for adding oil to the bulk supply reservoir.

Lubrimist

5. Power Selector Switch ATEX Version

2. Air Supply Ball Valves • Main Oil Mist Generator • Oil Supply Pump • Auxiliary Oil Mist Generator

4. Auxiliary Oil Mist Generator Air/Oil Heater Controller

7. Auxiliary Oil Mist Generator Mist Pressure Gauge

9. Bulk Oil Reservoir Threaded Fill Port

9. Spin On Oil Filter

6. Toggle Valves For Manual Oil Filling Of Reservoirs

3. Air Pressure Regulators • Main Oil Mist Generator • Oil Supply Pump • Auxiliary Oil Mist Generator

1. Operator Keypad And Display

8. Oil Mist Generator Reservoir Level Gauge (typical)

5. Power Disconnect Switches NEC Version

8. Oil Mist Generator Drain Valve w/ Drain Plug (typical)

8. Bulk Oil Reservoir Drain Valve w/ Drain Plug

B
View B-


Inlet Air Supply The inlet air supply enters from the rear of the IVT Oil Mist Generator (IVT). Air is filtered through an inline filter (1) and enters a distribution manifold (2). The distribution manifold serves to distribute the air to three separate ball valves (3). The ball valves provide ON-OFF control to, a) the main oil mist generator head, b) the oil supply pump or c) the auxiliary oil mist generator head. The air supply to each device has a ¼ turn ball valve (3) to manually isolate each device for servicing.

Inlet Air Connection ½ 150 # RF T-304 Flange

2. Air Distribution Manifold

1. Air Filter

2. Air Distribution Manifold

3. Ball Valve c) Air To Auxiliary Mist Generator

3. Ball Valve b) Air To Oil Supply Pump

3. Ball Valve a) Air To Main Mist Generator Head
View G-G
View H-H


Mist Outlet Valve Assembly The oil mist-generating head uses compressed air to produce a small droplet of oil (1-3 micron). The oil droplets are suspended in the air and are discharged into a distribution-piping network. The piping system then supplies the oil mist to user machinery for bearing lubrication. A specially designed outlet-switching valve controls the flow of mist out of the IVT. The switching valve is pneumatically controlled. As the air supply to either mist head is opened to supply air to its associated mist-generating head, main or auxiliary, the switching valve automatically closes the outlet of the unused generator and opens the outlet of the one being used to generate the oil mist. The generated oil mist exits the top of the IVT cabinet through a 2” pipe. The mist outlet pipe is sealed as it exits the top of the IVT cabinet.

Mist Generator HThe oil mist generatincompartment of the Iare mechanically idemaintaining the air suthe top of the mist heThe heater cartridge

View F-F

Heat(typi

Mist Hea(typical 2

Air Hea(typical

Mist Out

ead With Air / Oil Heater g heads (main and auxiliary) are mounted inside of the mechanical

VT. Each uses oil held in separate reservoirs. Both mist generating heads ntical. Each mist head features an inline air heater element for heating and pply at a controlled temperature. The air heater element is installed through ad body (a block of machined aluminum) and attaches with a ½ NPT thread. extends into a second manifold made of machined aluminum rod.

View I-I

er Manifold cal 2 places)

d Body places)

ter Element 2 places)

Main Oil Mist Generator Reservoir

Cabinet Seal

Mist Outlet Switching Valve

Auxiliary Oil Mist Generator Reservoir


Air Heater Control and Cutout Sensors

The heater manifold extends into the oil reservoir to a point below the oil level. As oil is drawn into the mist generator head, the oil passes through a drilled port in the heater manifold. In this manor, the air heater element not only heats the air, but also heats the oil being generated into oil mist. A type K thermocouple senses the air temperature as it enters the mist generator to provide the temperature control and high – low alarm signal. A second type K thermocouple is installed in the air stream as it exits the air/oil heater manifold to function as a high temperature heater cutout. The IVT controller maintains the air temperature of the main oil mist generator. The controller produces a DC voltage output signal to control a solid state non-arcing relay for switching power to the heater element. A separate controller and solid state relay is used for controlling temperature for the auxiliary unit. The heater element is interlocked through the IVT controller with the low air pressure alarm. The heater is inoperable if the regulated air pressure is set lower than the low alarm set-point. This ensures that air is flowing over the element before power is applied.

View A-A

Thermocouple For Air Temperature Measurement, Heater Control, And High / Low Alarm Signals.

Mist Generating Head w/ Air/Oil Heater

Thermocouple For High Air Temperature Heater Cutout


Oil Supply Transfer Pump and Control The IVT Oil Mist Generator has a maximum bulk oil reserve capacity of approximately 75 gallons (US) / 284 liters. A pneumatically operated pump transfers the oil from the bulk compartment to the main or auxiliary mist generator reservoir as need. Control for the main oil mist generator is maintained automatically. As oil mist is generated and dispensed out of the IVT, the oil level in the mist generating reservoir drops. The IVT controller receives a signal from a level switch when oil level drops to a determined level. The controller then energizes a DC voltage solenoid operated air valve, which in turn starts the pump. The pump fills the reservoir until the switch contacts signal the controller to de-energize the air solenoid valve. The oil level switch assembly has a second level switch contact to provide a low level alarm signal. Both switches are hermetically sealed reed switches. An interlock is provided through the IVT controller that makes the air heater element inoperable while a low-level alarm is active. The switch assembly mounts through the top of the reservoir. The oil level for the auxiliary unit is manually maintained.


Main Oil Mist Generator Controller

The IVT Oil Mist Generator includes instrumentation to monitor its operation. The operation of the main oil mist generator and the auxiliary oil mist generator are independent, and are energized through separate disconnect switches. In the main oil mist generator ten process variables are monitored. If any monitored variable exceeds a predetermined high limit, or decreases below a predetermined low limit, a fault signal is provided. The monitored operating variables are: • Incoming Supply Air Pressure • Regulated Air Supply Pressure (Main Oil Mist Generator Head) • Air Temperature (Air / Oil Heater In The Main Mist Generator Head) • Oil Supply Pressure (When Oil Pump “On” To Verify Operation) • Bulk Oil Reservoir Oil Level • Bulk Oil Reservoir Oil Temperature • Mist Header Pressure • Mist Density • Low Oil Level (Main Oil Mist Generator Supply) • Ambient Temperature (No alarms are associated with the Ambient Temperature Sensor)

The IVT solid-state controller provides all monitoring and control functions. Segregation of power voltage (>30 VAC / 60 VDC) and control voltage (<30 VAC / 60 VDC) is provided by separate enclosures. All components in the power voltage enclosure are none arcing. The enclosure is a stainless steel NEMA type 12 enclosure. Power connections for the air/oil heater element and the red and green status lights are made in the power voltage enclosure. Both circuits are fused. Power to the heater is switched on/off using a non-arcing solid state relay. Switching between the red and green status lights is done using a relay with hermetically sealed contacts. A transformer located in the power voltage enclosure provides 24VAC supply to the low voltage controller. The control voltage enclosure contains microprocessor controlled P/C circuitry for polling the input signals of all peripheral sensors, transmitters and thermocouples. The input signals are interpreted by the microprocessor to perform control and alarm function for the IVT Oil Mist Generator. User accessible keypad and liquid crystal displays are accessible from the front operator compartment. All circuits in and connected to the control voltage enclosure are non-incendive.

Control Voltage Enclosure

View A-A

Power Voltage Enclosure


Inlet Supply Air Pressure Transducer The incoming air supply is monitored using a two-wire 4-20 mA output pressure transducer. It is mounted on the air distribution manifold in the inlet air supply. It is connected to the IVT controller with an integral flex cord. The transducer provides the signal for high inlet air pressure alarm and low inlet air pressure alarm. During operation the signal is used to provide an operating inlet air pressure value.

Ambient Air Temperature Sensor The ambient air temperature is monitored using a 100-ohm platinum RTD. The RTD sensor is installed in a machined plastic bulkhead by use of a thermocouple tube connector. It is connected to the IVT controller with an integral flex cord. The ambient air temperature sensor is a monitor function only. There are no alarm functions associated with this device.

Plan View

Ambient Air Sensor

View G-G

Air Distribution Manifold

Supply Air Pressure Transducer


Regulated Air Pressure Transducer The incoming air supply to the mist generator is controlled using a manually operated air pressure regulator. The air pressure regulator adjusts and controls the airflow through the mist head by controlling the inlet air pressure. Once the oil mist system has been commissioned, only minor adjustments to the regulated air pressure is needed to maintain proper system operation. The regulated air pressure transducer is located on the main oil mist-generating head. It is a two-wire 4-20 mA output pressure transducer. It is connected to the IVT controller with an integral flexible cord. The transducer provides the signal for high regulated air pressure alarm and low regulated air pressure alarm. During operation the signal is used to provide an operating regulated air pressure value.

Regulated Air Pressure Transducer

View A-A


Bulk Oil Reservoir Level Transmitter The oil level in the bulk supply reservoir is gauged using a level transmitter. The transmitter consists of a 316SS float that travels the length of the sensor tube. The sensor tube houses a circuit string of resistors and magnetically operated reed switches. There is a switch and resistor every ½ inch along the length of the tube. The circuit containing the resistors and switches is the same length as the measured range. As the level inside the reservoir varies, the magnetic float moves up or down the tube. When oil is added to the reservoir the float rises to the top of the stem. The float moves down the stem as oil is consumed. As the float moves, switches open/close thereby changing the resistance in the circuit. The two-wire transmitter converts this resistance change to a 4-20 mA current signal corresponding to fluid level. Resolution of the transmitter is ½ inch (proportional to the spacing of the sensor switches). The level transmitter is connected to the IVT controller with a flexible cord. Through the controller, the level transmitter monitors the level in the bulk oil reservoir and gives a high and low level alarm.

Mist Pressure Transducer A solid state pressure transducer is used to monitor the pressure of the mist distribution system. This variable is referred to as Mist Pressure. The mist pressure transducer is mounted on top of the bulk supply reservoir. It is a two-wire 4-20 mA output pressure transducer. The mist pressure transducer is connected to the IVT controller with a flexible cord. Through the controller, the transducer monitors the mist header pressure and gives a high and low alarm signal.

Bulk Oil Reservoir Oil Temperature Sensor A type K thermocouple monitors the temperature in the bulk oil reservoir. The thermocouple connects to the IVT controller with a flexible cord and monitors the oil temperature in the bulk oil reservoir. High and low alarms are active when the oil temperature is not within a prescribed operating range.

View E-E View D-D

Bulk Oil Thermocouple

Mist Pressure Transducer

Bulk Oil Reservoir Level Transmitter


Mist Density Sensor The LubriMist® monitor is a proprietary sensor manufactured by Lubrication Systems Company. The mist monitor is a solid state device that detects fluctuations in oil mist density. The LubriMist® oil mist monitors user selectable sensitivity adjustment provides continuous on-line monitoring of the oil mist density in the supply header, allowing oil mist users to optimize oil consumption without over or under lubricating machinery. Continuous monitoring is accomplished through the IVT controller. Once the oil mist flow reaches the detector, the LubriMist® monitor will automatically respond to changes in oil / air ratio. In operating the LubriMist® monitor, it is important to understand that although any given out-put reading may correspond to a quantitative oil/air ratio, the LubriMist® monitor does not make a mass measurement of the amount of oil suspended in the air. The out-put signal range of 0-100 percent mist density, represents a change in the ability of a light beam to penetrate the oil mist sample as it passes between a light source and a light detector. A mist density reading of zero indicates that no or a very small amount of oil mist is present, thereby allowing the light to easily reach the photo detector. As the oil/air ratio increases, the small oil particles reflect and block the light from the detector causing a change in the mist density reading. When the light can no longer penetrate the photo optical bench, the LubriMist® monitor reads 100%. The LubriMist® monitor is designed to detect and respond to changes in oil/air ratio. The LubriMist® monitor is connected to the controller with a flexible cord. Alarms for high and low mist density annunciate when the monitor detects an opacity reading outside of preset operating set-points.

View E-E

Mist Density Monitor


Oil Supply Pressure Transducer A solid state pressure transducer is used to monitor the operation of the oil transfer pump when the automatic oil fill feature is energized (see Oil Supply). When the level switch in the main oil mist generator reservoir initiates the fill cycle, the pressure transducer confirms that pump operation has started. When the oil transfer pump is cycling, its operation is monitored. The oil pressure transducer is mounted in a manifold at the oil pump outlet. It is a two-wire 4-20 mA output pressure transducer. The oil pressure transducer is connected to the IVT controller with a flexible cord. Through the controller, the transducer monitors the oil pressure when the auto fill sequence is active and gives a high and low level alarm. If a pressure alarm is detected, the alarm remains active after the fill cycle is complete.

Pump Outlet Manifold

Oil Pressure Transducer

View G-G View C-C


Auxiliary Oil Mist Generator

The IVT includes an auxiliary or spare oil mist generator. The auxiliary unit is provided for use when maintenance or repair operations are being performed on the main oil mist generator. A power switch is located in the operator panel for removing electrical power to the auxiliary unit when it is not in service. The auxiliary unit is equipped with a mist generating head with air / oil heater (see Mist Generating Head With Air/Oil Heater). A type k thermocouple and a solid state PID type controller provide heater control. A second type k thermocouple connected to the controller is used for high temperature alarm and cutout. The fused input AC voltage is connected to a local terminal strip in a NEMA 12 electrical enclosure. Distribution from the terminal strip is made to power the controller and heater element. The controller produces a DC voltage output signal to a solid state non-arcing relay for switching power to the heater element. A second solid state relay is wired to open the air heater element supply power if the controller detects a high temperature condition. An alarm indicator on the operator interface of the controller indicates when an alarm condition has been detected. Acknowledgment of the alarm is required before heater operation is resumed. The heater element on the auxiliary unit is interlocked with a low air pressure switch. The heater is inoperable if a low regulated air pressure condition exists. This ensures that airflow is established before power is applied to the element. The low air pressure switch is explosion proof.

Terminal Strip w/ Fuses

Heater Controller

Low Air Pressure Switch

Auxiliary Oil Mist Generating Head w/ • Air / Oil Heater • Heater Control Thermocouple • High Temperature Thermocouple

Solid State Relays

View H-H


Optional Equipment

The LubriMist® Model IVT Oil Mist Generator can be equipped with several optional features. Check the Model Code designation on the equipment tag to determine if any option has been included with your unit. Reference the Model Code Designation Key (page 5) to identify the specific IVT model you have.

The different IVT equipment options are (1) Oil Reclamation for use when using LubriMist® Closed Loop technologies, (2) Warm Ambient Option is for use in hot ambient climates, (3) Air Purge for use in aggressive or highly corrosive environments, (4) Cold Ambient Option is for geographic areas that are subject to sever cold and (5) Auto Bulk Oil Fill for IVT oil mist consoles that will be connected to a centralized bulk oil supply system.

These are further discussed below. For operating information reference the specific option instruction in other sections of this manual. The options are

1. Oil Reclamation

2. Warm Ambient Option (Cabinet cooling)

3. Air Purge (Rotometer)

4. Cold Ambient Option (Air Preheating – NEC and ATEX, Cabinet heating – ATEX only)

5. Auto Bulk Oil Fill


Oil Mist Reclamation The Oil Mist Reclamation option is used when LubriMist® Closed Loop Oil Mist systems are being installed. LubriMist® Closed Loop Oil Mist Systems uses the same principles to apply oil mist for machinery lubrication as non-closed loop oil mist systems. However when closed loop systems are installed, after the oil mist has been applied, the oil is continually reclaimed for reapplication to the serviced rotating machinery. As the oil mist flows through the rotating equipment bearings and bearing housings, a part of the oil mist coalesces into liquid oil. A lesser amount of oil remains suspended in the air as it vents from the bearing housing. This is often referred to as Stray Mist. User equipment items are equipped with oil collection containers to collect the liquid oil that is manually pumped into the return mist header. The stray mist is collected into a return mist header as it vents from the bearing housing. The return mist header is connected to the Oil Mist Reclamation Unit.

Air Vent to Atmosphere

Oil Level Gauge

Over Flow Connection.

High Level Alarm Switch

Mist Return Connection 2-1/2 In 150 # RF

Centrifugal Coalescer w/ Motor Driver

Mist Outlet Connection 2 In 150 # RF

IVT Oil Mist Generator

Enclosure Contains Pump ControlsBulls Eye Sight

Low Point Drain

An oil over flow connection is located on the right side of the reservoir. This connection allows oil to be drained away should the reservoir be overfilled. It is located above the high-level switch position. The Oil Mist Reclamation unit is a self-contained unit that mounts onto the rear of the IVT Oil Mist Generator cabinet. The returning stray mist is stripped of its oil by an electric motor driven rotating coalescer. The returning air is vented from the unit to atmosphere. The coalesced oil is collected in an integral receiving reservoir. A pneumatic driven transfer pump transfers the liquid oil to the IVT bulk oil reservoir for reuse. The reservoir is equipped with a liquid level gauge to monitor the oil level in the reservoir. A bulls-eye sight glass is located at the reservoir bottom to check for contamination. A high-level alarm switch interlocks with the controller in the IVT main oil mist generator to provide a system alarm. A separate output signal is provided to interlock with the motor driver control circuit.
NOTE: SEPARATE MOTOR DRIVER STARTER AND CONTROL CIRCUITRY ARETO BE PROVIDED AND INSTALLED BY THE USER.


Warm Ambient Option (Cabinet cooling) for NEC constructions The Warm Ambient Option (Cabinet cooling) option for the NEC constructed IVT Oil Mist Generator is recommended when it is installed in geographical locations where the maximum ambient temperature exceeds 115°F (46°C). The IVT Oil Mist Generator Cabinet Cooler system is designed to provide internal cooling protection to the IVT Controller electronic components. The cabinet cooling system uses a pneumatic operated vortex cold air generator for reducing and maintaining the operating temperature inside of the console cabinet. The air temperature inside of the IVT cabinet is monitored and maintained at reduced temperature levels by a mechanical thermostat that requires no electrical power. The thermostat is factory set and nonadjustable. Each cooling cycle starts when the internal operating temperature reaches approximately 124º F ( 51º C ) and remains on until the temperature in the controller enclosure is reduced to 80º F ( 27º C ). The IVT Oil Mist Generator Cabinet Cooling system includes the vortex cold air generator with integral mechanical thermostat. An integral air pressure regulator / air filter is used for filtering the air supply and regulating the inlet air pressure to the cold air generator

Vortex Cold Air Generator Introduced Chilled Air Into The Cabinet For Cooling.

Block Valve

IVT Inlet Air Connection Air Pressure Regulator w/ Air

Pressure Gauge For Controlling Air Flow

Warm Ambient Option (Cabinet cooling) - NEC constructions

When the IVT Oil Mist Generator is equipped at the factory with a cabinet cooling system, no additional user connections or installation is required. The instrument air supply serving the oil mist generator for producing the oil mist also provides air to the cold air generator. A block valve is provided for servicing if necessary.


Warm Ambient Option (Cabinet cooling) for ATEX constructions The Warm Ambient Option (Cabinet cooling) option for the ATEX constructed IVT Oil Mist Generator is REQUIRED when it is installed in geographical locations where the maximum ambient temperature exceeds 40°C (104°F). See page 15 for more information regarding permissible ambient temperatures. The IVT Oil Mist Generator cabinet cooling system is designed to provide internal cooling protection to the IVT Controller electronic components. The cabinet cooling system uses a pneumatic operated vortex cold air generator for reducing and maintaining the operating temperature inside of the console cabinet. A temperature switch provides ON-OFF control to a solenoid operated air valve, which regulates the air supply to the vortex cooler. The internal cabinet temperature is controlled at approximately 32°C (90°F). The thermostat is factory set. The IVT Oil Mist Generator Cabinet Cooling system for the ATEX construction includes the vortex cold air generator with temperature switch, solenoid operated air valve, wire terminal enclosure, an air temperature gauge and a power disconnect switch. An air pressure regulator is provided for controlling the inlet air pressure to the vortex cold air generator.

774

32

1G

55G

12

34

661010

988

91111

Block Valve

Air Pressure Regulator w/ Air Pressure Gauge For Controlling Air Flow

Vortex Cold Air Generator

Solenoid Operated Air Valve

Power Disconnect Switch

Air Temperature Gauge

Temperature Switch

Air Inlet

Warm Ambient Option (Cabinet cooling) - ATEX constructions

When the IVT Oil Mist Generator is equipped at the factory with a cabinet cooling system, no additional user connections or installation is required. The instrument air supply serving the oil mist generator for producing the oil mist also provides air to the cold air generator. An air block valve and an electrical disconnect switch are provided for servicing if necessary.


Air Purge The IVT Oil Mist Generator Controller Air Purge Option is designed to provide an inert gas purge for the purpose of providing protection to the IVT controller electronic components. This system intended for use in equipment located in areas that are subject to highly corrosive or humid operating conditions. The cabinet purge system uses a rotometer to monitor inlet airflow as it is supplied to the interior of the IVT Controller enclosure.

Instrument Block Valve For Servicing

Rotometer Introduces Inert Gas Into Electrical Enclosure

Spent Air Exhausts Through Vent Into Cabinet

The IVT Oil Mist Generator Controller Air Purge Assembly includes an air purge meter (rotometer) and supply air block valve. Spent air is exhausted through an enclosure vent after it has been circulated through the IVT controller. Installation tubing, fittings and hardware necessary for interconnecting the operating components and mounting the system to the oil mist generator cabinet is included. When the IVT Oil Mist Generator is equipped at the factory with an air purge system, no additional user connections or installation is required.


Cold Ambient Option (Air Preheating) for NEC constructions The Cold Ambient Option (Air Preheating) option for NEC constructions is recommended when the IVT Oil Mist Generator is installed in geographical locations where the minimum ambient temperature falls below 15°F / -10°C. The IVT Air Pre-heater system is designed to insure that during cold ambient conditions, proper air and oil temperatures are maintained at the oil mist generator. The pre-heater is installed in the incoming air supply. A sensor at the inlet of the heater senses the inlet air temperature. When the inlet air temperature falls below 40°F / 5°C, the pre-heater is activated. The discharge temperature from the pre-heater is supplied to the mist head and air/oil heater at a controlled 60°F / 16°C. A second sensor provides heater control and high-low alarm input signals. A third sensor is used for high temperature heater cutout. The IVT cabinet enclosure is insulated to retain radiated heat from the air pre-heater and discharge tubing. When the IVT Oil Mist Generator is equipped at the factory with the air preheating system, no additional user connections or installation is required.

Inlet Air Connection

Inlet Air Temperature Sensor

Air Preheater

Heater Control And Cutout Sensors Are Located In The Heater Discharge


Cold Ambient Option (Air Preheating and Cabinet Heating) for ATEX constructions The Cold Ambient Option (Air Preheating and Cabinet Heating) option for ATEX constructions is recommended when the IVT Oil Mist Generator is installed in geographical locations where the minimum ambient temperature falls below -10°C (15°F). This option is REQUIRED where the ambient temperature drops below -20°C (-4°F) to maintain the ATEX certification. See page 15 for more information regarding permissible ambient temperatures. The IVT Air Pre-heater system is designed to insure that during cold ambient conditions, proper air and oil temperatures are maintained at the oil mist generator. The pre-heater is installed in the incoming air supply. A sensor at the inlet of the heater senses the inlet air temperature. When the inlet air temperature falls below 5°C (40°F), the pre-heater is activated. The discharge temperature from the pre-heater is supplied to the mist head and air/oil heater at a controlled 16°C (60°F). A second sensor provides heater control and high-low alarm input signals. A third sensor is used for high temperature heater cutout. The IVT cabinet enclosure is insulated to retain radiated heat from the air pre-heater and discharge tubing. When the IVT Oil Mist Generator is equipped at the factory with the air preheating system, no additional user connections or installation is required.

Heater Control And Cutout Sensors Are Located In The Heater Discharge

Air Preheater

Cold Ambient Option (Air Preheating) - ATEX constructions

Inlet Air Connection

Inlet Air Temperature Sensor


The IVT Cabinet Heating system (ATEX) is designed to insure that during cold ambient conditions, the internal cabinet temperature is maintained above -20°C (-4°F). This option is REQUIRED where the ambient temperature drops below -20°C (-4°F) to maintain the ATEX certification. See page 15 for more information regarding permissible ambient temperatures. During startup and commissioning where the ambient temperature is below -20°C (-4°F ) the cabinet heater system is energized prior to start up. Startup is delayed until the cabinet temperature exceeds -20°C (-4°F). The internal cabinet temperature is monitored by use of a temperature gauge located on the rear of the IVT cabinet. Two radiators (heaters) warm the internal cabinet spaces; one is located in the mechanical compartment and the other inside of the operator interface compartment. Each has an integral thermostat to control the cabinet internal temperature. Thermostats turn the heaters ON at 10°C (50°F) and OFF at 18C (65°F). The IVT Oil Mist Generator Cabinet Heating system for the ATEX construction includes two enclosure radiators (heaters) with thermostats, wire terminal enclosure an air temperature gauge and a power disconnect switch. The IVT cabinet enclosure is insulated to retain radiated heat. When the IVT Oil Mist Generator is equipped at the factory with the Cabinet Heating system, no additional user connections or installation is required.

Cold Ambient Option (Cabinet Heating) - ATEX constructions


Auto Bulk Oil Fill The Auto Bulk Oil Fill option is used for IVT oil mist consoles that will be connected to a pressurized bulk oil supply system. The IVT Auto Bulk Oil Fill system is designed to maintain a specified oil level within the IVT bulk oil reservoir. The Auto Bulk Oil Fill ¾” NPT connection is located at the rear of the IVT. A ¾” shut off valve is provided for servicing a 10 micron spin-on type oil filter. Supply oil pressure can be observed via a 0-300 PSI (0-21 Bar) pressure gauge. The bulk oil reservoir level is continuously maintained by the IVT solid state controller. A solenoid operated oil valve is energized when the level falls in the IVT bulk oil reservoir to 45 gallons (170 Liters) and de-energizes when the level rises to 53 gallons (200 Liters). The supplied bulk oil enters the IVT bulk oil reservoir through a 10PSI (0.7 Bar) check valve.

Supply Oil Pressure Gauge

Check Valve

Solenoid Operated Oil Valve

Spin-on Oil Filter

Block Valve


INSTALLATION

Warning: If the equipment is not used in the manner described in this manual the protection provided by the equipment may be impaired. THIS INSTRUMENT MUST BE EARTHED.

Note: All ATEX approved construction must be installed in accordance with the requirements of BS EN60079-14:1997 – Part 14 Electrical installations in hazardous areas (other than mines).


Location / Mounting Choose a central convenient location, allowing enough room to connect air and electrical services at the rear of the IVT console enclosure. Ensure that unrestricted operator access is maintained at the front of the unit when the cabinet door is open. The IVT has maintenance access doors on both sides of the cabinet. Ensure that unrestricted access is provided for system troubleshooting and maintenance. The IVT console is constructed with an integral skid base. The base is fashioned with slots for lifting and handling the IVT using a fork truck. Slot dimensions are 8 ¾" (w) x 4” (h) or 222 mm x 100 mm. Install the IVT cabinet in an upright and level position. Use four anchor bolts suitable for the type of foundation used (i.e. wood, concrete, steel etc.) Anchor bolts are not provided with the unit. Dry weight of the IVT Mist Generator is 1200 pounds / 545 Kg.

Mist Distribution System Connection Connect the oil mist distribution system to the oil mist outlet (ANSI 2” 150 lb. RF Flange) located on the top right side of the cabinet. When threaded flanges are use to connect to the header system, do not use Teflon tape or conventional pipe dope. A non-hardening thread lubricant such as LubriMist® Part No. 77-600-947 should be used on the pipe thread. The mating flange, gasket and bolting are mounted to the cabinet mist outlet flange and shipped with the unit.


Compressed Air Supply Connect a clean, dry compressed air supply to the inlet air supply (ANSI 1/2” 150 lb. RF Flange) located at the right rear of the unit. . When threaded flanges are use to connect to the header system, do not use Teflon tape or conventional pipe dope. A non-hardening thread lubricant such as LubriMist® Part No. 77-600-947 should be used on the pipe thread. The mating flange, gasket and bolting are mounted to the cabinet air inlet flange and shipped with the unit.

The inlet air supply must be capable of delivering the SCFM rating of the mist generating assembly installed on the air/oil heater base. Available mist generating flow rates are indicated in the chart below. See the tag information for assigning serial numbers described in the “Unit Identification and Labeling” to determine the mist generating capacity of your mist generating assembly. Recommended minimum air service is 65 PSIG / 4.5 BAR. The minimum required air supply needed to ensure that the unit is operable at the maximum mist output capacity is shown in the tables below.

INLET AIR SUPPLY SYSTEM MUST BE EQUIPPED WITH A

SAFETY RELIEF VALVE FOR OVER PRESSURE PROTECTION

Installation of an air supply block valve in the supply piping is recommended. The valve should be located just prior to connecting to the IVT air supply connection and be accessible from grade. The purchaser furnishes the air supply block valve.

Mist Generating Flow Range IVT Mist Generator Size US Units Metric Units

60 BI 0.60 - 1.80 SCFM 1.02 – 3.06 M3 / Hr 213 BI 1.75 – 6.40 SCFM 2.97 – 10.87 M3 / Hr 475 BI 2.48 – 14.30 SCFM 4.21 – 24.30 M3 / Hr 933 BI 5.70 – 28.0 SCFM 9.68 – 47.57 M3 / Hr

Minimum Recommended Air Supply Capacity ∴ IVT Mist Generator Size US Units Metric Units

60 BI 5 SCFM @ 65 PSIG 8.5 M3/HR @4.5 BAR 213 BI 10 SCFM @ 65 PSIG 17 M3/HR @4.5 BAR 475 BI 18 SCFM @ 65 PSIG 31 M3/HR @4.5 BAR 933 BI 32 SCFM @ 65 PSIG 55 M3/HR @4.5 BAR

∴ Includes the airflow requirement needed to operate the oil transfer pump.

NOTE: MAXIMUM AIR SUPPLY PRESSURE IS 150 PSI / 10.3 BAR


Electrical Power Connection There are no ventilation requirements as long as the unit meets the operating conditions. Service power to the main and auxiliary oil mist generators originate at a terminal strip located in a terminal enclosure located at the rear of the IVT console cabinet. See the diagrams below for terminal enclosure location and user terminal connection identification. The power connection for the IVT oil mist generator is single phase. Voltage is as specified on the equipment nameplate

EXPLOSION HAZARD – Do not disconnect equipment unless power has been switched off or the area is known to be non-hazardous.

WARNING

1-1/4 Conduit Two Places

Power Terminal Enclosure

Right Side View Rear View

Model IVT Oil Mist Generator – NEC Construction

Model IVT Oil Mist Generator – ATEX Construction

Power Terminal Enclosure

20 mm Entrance Connection w/ Stopping Plug – 2 places

Rear View Right Side View


The power circuit requirements for NEC and ATEX constructed LubriMist® IVT consoles are indicated in the table below. The table shows amperage rating either with or without the Cold Ambient Options.

IMPORTANT:

ALL ELECTRICAL CONNECTIONS SHOULD BE MADE BY A

QUALIFIED ELECTRICIAN.

IMPORTANT:

ELECTRICAL POWER SERVICE MUST HAVE ADEQUATE CIRCUIT

PROTECTION. USE TABLE BELOW FOR SELECTION OF USER

PROVIDED INTERRUPT DEVICE.

A switch or circuit breaker shall be included in the building installation; it shall be in close proximity to the equipment and within easy reach of the OPERATOR; it shall be marked as the disconnecting device for the equipment.

NEC Equipment: CL I Div 2 Grp B, C, D – T4 ATEX Equipment:

Volts Without Cold Ambient Option

With Cold Ambient Option

Without Cold Ambient Option

With Cold Ambient Option

115 15.5 Amperes 23 Amperes 8.1 Amperes N/A

230 7.8 Amperes 11.5 Amperes 4.1 Amperes 9.0 Amperes

3 G EEx nC IIC T4

LubriMist® IVT Oil Mist Generator Power Requirements

The values shown in the table above do no include power to electric motor drivers for oil reclamation units. Electric motor driver must be connected to a separate source of supply. All contactors and start controls are furnished by the purchaser and installed according to all applicable codes and standards. Consult the motor nameplate for specific voltage and power requirements. Also see Remote Alarms and Annunciation.


Remote Communication And Alarm Connections

The LubriMist® Model IVT is equipped to provide remote monitoring by either of two methods.

1. A basic ON-OFF closure from the dry FORM-C contact can be connected to a user sourced

alarm.

TO AVOID RISK OF EXPELECTRICAL POWER CIR

2. An RS-422/485 serial connection is available for dlocated personal computer (PC) or DCS.

CAUTION:

LOSION HAZARD, REMOTE ALARM CUITS SHOULD BE NONINCENDIVE

ata transmission to the users remote


Remote Alarm Contacts A dry FORM C contact is available to operate remote annunciation to indicate a unit fault or loss of power. The relay contact is part of the same hermetically sealed relay that operates the red and green unit status lights. Each time the unit status lights operate the remote alarm contacts also operate. WARNING:

ENSURE THAT ALL PREVIOUSLY CONNECTED SOURCES OF ELECTRICAL POWER ARE DISCONNECTED BEFORE OPENING THE AC POWER ENCLOSURE AND ATTEMPTING TO CONNECT TO THE REMOTE ALARM CONTACTS.

WARNING Terminal connections for the remote alarm contacts in the NEC version of the Model IVT Oil Mist Generator are located in the AC power enclosure. 1. To access the AC power enclosure, open the mechanical access door on the left side of the

IVT console cabinet. Inside the mechanical compartment and located above the reservoir are two electrical control enclosures. The electrical enclosure located to the left is the AC power enclosure. Conduit is provided inside the mechanical compartment for the users alarm wiring. The conduit connects the external remote alarm connection and the AC power enclosure.

2. Open the AC power enclosure and locate the terminal strip. The remote alarm terminals are colored white for easy identification. Install the alarm wiring through Close and secure the AC power enclosure door.

For NEC Constructions, Connect The Remote Alarm Wiring To Terminal Numbers 1 - 2 - 3

1 - COM 2 - N.O. 3 - N.C.

Locate The AC Power Enclosure

Conduit For Remote Alarm Wiring

Remote Alarm Connection ¾ Inch Conduit


Terminal connections for the remote alarm contacts in the ATEX version of the Model IVT Oil Mist Generator are located in a terminal enclosure located at the back of the IVT console cabinet. A. To access the remote alarm contacts, find the two terminal enclosures mounted on the rear

of the IVT console cabinet. The terminals for connecting to the remote alarm are located in the lower enclosure.

WARNING: Take care to ensure that you are accessing the correct enclosure. Failure to do so may result in serious personal injury or damage to equipment.

WARNING

B. Locate the lower enclosure and remove the cover. Install the alarm wiring through the cable connection, and connect to the proper terminals.

C. Close and secure the remote alarm circuit enclosure cover.

For ATEX Constructions, Connect The Remote Alarm Wiring To Terminal Numbers 1 - 2 - 3

1 - COM 2 - N.O. 3 - N.C.

Locate The Remote Alarm Terminal Enclosure


Remote Communication Serial Port The IVT Oil Mist Generator is equipped with a serial data communication port (RS-422/485) that can be connected to a user furnished serial communication device. The data communication port will accommodate either a 2 wire RS-485 or 4 wire RS-422 configuration. For addition information on the serial port see Serial Data Port – RS-422/485 in the REMOTE COMMUNICATION AND ALARM section of this manual.

WARNING: Ensure that all previously connected sources of electrical power are disconnected before opening the ac power enclosure and attempting to connect to the remote alarm contacts.

WARNING

WARNING: Ensure that source power for the remote alarm circuit is disconnected before attempting to connect the remote alarm signal. WARNING

Terminal connections for RS-422/485 serial port in the NEC version of the Model IVT Oil Mist Generator are located in the low voltage controller enclosure. 1. To access the controller enclosure, open the mechanical access door on the left side of the

IVT console cabinet. Inside the mechanical compartment and located above the reservoir are two electrical control enclosures. The electrical enclosure located to the right is the controller enclosure. Conduit is provided inside the mechanical compartment for the users wiring. The conduit connects the external remote alarm connection and the controller enclosure.

2. Open the controller enclosure. Locate the I/O expansion board mounted on top of the main controller circuit board. The RS-422/485 data communication terminals are located on the expansion board, and are labeled TX-, TX+, RX-, RX+. Install the communication wiring through the conduit, and connect the circuit to the proper terminals.

3. Close and secure the controller enclosure door.

See page 97 for wiring instructions

RX+ RX- TX+ TX-

Locate The Controller Enclosure

Conduit For Wiring

Remote Alarm Connection ¾ Inch Conduit


Terminal connections for the remote alarm contacts in the ATEX version of the Model IVT Oil Mist Generator are located in a terminal enclosure located on the back of the IVT console cabinet. 1. To access the remote alarm contacts, find the two terminal enclosures mounted on the rear

of the IVT console cabinet. The terminals for connecting to the remote alarm are located in the lower enclosure.

WARNING: Take care to ensure that you are accessing the correct enclosure. Failure to do so may result in serious injury or damage to equipment.

WARNING

2. Locate the lower enclosure and remove the cover. Install the alarm wiring through the conduit, and connect the circuit to the proper terminals.

3. Close and secure the remote alarm circuit enclosure cover.

See page 97 for wiring instructions

TX+ TX- RX+ RX-

4 = RX- 5 = RX+ 6 = TX- 7 = TX+

Locate The Remote Alarm Terminal Enclosure


Oil Reclamation Unit If the LubriMist® system being installed utilizes the patented LubriMist® Closed Loop technologies, the optional IVT Oil Reclamation unit will be included as part of the purchased package. The oil reclamation unit is located on the rear of the IVT oil mist generator cabinet. The Oil Reclamation unit is equipped with an electric motor driven coalescer. A separate electrical motor control circuit must be supplied and installed by the user. Reference the Model Code Designation Key for available motor voltage options. The Oil Reclamation unit is also equipped with a high level switch. The high level switch is wired to the main oil mist generator controller and provides a local and unit alarm should a high level condition occur. When a high level condition occurs, the controller 24 VDC output signal is de-energized (1 amp max). LSC recommends that the user provide and install a motor interlock to break electrical power to the coalescer motor when a high level condition occurs. Follow these steps to complete the IVT installation when the Oil Reclamation option is included as part of your package.

IMPORTANT: Ensure that the motor control system has been installed according to all local codes and standards. Only a qualified electrician or other authorized person should make installation.

IMPORTANT: All customer furnished motor contactors must include motor overload and thermal protect devices.


Installation instructions for Oil Reclamation units in NEC and ATEX Model IVT Oil Mist Generators

For NEC Constructions 1) Ensure that the return mist header is properly installed and connected to the return mist

connection. The return oil mist connection is a 2-1/2 inch 150# RF ANSI flange. The mating flange, gasket and bolting are mounted to the return mist connection and shipped with the unit.

2) Locate the high oil level overflow connection located on the right side of the reservoir. Connect the oil over flow connection to a suitable drain. The connection size is ¾ NPT.

3) Connect the electrical motor to an appropriate motor control circuit. A motor circuit interrupt should occur when a high level alarm in the Oil Reclamation reservoir occurs. A user furnished local emergency disconnect switch should also be installed adjacent to the oil mist reclamation unit. a) Power connection to the electric motor is made at the motor terminal enclosure. Check

the motor nameplate or refer to specific motor vendor data provided separate from this manual to determine specific motor power requirements.

b) High level output terminals for the port in the NEC version of the Model IVT Oil Mist Generator are located in the low voltage controller enclosure. To access the controller enclosure, open the mechanical access door on the left side of the IVT console cabinet. Inside the mechanical compartment and located above the reservoir are two electrical control enclosures. The electrical enclosure located to the right is the controller enclosure. Conduit is provided inside the mechanical compartment for the users wiring. The conduit connects the external remote alarm connection and the controller enclosure. (Reference Remote Alarm Wiring for NEC version of Model IVT).

c) Open the controller enclosure. Locate the I/O expansion board mounted on top of the main controller circuit board. The interlock output signal terminals are located on the expansion board, and are labeled DO #4 - and DO #4 +. Install the motor interrupt wiring through the conduit, and connect the circuit to the proper terminals.

d) Close and secure the controller enclosure door.

Electric Motor

For NEC Constructions, Connect The Motor interlock Wiring To Terminal Numbers DO#4- and DO#4+

Connect ¾ Inch Overflow Connection To Drain

Connect Return Oil Mist Header To 2-1/2 Inch Return Connection

Remote Alarm Connection


For ATEX Constructions 1) Ensure that the return mist header is properly installed and connected to the return mist

connection. The return oil mist connection is a 2-1/2 inch 150# RF ANSI flange. The mating flange, gasket and bolting are mounted to the return mist connection and shipped with the unit.

2) Locate the high oil level overflow connection located on the right side of the reservoir. Connect the oil over flow connection to a suitable drain. The connection size is ¾ NPT.

3) Connect the electrical motor to an appropriate motor control circuit. A motor circuit interrupt should occur when a high level alarm in the Oil Reclamation reservoir occurs. A user furnished local emergency disconnect switch should also be installed adjacent to the oil mist reclamation unit. a) Power connection to the electric motor is made at the motor terminal enclosure. Check

the motor nameplate or refer to specific motor vendor data provided separate from this manual to determine specific motor power requirements.

b) High level output terminals in the ATEX version of the Model IVT Oil Mist Generator are located in the remote alarm terminal enclosure.

c) Open the controller enclosure. The interlock output signal terminals are located on the terminal strip, at terminal number 10 (DO #4 -) and terminal number 11 (DO #4 +).

d) Close and secure the controller enclosure cover.

For ATEX Constructions, Connect the motor interlock wiring to terminal number 10 (DO#4-) and terminal number 11 (DO#4+)

Connect ¾ Inch Overflow Connection To Drain

Electric Motor

Connect Return Oil Mist Header To 2-1/2 Inch Return Connection


COMMISSIONING

CAUTION: For ATEX construction IVT Oil Mist Generators equipped with either the Warm Ambient Option (Cabinet cooling) or Cold Ambient Option (Air Preheating and Cabinet Heating), refer to the respective start-up instructions prior to start-up. The interior of the cabinet must be conditioned prior to energizing the IVT Oil Mist Generator.


Bulk Oil Supply The LubriMist® IVT Oil Mist Generator has an integral 75-gallon oil supply reservoir. Prior to commissioning the system, the bulk oil reservoir must be charged with a fresh clean supply of oil. Oil may be pumped directly from drums or other bulk supply source through a supply hose. A clean 10-micron (nominal) oil filter should be used while filling the bulk supply reservoir. To fill the reservoir, follow these steps. Reference the diagram on the next page for clarification. 1) Fill the bulk oil reservoir

a) Open the operator compartment door. Verify that the Drain valves for the bulk oil reservoir, the main oil mist generator reservoir and the auxiliary oil mist generator are in the closed position. Valves are closed when their handles are rotated to the full clock-wise position. Valves should have drain plugs installed and secure.

b) Locate the bulk oil reservoir fill cap. The cap is located to the right of the spin-on oil filter. Loosen and unscrew the oil fill cap and set aside. Note that the cap is connected to the reservoir with a chain to discourage misplacing.

c) Check the end of the oil fill hose for contamination. Clean away any dirt and grit that may be in or on the hose end nozzle. Insert the hose into the fill connection and fill the reservoir. Initial fill should be a minimum of 55-gallon drum.

IF more than one 55-gallon drum of oil is used to fill the bulk oil supply reservoir, monitor the oil level gauge. DO NOT OVER FILL.

The reservoir will hold approximately 75 gallons maximum. Overfilling will result in oil overflowing out of the fill connection and onto the ground.

WARNING

d) Once filling is complete, remove the oil supply hose and reinstall the oil fill cap. The cap

is threaded and seals with an o-ring. Care should be taken to ensure proper thread alignment and engagement. The cap needs only to be firmly tightened by hand. The oil hose should be wiped clean and stored in a manor to avoid contamination. It will be needed in the future for refilling the oil reservoir.

Do not use pliers or any other hand tool to grip and tighten the oil fill cap. Tighten hand tight. DO NOT OVER TIGHTEN.

2) Prime the oil transfer pump. The oil transfer pump is pneumatically operated and must be

primed with oil. Before priming the pump check the spin on oil filter to ensure that it is tight. a) To prime the oil transfer pump, open the air supply valve (center) by turning the handle to

the full clock-wise position. b) Hold the air toggle valve in the OPEN position and adjust the air pressure regulator to

start the pump. The center regulator supplies air pressure to the oil transfer pump. As the air pressure increases the oil transfer pump will start to operate. The pumps operation will produce a “clicking” sound from within the IVT’s mechanical compartment. Once the pump is primed the cycle rate will suddenly decrease and slow down.

c) Once the pump has primed, hold down the air toggle valve and while adjusting the air pressure regulator, set the pump cycle speed between 160 and 200 cycles per minute. Maximum oil fill rate to the main oil mist generator is at 200 cycles per minute. Once the pump speed has been set, release the air toggle valve, leaving the air pressure setting as is.

Do not exceed 200 cycles per minute while priming or performing final adjustment of the pump speed. The maximum continuous pump speed is 200 cycles per minute. Over speed may damage the pump.

WARNING


Lubrimist

Remove The Fill Cap To Pump Oil Into The Bulk Oil Reservoir.

The Main Oil Mist Generator Reservoir Drain Valve Should Be Closed And Plugged Before Filling The Bulk Oil Reservoir.

The Bulk Oil Reservoir Drain ValveShould Be Closed And Plugged Before Filling The Bulk Oil Reservoir.

The Auxiliary Oil Mist Generator Reservoir Drain Valve Should Be Closed And Plugged Before Filling The Bulk Oil Reservoir.

Before Priming The Oil Transfer Pump Ensure That The Spin On Oil Filter Element Is Tight.

Place Air Block Valve In The OPEN Position By Turning The Handle To The Full Clock-Wise Position

Use The Air Pressure Regulator To Adjust Pump Speed.

Hold The Air Toggle Valve OPEN To Manually Operate The Oil Transfer Pump

Commissioning The Bulk Oil Supply


Starting The Model IVT Oil Mist Generator CAUTION: For IVT Oil Mist Generators equipped with either the Warm Ambient Option (Cabinet cooling) or Cold Ambient Option (Air Preheating and Cabinet Heating) or the for ATEX constructions, refer to the respective start-up instruction prior to starting the IVT Oil Mist Generator. The interior of the cabinet must be conditioned prior to energizing the IVT Oil Mist Generator.

Prior to start-up recheck all connections and insure that all fittings are tight and electrical connections are properly made. Insure that the oil mist distribution system, reclassifies and application point connections, vents and drains are properly installed. Verify that the equipment and systems used to maintain the air supply is in proper working order and that these supplies are turned on at the unit air inlet connection. The LubriMist® Model "IVT" oil mist generator features a programmable solid state controller that monitors and controls operating variables. Pre-set factory values are preprogrammed and installed into the system both for control and alarm set points. No adjustments to the factory set points are necessary during start-up. See Reading Alarm And Control Set Points in the section titled OPERATING GUIDE for a listing of the factory default values for each operating variables. Start-up of the LubriMist® Model IVT is very simple and requires only a few operator initiated actions. The steps for starting-up of the Model IVT oil mist generator are: 1. Turn ON the inlet air supply. 2. Turn ON the electrical power. 3. Set the mist header pressure. 4. Depress the “CLEAR” key. These four steps are further discussed below: 1. TURN ON THE INLET AIR SUPPLY.

1.1. Locate the purchasers’ inlet air supply block valve installed in the supply instrument airline between the compressed instrument air source and IVT inlet air connection. The valve should be full opened position.

1.2. Open the door the IVT operator compartment. Locate and open the air block valves to the main oil mist generator. Valves are open when the handles are rotated to the full clock-wise position. Note that when the air supply is opened to the main oil mist generator, the mist outlet valve will automatically operate. The mist outlet valve is pneumatically operated and requires no operator action. The outlet to the main oil mist generator will be opened. The auxiliary oil mist generator outlet will be blocked. For additional information regarding the mist outlet valve operation, see Mist Outlet Switching Valve in the section titled AUXILIARY OIL MIST GENERATOR of this manual.

2. TURN ON THE ELECTRICAL POWER. Before turning on the electrical power, insure that all user provided connections are securely fastened and that covers to all electrical enclosures and junction boxes are tightly secured. Once the system's electrical power is turned on, the solid state control system will power up to monitor current operating conditions by interpreting peripheral input signals. As preset critical alarm conditions are cleared the solid state system controls all of the dependent power systems. The solid state control used in the IVT incorporates built-in safety cutouts for the power circuits (heaters and solenoids). When the power is first turned on, only the air solenoid will be energized to start the oil transfer pump. For a further discussion of how all of the unit alarms are interlocked and displayed see "LOCAL ALARMS, INDICATORS AND READOUT". The LubriMist® Model IVT oil mist generator is equipped with electrical devices that interrupt

the electrical power to either the main oil mist generator or the auxiliary oil mist generator. This commissioning procedure is to start the main oil mist generator. IMPORTANT: The LubriMist® Model IVT oil mist generator is equipped with electrical devices that interrupt the electrical power to either the main oil mist


generator or the auxiliary oil mist generator. THIS COMMISSIONING PROCEDURE IS TO START THE MAIN OIL MIST GENERATOR. Note that the power switch arrangements for the NEC and ATEX models are different. 2.1. Locate and energize the electrical power supply at the source. The supply circuit should

be protected with a suitable current limiting device for the service. For additional information regarding voltage and amperage ratings for the IVT Oil Mist Generator see Electrical Power Connection in the section titled INSTALLATION of this manual.

2.2. From the IVT operator panel, locate the power switch. • NEC models are equipped with separate ON – OFF power switches for the main and

auxiliary oil mist generators. The main oil mist generator power switch is located at the top of the panel, directly above the air supply block valve servicing the main oil mist generator.

• ATEX models are equipped with a three-position selector switch ( I-O-II ). The switch is located at the top of the operator panel. The switch center position is the OFF position ( I-O-II ). To energize the main oil mist generator the selector switch should be placed in the full counter clock-wise position. ( I-O-II )

2.3. Now turn on the power to the main oil mist generator. The air solenoid valve will open and start the oil transfer pump. The main oil mist generator reservoir will begin to fill with oil. The rising level in the reservoir can be monitored in the oil level gauge. The low oil level alarm will clear as the level rises above the oil reservoir low-level switch. The oil level will continue to rise until it reaches the pre-set operating control level switch. The air solenoid valve then de-energized once the level rises to the normal operating oil level. A fixed position level switch located in the main oil mist generator reservoir maintains this level.

3. SET THE MIST HEADER PRESSURE. Note that with the electrical power ON and no air passing through the system, the IVT controller indicates alarm conditions for: • Low regulated air pressure. • Low mist pressure. • Low air temperature. • Mist Density Also note that the air / oil heater is de-energized. The heater will not turn on until the low regulated air pressure alarm is cleared. This is to insure that airflow through the air heater is established before the heating element is energized. For a further information regarding all unit alarms and their set-points, see the section titled OPERATING GUIDE of this manual. 3.1. Find the display keypad located on the operator panel and locate the button labeled

"Mist Pressure". Depress the mist pressure button. The control system display now reads "Mist Pressure is 0".

3.2. From the IVT operator panel, locate the air pressure regulator for the main oil mist generator. It is located directly under the air block valve for the main oil mist generator. To increase the mist pressure, the knob on the air filter/pressure regulator is turned in a clockwise direction. To decrease the mist pressure, turn the knob in a counter clockwise direction. Depress the "Mist Pressure" key and monitor the mist pressure as air pressure regulator adjustments are made. Continue to make adjustments with the air pressure regulator until the proper mist pressure is achieved and maintained.

As the regulated air pressure increases and exceeds its low alarm set point the regulated air pressure alarm will clear and the air / oil heater energizes. The air temperature will increase to the normal heater control setting. If the supply air is cooler than the low temperature setting, the low air temperature alarm will clear as the air temperature rises above the low alarm setting.

Once the mist pressure is set, and the mist generator is operating, the mist density reading will increase and clear the low alarm condition. The mist density output reading increases as the oil flows through the heater manifold in air / oil heater and increases in temperature. For


additional information regarding adjusting the mist density, see the section titled CONTROLLING THE MIST.

4. DEPRESS THE “CLEAR” KEY

Once all of the alarms have cleared and normal operating conditions are maintained, use the "CLEAR" key on the control panel keypad to put the IVT Oil Mist Generator into the normal operating mode. Press the “CLEAR” key once to clear each of the alarm conditions that were logged during startup. Once all of the alarm messages have been cleared, press the “CLEAR” key once more to reset the status lights from fault (red-ON / green-OFF) to normal (red-OFF / green-ON). Your LubriMist® Model IVT Oil Mist Generator is now running and in full operation.

Lubrimist

NEC Power Switch Location

2) Turn ON The Main Oil Mist Generator Power Switch. The Auxiliary Power Switch Should Be In The OFF Position.

1) Turn ON The Air Supply To The Main Oil Mist Generator Air Block Valve

Operator Panel

3) Press “MIST PRES” To Monitor The Mist Pressure As The Air Pressure Regulator Is Adjusted To Proper Setting. 4) Press “CLEAR” To Clear All Alarm Messages. Press “CLEAR” To Reset The Unit Status Lights And Remote Alarm Contacts To Normal Operation.

3) Use The Main Oil Mist Generator Air Pressure Regulator To Set The Mist Pressure

ATEX Power Switch Location

2) Place The Three Position Selector Switch in the I-O-II.


Mist Density Sensor

Operation It is important to recognize that although any given output reading may correspond to a quantitative oil/air ratio, the oil mist sensor does not make a quantitative mass measurement of the amount of oil in the mist. The output signal range of 0-100% represents the ability of a light beam to penetrate the oil mist as it passes between a light source and a light detector. A mist density reading of ZERO indicates that no or very little mist is present; the light has easily reached the detector. As the oil/air ratio increases, the oil mist particles block the light from the detector causing a change in the mist density reading. When light can no longer penetrate through the oil mist particles and reach the light sensor, the monitor reads 100%. The mist density sensor detects and responds to changes in oil/air ratio. However, variations in oil type, grade, viscosity, and regulated air supply pressure to the mist generating head all influence the size of the mist particle created by the generator. This also affects the instrument reading. Other factors that effect particle size distribution and the mist density reading are oil temperature, air temperature and oil level. Before making adjustments, the IVT Oil Mist Generator should be in service and operating normally for a minimum of one hour prior to making sensitivity adjustments or changes in alarm set points. This period allows the oil output to stabilize and the mist sensor internal surfaces to become wetted with oil. Since the mist sensor does not measure the absolute quantity of oil in the mist, it is recommended that a “consumption test” be made if you are striving to achieve a specific oil/air ratio. Lubrication Systems Company recommends that the air oil ratio be adjusted to achieve an oil/air ratio of 0.65 cubic inches of oil / hour / SCFM airflow. For information regarding calibration services, contact Lubrications Systems Company.

Location Of The Mist Density Sensor The mist density is located on top of the bulk oil reservoir. See the product description for the mist density sensor.

Sensitivity Adjustments The mist density monitor is equipped with a user selectable sensitivity adjustment. This feature allows the instrument to adapt to a diverse range of lubricating oils and over a broad range of oil/air ratios. To access the sensitivity adjustment feature, remove the screw-on cover to the electrical enclosure of the sensor unit. Located adjacent to the wire terminals in the detector is a series of electronic dipswitches. Separate switches are provided for 1) low 2) medium and 3) high mist density settings. All units are shipped with the mid sensitivity switch (#2) in the “ON” position. Note the switch #4 interrupts power to the LED light array and should always remain in the ON position. After the IVT Oil Mist Generator has been commissioned and is operational, select a sensitivity setting to obtain a mist density reading of near 50%. Once the desired sensitivity setting has been selected, the IVT controller monitors adjustments or changes in the mist density.

#1 Low Mist Sensitivity Range #2 Mid Mist Sensitivity Range #3 High Mist Sensitivity Range #4 Power To LED Array

OFF Position ON Position


Commissioning Optional Equipment If your LubriMist® Model IVT Oil Mist Generator is equipped with any of the options outlined below, follow these instructions to commission each option.

Oil Reclamation Unit The IVT Oil Reclamation unit uses the compressed instrument air supply connected to the IVT Oil Mist Generator to operate the integral oil transfer pump. Additionally, a separate electrical motor power circuit must be installed to the electric motor. Prior to starting the Oil Reclamation unit, make the following pre-commissioning checks: • The Oil Reclamation unit requires that a separate electrical power and motor control circuit be

furnished and installed by the user. Ensure that the motor control system has been installed according to all local codes and standards.

• Ensure that the return mist header is properly installed and connected to the return mist connection.

• Check the oil reclamation unit reservoir drain valve and ensure that it is closed and the drain plug is secure.

• Open the air supply block valve to the IVT Oil Mist Generator Oil Reclamation unit. • Open the cabinet located on the left side of the Oil Reclamation Unit. Locate the air pressure

regulator. Using the air pressure regulator, adjust the regulated air pressure to 40 PSIG ( 2.7 Bar ). The oil pump should not start. Close and secure the cabinet door.

• Connect the users differential pressure gauge to the top of the reservoir. Once the Oil Reclamation Unit has been started, the by-pass air damper must be adjusted. (See figure below). A temporary user provided compound pressure gage, with an approximate range of 0.5 – 0 - 0.5 inches of water is needed to make this adjustment. It is recommended that a gauge similar to Dwyer Instruments model number 2301 Magnehelic Differential Pressure Gauge be used. A plugged ¼ NPT connection located on the top of the Oil Reclamation Unit reservoir is provided for making the temporary pressure gauge connection.

Open Air Supply Valve To Oil Reclamation Unit

Start Electric Motor Drive

Install Customers Pressure Gauge

Use Pressure Regulator To Adjust Air Supply Pressure To The Transfer Pump

Air Pressure Gauge Monitors Pressure To Transfer Pump

Ensure That The Drain Valve Is Closed And Plugged


To commission the Oil Reclamation unit A. Insure that the IVT Oil Mist Generator has been commissioned and operating so that the air

supply block valve to the IVT is in the full open position. B. Start the electric motor from the user supplied disconnect and motor control circuit. Check

electric motor rotation. Motor rotation must be counter-clock-wise when looking down at the fan. Disconnect all wiring and change if necessary.

C. Adjust the bypass damper to the correct position (1) The damper rotates in the bypass pipe on two pins set at 180° apart. The damper

position is locked and secured in position by lock nuts on each pin. The damper position is indicated by the orientation of the screwdriver slot in the end of the pins. When the slot is horizontal, the damper is in the closed position. When the slot is vertical, the damper is in the full open position.

(2) Locate and loosen both lock nuts. Using a flat blade screwdriver, adjust the bypass damper until the pressure gauge reads between –0.1 and zero inches of H2O.

(3) Tighten the lock nuts to secure the damper position. Remove the pressure gauge and reinstall the pipe plug.

The Oil Reclamation Unit is now operational.

Return Mist Connection

Adjust The Damper Until Pressure Is Set Between –0.1 And Zero Inches Of H2O

Screwdriver Slot In The End Of The Pin Indicates The Orientation Of The Damper


Cabinet Cooling For NEC Constructions The IVT Oil Mist Generator cabinet cooling system uses the compressed instrument air supply connected to the IVT Oil Mist Generator to operate. To commission the cabinet cooling system: A. Insure that the IVT Oil Mist Generator has been commissioned and operating so that the air

supply block valve to the IVT is in the full open position. B. Open the air supply block valve to the IVT Oil Mist Generator cabinet cooling system. C. Using the air pressure regulator, adjust the regulated air pressure to the vortex cold air

generator to 90 PSIG ( 6 Bar ). D. Ensure that the IVT Oil Mist Generator cabinet doors are closed and that the door latch is

secured in the closed position.

Adjust Pressure Regulator To Proper setting

Open Air Supply Block Valve

Pressure Gauge Monitors Pressure Setting


For ATEX Constructions The IVT Oil Mist Generator cabinet cooling system uses the compressed instrument air supply connected to the IVT Oil Mist Generator to operate. The ATEX construction is designed to meet specific operating ambient requirements. This option is included where the IVT is installed in conditions that are outside of the standard permissible operating ambient of –20C< AMBIENT < +40C. The permissible operating ambient for equipment including this option is –20C< AMBIENT < +45C. The IVT Oil Mist Generator should not be energized if the ambient conditions are outside of these permissible ambient temperature restrictions. To commission the cabinet cooling system:

CAUTION: Do not energize the IVT main or auxiliary oil mist generator prior to consulting and following these instructions on starting the IVT Oil Mist Generator cabinet cooling system – ATEX Construction.

A. Open the air supply block valve and check the regulated air pressure. Adjust the air pressure

regulator to 4.8 – 5.2 Bar (60-75 PSI). B. Turn the electrical power switch to the ON position. If the temperature inside of the cabinet is

greater than approximately 32C (90F), air will flow to the Vortex cooler and the cabinet will began cooling.

C. Find the thermometer that is located on the rear of the IVT cabinet and check the temperature inside of the cabinet. If the temperature reading is >+40C, allow the cabinet cooling system to reduce the internal cabinet ambient temperature to <+40C.

D. When the temperature inside of the cabinet is less than 40C, the IVT oil mist generator may be started. See Starting The Model IVT Oil Mist Generator.

E. Ensure that the IVT Oil Mist Generator cabinet doors are closed and that the door latch is secured in the closed position.

10109

889

111177

43

21

G55

G1

23

466

Adjust Pressure Regulator Setting Open Air Supply

Block Valve

Check Pressure

Turn the Electrical Power Switch to the ON position

Check Temperature


Air Purge The IVT Oil Mist Generator Controller Air Purge Assembly uses the compressed instrument air supply connected to the IVT Oil Mist Generator to operate.

To commission the cabinet cooling system:

A. Insure that the IVT Oil Mist Generator has been commissioned and operating so that the air supply block valve to the IVT is in the full open position.

B. Open the air supply block valve to the IVT Oil Mist Generator air purge system. C. Locate the airflow needle valve located at the base of the rotometer. Adjust the needle

valve until the ball float in the rotometer tube rises to approximately mid scale. D. Ensure that air is venting from the enclosure vent fitting, and that both electrical controller

enclosure doors are securely closed. E. Ensure that the IVT Oil Mist Generator cabinet doors are closed and that the door latch is

secured in the closed position.

Open Block Valve

Adjust Needle Valve (Located On Rotometer)

Check Air Flow Through Vent.


Air Pre-heater When installed, the Air Preheating option is an integral part of the Model IVT Oil Mist Generator and it is automatically controlled by the IVT solid-state control system. No additional user actions are required to start or commission the Air Pre-heater.

Cabinet Heating System - ATEX Constructions The IVT Oil Mist Generator cabinet heating system uses the radiant heaters located in the operator interface compartment and the mechanical compartment. See page 38 for a full description. This option is included where the IVT is installed in conditions that are outside of the standard permissible operating ambient of –20C< AMBIENT < +40C. The permissible operating ambient for equipment including this option is –40C< AMBIENT < +40C. The IVT Oil Mist Generator should not be energized if the ambient conditions are outside of these permissible ambient temperature restrictions.

CAUTION: Do not energize the IVT main or auxiliary oil mist generator prior to consulting and following these instructions on starting the IVT Oil Mist Generator Cabinet Heating System – ATEX Construction.

To commission the cabinet heating system: A. Locate the proper power switch located on the rear of IVT cabinet. Turn the electrical power

switch to the ON position. If the temperature inside of the cabinet is less than 10°C(50°F), the heaters will energize and begin warming the cabinet interior.

B. Find the thermometer that is located on the rear of the IVT cabinet and check the temperature inside of the cabinet. If the temperature reading is <-20°C (-4°F), allow the cabinet heating system to warm the internal cabinet ambient temperature to at least >-20°C before energizing the IVT Oil Mist Generator.

C. When the temperature inside of the cabinet has been heated to at least <-20°C (-4°F), the IVT oil mist generator may be started. See Starting The Model IVT Oil Mist Generator.

D. Ensure that the IVT Oil Mist Generator cabinet doors are closed and that the door latch is secured in the closed position.

Turn the power switch to the ON position to energize the Cabinet Heating System

Use the thermometer to monitor the cabinet temperature.


Auto Bulk Oil Fill The IVT Oil Mist Generator Auto Bulk Oil Fill system uses supply oil from a centralized bulk oil supply system connected to the IVT Oil Mist Generator to operate. To commission the Auto Bulk Oil Fill system:

A. Connect the Bulk Oil Supply at the block valve located at the rear of the IVT cabinet. B. Insure that the centralized bulk oil supply system has been commissioned and operating. C. Open the oil supply block valve to the IVT Oil Mist Generator auto bulk oil fill system. D. Open left cabinet door to the IVT. Locate the oil supply pressure gauge located next to

the solenoid operated oil valve. Adjust supply oil pressure to manufactures suggested pressure range insuring not to exceed 300 PSI (21 Bar).

E. Ensure that the IVT Oil Mist Generator cabinet doors are closed and that the door latch is secured in the closed position.

F. Oil filter element (P/N 77-500-487) should be changed on a semi-annually basis.

Open Block Valve

Check Supply Oil Pressure

Change Oil Filter Element Semi-Annually


OPERATING GUIDE


Operating The Control Panel

General Control Operation The IVT oil mist unit is controlled by a programmable solid-state controller. When power is supplied it first performs a self-diagnosis to ensure that the Operator Interface Keypad and Main Circuit Board are functioning properly. The IVT programmable solid-state controller is made up of the following components. 1. Liquid crystal display (LCD) which displays operating status and alarm variable values. 2. Keypad with 16 membrane-type buttons that allows the user to access variables and select

various aspects specific to the operation of the IVT Oil Mist Generator. 3. Light enunciators that show the status of each variable. Status is indicated as either in Alarm

or Normal condition.

Membrane-Type Buttons

Liquid Crystal Display

LED Light Enunciators

Keypad Buttons The 16 buttons located on the operator interface keypad perform the following functions: • AIR TEMP – When depressed this key displays, in real time (°F or °C), the air temperature as

it enters the vortex mist generator. This temperature is the temperature of the exiting air after heated by the air heater element.

• OIL TEMP - When depressed this key displays, in real time (°F or °C), the temperature of the oil contained within the 75 Gallon bulk oil storage tank.

• AMB TEMP - When depressed this key displays, in real time (°F or °C), the ambient temperature outside of the IVT console cabinet. The temperature sensor is located on the rear of the cabinet.

• OIL LEVEL – When depressed this key displays the oil reserve in the bulk oil reservoir (Gallon or Liter).

• SUP AIR PRES – When depressed this key displays inlet air pressure ( PSI or BAR ) being supplied to the IVT inlet air connection.


• REG AIR PRES – When depressed this key displays the air supply pressure ( PSI or BAR ) being supplied to the main oil mist generator.

• SUP OIL PRES – When depressed this key displays the oil transfer pump outlet pressure ( PSI or BAR ). When the pump is idol, the pressure is static.

• MIST PRES – When depressed this key displays IVT mist outlet pressure (In. H20 or m BAR). This is the pressure of the mist supply being discharged and distributed to user machinery.

• MIST DENS – When depressed this key displays a numeric value relative to the mist density (%).

• CLEAR – Used to clear an alarm condition or to return to run mode while in programming mode. Press after correcting an alarm condition. Pressing the CLEAR key once clears an alarm. Pressing the CLEAR key a second time clears the overhead status lights from red to green.

• TIME – When depressed this key displays the current date and time (HH:MM:SS - 24 hour). This key is also used during time editing.

• DATE – When depressed this key displays the current date and time (DAY:DATE:MONTH:YEAR). This key is also used during date editing.

• SET – Used to initiate an alteration to a set value for a variable or pre-programmed solvent setting.

• ENTER – Used to log altered set values for variables and options into Random Access Memory (RAM). Also used as a confirmation while navigating within the program.

• INC – Used to increase a value to be changed. This key can be toggled manually by pressing rapidly or automatically by holding down key.

• DEC – Used to decrease a value to be changed. This key can be toggled manually by pressing rapidly or automatically by holding down key.


Setting The Current Date The IVT solid-state controller has a 24-hour timer and year 2000 compatible date features. The current date format is displayed as DAY - DATE – MONTH – YEAR. The date may be adjusted while unit is in operation. The following are instructions for changing date settings. 1. Press the (a) DATE key (b) to display the current day of the week entered into the controller. 2. If the day and date displayed are not correct, (a) press the SET, (b) and DATE keys. (c)The

unit will read SET DATE and the date value currently entered. 3. Program cursor will be under the day, (a) use the INC and DEC keys to adjust. Once finished,

(b) press ENTER key. 4. Program cursor will be under the date, (a) use the INC and DEC keys to adjust. Once

finished, (b) press ENTER key. 5. Program cursor will now be under the month, (a) use the INC and DEC keys to adjust. Once

finished, (b) press ENTER key. 6. Program cursor will now be under the year, (a) use the INC and DEC keys to adjust. Once

finished, (b) press ENTER key. 7. Press ENTER once again to return program to run mode.

1(b). Date Value Is Displayed 2(c) Date Value Is Displayed 3 DAY Value Is Displayed 4 DATE Value Is Displayed 5 MONTH Value Is Displayed 6 YEAR Value Is Displayed

3(b), 4(b) 5(b) 6(b). Use the ENTER Key Input DAY – DATE - MONTH - YEAR Values Into Memory

2 (a) (b). Press SET And Date Keys To Enter Edit Mode

7. Press ENTER Key To Return To Run Mode

3(a), 4(a) 5(a), 6 (a). Use The INC and DEC keys to change Date Values

1(a). Press Date Key To Query Date


Setting The Current Time The IVT solid-state controller has a 24-hour timer and year 2000 compatible date features. The time is given in 24-hour military time format. The time may be adjusted while unit is in operation. The following are instructions for changing time settings. 1. Press the (a) TIME key (b) to display the current time entered into the controller. 2. If the time displayed is not the current time, (a) press the SET, (b) and TIME keys. (c)The unit

will read SET TIME and the existing time value currently entered. 3. Program cursor will be under the hour value, (a) use the INC and DEC keys to adjust. Once

finished, (b) press ENTER key. 4. Program cursor will now be under the minute value, (a) use the INC and DEC keys to adjust.

Once finished, (b) press ENTER key. 5. Press ENTER once again to return program to run mode. 6. To program time repeat steps 1 through 6. Press ENTER when finished

3(b), 4(b). Use the ENTER Key Input HOUR – MINUTE Values Into Memory

2 (a) (b). Press SET And TIME Keys To Enter Edit Mode

5. Press ENTER Key To Return To Run Mode

3(a), 4(a). Use The INC and DEC keys to change Time Values

1(a). Press Time Key To Query Time

1(b). Time Value Is Displayed 2(c) Time Value Is Displayed 3 HOUR Value Is Displayed 4 MINUTE Value Is Displayed


Reading Unit Operating Conditions Once the LubriMist® Model IVT has been properly installed and commissioned, current operating conditions of each operating variable can be prompted. Simply by pressing any system function key the operating variable and its current value will be displayed

2. Operating Condition And Value Is displayed

1. Press Any Function Key To Read Current Condition: • Air Temperature • Oil Temperature • Ambient Temperature • Oil Level (Bulk Supply) • Supply Air Pressure • Regulated Air Pressure • Supply Oil Pressure • Mist Pressure • Mist Density


Reading Alarm And Control Set Points In addition to being able to read existing operating conditions, the factory set alarm and control set points can also be prompted and displayed. The operating variables that are monitored have preset alarm set points for high and low limits. The air / oil heater and optional air pre-heater also have a control function to control air temperature. The systems control and alarm set point values are listed in the table below. Note that the main oil mist generator reservoir has a non-adjustable low oil level switch that provides an alarm when the oil level falls below the set level, however there is no programmable set point feature for this alarm.

Factory Default Set point Values Set Point Variable Imperial

Units Metric Units

Air Temperature - Control Set-point 120° F 49° C Air Temperature - High Alarm Set-point 140° F 60° C Air Temperature - Low Alarm Set-point 100° F 38° C Air / Oil Heater - High Temperature Cutout Set-point 150° F 65° C Supply Air Pressure - High Alarm Set-point 150 PSI 10.3 BAR Supply Air Pressure - Low Alarm Set-point 25 PSI 1.7 BAR Regulated Air Pressure - High Alarm Set-point 65 PSI 4.5 BAR Regulated Air Pressure - Low Alarm Set-point 10 PSI 0.7 BAR Supply Oil Pressure - High Alarm Set-point 150 PSI 10.3 BAR Supply Oil Pressure - Low Alarm Set-point 10 PSI 0.7 BAR Mist Pressure - High Alarm Set-point 30 In. H20 75 m BAR Mist Pressure - Low Alarm Set-point 10 In. H20 25 m BAR Mist Density - High Alarm Set-point 90 % 90 % Mist Density - Low Alarm Set-point 10 % 10 % Bulk Oil Reservoir Temperature - High Alarm Set-point 160° F 71° C Bulk Oil Reservoir Temperature - Low Alarm Set-point 10° F -12° C Bulk Oil Reservoir Level - High Alarm Set-point 75 Gallons 284 Liter Bulk Oil Reservoir Level - Low Alarm Set-point 10 Gallons 38 Liter Air Pre-heater Temperature - Enable Set-point 40° F 5° C Air Pre-heater Temperature - Control Set-point 60° F 16° C Air Pre-heater Temperature - High Alarm Set-point 80° F 27° C Air Pre-heater Temperature - Low Alarm Set-point 30° F -1° C Air Pre-heater – High Temperature Cutout Set-point 100° F 38° C

The factory default control and alarm set points for the operating functions listed above can be prompted and displayed for review. The first step is to identify which function the controller is to display. To view the variable control and alarm set point values follow these steps. 1. Press the SET key. 2. Press the <FUNCTION> key that is to be viewed. 3. Use the ENTER key to toggle through the control-high-low -cutout set point values for each

operating variable. Note that as the set point variables are scrolled, a message is displayed to alert the operator that set point adjustments are not allowed.

4. After the last set point value is displayed for the specified operating variable, press ENTER to return the screen to normal view.

The controller continues to monitor and control normally while doing set point queries. To change the factory default control and alarm set point values see Programming User Established Alarm And Control Set Points in the section titled OPERATING GUIDE of this manual.


The following diagrams illustrate the proper key sequences for entering custom alarm and set point values. The diagrams use the following logic symbols.

This symbol is used to indicate the start and end of each key sequence. The following illustrations assume that key sequences are initiated and completed while the unit is operating normally. This symbol is used to indicate that the operating variable or message is being shown on the display. This symbol is used to indicate where the user requires an input operation. This symbol indicates where a decision is to be made. The question is indicated in the border of the symbol.

XXX

SET POINT ADJUSTMENTSNOT ALLOWED

PRESSENTER

PREHEAT STARTRUN MODEIN NORMALPROGRAM

(1)

(1)HAVE CONTROLDOES VARIABLE

NO

SET POINT

YESSET XXX

KEY<FUNCTION>

PRESS

PRESS

PROGRAMIN NORMALRUN MODE

SET KEY

<VARIABLE>

HIGH XXX<VARIABLE>

ENTERPRESS

NOT ALLOWEDADJUSTMENTSSET POINT

SET POINT ADJUSTMENTSNOT ALLOWED

PRESSENTER

ENTERPRESS


<VARIABLE>LOW XXX

<VARIABLE>ENTERPRESS


CUT-OUT XXX

SET POINT

DOES VARIABLE NO

YES

HAVE CUT-OUTPROGRAMIN NORMALRUN MODE

YES(2)

NO PROGRAMIN NORMALRUN MODESET POINT

HAVE START TEMPDOES VARIABLE

(3)

Notes 1. Applies Only To Air / oil Heater And Air PreHeater 2. Applies To Air Preheater Only 3. Use the AMBIENT Key To Check The Air Preheater Functions

RUN MODEIN NORMALPROGRAM

PRESS< function >

XXXSET <VARIABLE>

YES

NO

Sequence Diagram For Viewing Operating Variable Set Points


Programming User Established Alarm And Control Set Points The LubriMist® Model IVT Oil Mist Generator is shipped with standard preset values for each of the monitored variables. However user established control and alarm set points can be established to meet particular operating needs. To enter custom program values a selector switch located on the main control board must be in the proper position.

WARNING: Ensure that all previously connected sources of electrical power are disconnected before opening the ac power enclosure and attempting to toggle the program enable toggle switch.

WARNING

WARNING: Ensure that source power for the remote alarm circuit is disconnected before attempting to open the ac power enclosure. WARNING

he main control board is located in the low voltage controller enclosure. on the left side of the

2. closure. Locate the I/O expansion board mounted on top of the main

3. itch (6 switch

4. ith the retaining nuts. Close and secure the controller

5. values.

PORTANT NOTE: If the number 6 dip switch is moved to the UP position after

Check DIP switch setting before making set point changes Place #1 dip switch in the UP position to allow user established set points.

T1. To access the controller enclosure, open the mechanical access door

IVT console cabinet. In side the mechanical compartment and located above the reservoir are two electrical control enclosures. The electrical enclosure located to the right is the controller enclosure. Open the controller encontroller circuit board. The expansion board is mounted over the main control board using metal spacers. The left side is hinged and swings to the left. Remove the retaining nuts on the left side of the expansion board and swing it away from the main board. Locate the DIP switch package (red) on the main board. Place the #1 dip sw th

from the left) in the UP position. Re-secure the expansion board wenclosure door and the mechanical compartment door. Turn on the electrical power and remote alarm circuits.

The IVT will now accept custom control and alarm set point IMcustom alarm and / or set points have been entered, the program will revert back to the factory values. All custom values will be lost and must be reentered.


All user established set points are made with the key pad located in the operator compartment.

a

ly accept new values that are between the factory established high and low

suit operating variables.

User Defined Set Point Ranges

Once the program dip-switch is in the proper position, the operator has the ability to program new alarm and/or control set points. By pressing the proper function key sequence any of the control or alarm settings can be changed. Any number of operating variables may be changed, and theymay be addressed in any order. Exiting can be done at any time and will effect only those settings that have been "entered" while in the program mode. Pressing the ENTER key logsvalue into memory. The controller will onsettings. The programming mode therefore, allows the user to establish a narrower alarm band around a set point within the minimum and maximum allowable values. The following table lists the range within which the user can set limits to

Set Point Units Metric Units Variable USAir Temperature - 1 Control Set-point 00-150° F 38-65° C Air Temperature - High Alarm Set-point 120-170° F 49-76° C Air Temperature - Low Alarm Set-point 80-130° F 26-55° C Air / Oil Heater - High Temperature Cutout Set-point 130-180° F 55-82° C Supply Air Pressure - High Alarm Set-point 65-150 PSI 4.5-10.3 BAR Supply Air Pressure - Low Alarm Set-point 25-75 PSI 1.7-5.2 BAR Regulated Air Pressure - High Alarm Set-point 10-65 PSI 0.7-4.5 BAR Regulated Air Pressure - Low Alarm Set-point 10-65 PSI 0.7-4.5 BAR Supply Oil Pressure - High Alarm Set-point 130-150 PSI 9.0-10.3 BAR Supply Oil Pressure - Low Alarm Set-point 1-100 PSI 0.1-6.9 BAR Mist Pressure - High Alarm Set-point 3 70-60 In. H20 5-150 m BARMist Pressure - Low Alarm Set-point 10-25 In. H20 25-62 m BAR Mist Density - High Alarm Set-point 55-100 % 55-100 % Mist Density - Low Alarm Set-point 10-50 % 10-50 % Bulk Oil Reservoir Temperature - High Alarm Set-point 1 30-180° F 55-82° C Bulk Oil Reservoir Temperature - Low Alarm Set-point 0-80° F -17-27° C Bulk Oil Reservoir Level - High Alarm Set-point 50 s 1 r -75 Gallon 89-284 LiteBulk Oil Reservoir Level - Low Alarm Set-point 10-25 Gallons 38-95 Liter Air Pre-heater Temperature - Enable Set-point 15-40° F -9-5° C Air Pre-heater Temperature - Control Set-point 40-80° F 5-27° C Air Pre-heater Temperature - High Alarm Set-point 60-90° F 16-32° C Air Pre-heater Temperature - Low Alarm Set-point 20-50° F -7-10° C Air Pre-heater – High Temperature Cutout Set-point 80-100° F 27-38° C

o input a new set point, press the SET and appropriate key for the desired operating function.

new

y now be selected by pressing SET and the appropriate function key

ional.

TThe selected function will be displayed, giving the option to change the first variable or move to the next. If the "ENTER" key is pressed, the previously displayed function set point is not changed. Once the desired selection is made, use the “INC” and “DEC” keys to display thesetting and press "ENTER". Another set point variable maand proceeding as already described. Once all new set points have been entered, press the "CLEAR" key. Now all new settings reside in program memory and are operational. See "Reading Unit Operating Conditions" on how to verify that the new settings are now operat


IMPORTANT: All alarms, heaters and solenoids are fully operational while the controller is in "Program Mode". New values are not recognized until the new value is entered into memory by selecting the “ENTER” key.

The display changes to the next prompt message or normal screen only after the correct button is pressed. The run mode screen is displayed at any time by pressing the “CLEAR” button. The following diagrams illustrate the proper key sequences for entering custom alarm and set point values. The diagrams use the following logic symbols.

This symbol is used to indicate the start and end of each key sequence. The following illustrations assume that key sequences are initiated and completed while the unit is operating normally.

This symbol is used to indicate that an operating variable or message is being shown on the display.

This symbol is used to indicate where an input operation is required by the user.

This symbol indicates where a decision is to be made. The question is indicated in the border of the symbol.


PRESS< function >

XXXSET <VARIABLE>

YES

NO


SET KEY

ENTERPRESS

DEC KEY TOACHIEVE SETPOINT

PRESS INC &NO

NO


PRESSENTER

NO

PRESSCLEAR

YES

RUN MODE?TO NORMALRETURN

POINT

DEC KEY TOACHIEVE SET

NO

YES

HIGH TEMP XXXSET AIR HEATER

SET POINTCORRECT?

PRESS INC &

NO

ACHIEVE SETDEC KEY TO

POINT

NOENTERPRESS

PRESS INC &

ENTERPRESS

RUN MODEIN NORMALPROGRAMPROGRAM

IN NORMALRUN MODE

CORRECT?SET POINT NO

YES

CLEARPRESS

CUT OUTSET AIR HEATER

TEMP XXX


POINT

PRESS INC &

YES

YES

YES


TEMP XXXSET AIR HEATER


CLEARPRESS

SET POINTCORRECT?

KEYAIR TEMPPRESS

YES


CORRECT?SET POINT

SET AIR HEATERLOW TEMP XXX

RETURNTO NORMALRUN MODE?

CLEARPRESS


PRESS

Key Sequence Diagram For Setting Air / Oil Heater Set-point


YES

PRESSSET KEY

CORRECT?SET POINT

PRESSCLEAR


YES


AMBIENT / PRE HTR

SET PREHEATERTEMP XXX

KEY

PRESS

NO

NO

PRESSCLEAR

YES


YES

LOW TEMP XXXSET PREHEATER

SET POINTCORRECT?CORRECT?

SET POINT

SET PREHEATERHIGH TEMP XXX

YES

NO


POINT


YES

CLEARPRESS

NOENTERPRESSNO

POINTACHIEVE SETDEC KEY TO

PRESSENTER

NO PRESS INC & PRESS INC &


DEC KEY TOPRESS INC &

ACHIEVE SET

ENTERPRESS

POINT

NO

NO

PRESSCLEAR

YES

RUN MODE?

RETURNTO NORMAL

YES

SET POINTCORRECT?

TEMP XXXCUT OUT


PRESSENTER

DEC KEY TOPRESS INC &

POINTACHIEVE SET

SET PREHEATER

CLEARPRESS

YES

SET PREHEATERSTART TEMP XXX

ACHIEVE SETDEC KEY TOPRESS INC &


PRESSENTER

CORRECT?SET POINT

POINT

NO

Key Sequence Diagram For Setting Air Pre-heater Set-point


YES

NONO

YES

ENTERPRESS

HIGH XXX


PRESSCLEARCORRECT?

SET POINTRUN MODE?TO NORMALRETURN

POINTACHIEVE SETDEC KEY TOPRESS INC &

KEY

PRESS

SET KEYPRESS


<FUNCTION>

SET <VARIABLE>

SET <VARIABLE>

PRESS INC &DEC KEY TOACHIEVE SETPOINT

SET POINTCORRECT? CLEAR

PRESS

PRESSENTER

YES

NO

LOW XXX

For setting alarm set points for the following operating <FUNCTIONS>: 1. Oil Temp = Bulk Reservoir Oil Temperature 2. Oil Level = Bulk Reservoir Oil Level 3. Sup Air Press = Supply Air Pressure 4. Reg Air Press = Regulated Air Pressure 5. Sup Oil Press = Supply Oil Pressure 6. Mist Press = Mist Pressure 7. Mist Dens = Mist Density

Key Sequence diagram For Setting High And Low Set-points Of Variables Without Control Set-points


Special Key Pad Sequence Routines The following key sequences can be used to retrieve the information as shown in the table. KEY SEQUENCE DATA / INFORMATION DISPLAYED SET / CLEAR Initiates Oil Pump Operation After Low Oil Supply Pressure Alarm SET / DATE Set the DATE SET / ENTER Change Unit Number SET / TIME Set the TIME SET / SET / AIR TEMP Displays Inlet Air Supply Temperature SET / SET / CLEAR Clears the EVENT LOG SET / SET / DATE Clears the DATA LOG SET / SET / TIME Displays Number of DATA Entries In Memory SET / SET / ▲ Displays MB Bus Slave Count SET / SET / ▼ Displays Language – English of Spanish SET / SET / SET Displays IVT Program Version SET / PRE-HEATER Set Air PreHeater Settings SET / SET / AMB TEMP Displays Current Readings For Air PreHeater SET / SET / PRE-HEATER Displays Settings For Air PreHeater ENTER Displays Number of Events In The Event Log ENTER again Displays The Last Entry Made To The EVENT LOG ENTER again Displays Operating Conditions At The Last EVENT LOG Entry ENTER again Displays Cause Of The EVENT LOG Entry

Dip Switch Definition For Hard Program Options. The IVT has several program features that are hard program selectable. These program options are activated by use of a dipswitch package located on the main control board. The IVT Oil Mist Generator is shipped with the dip switches located in the proper positions for the option package being provided. The standard IVT Oil Mist Generator Console is shipped with dipswitches in the position highlighted in the table below. Note that the dipswitches are numbered 1 through 6 from RIGHT to LEFT. SWITCH NO

ORIENTATION FUNCTION

1 (“a”) OFF (up position) ON (down position)

Allows user established set points to be established User established set points will not be accepted in memory

2 (“b”) OFF (up position) ON (down position)

MODBUS protocol is not active at ComPort for remote communication. Serial port is active for Local PC access to Data and Event Logs. MODBUS protocol is active at ComPort for remote communication. Serial port is not active for Local PC access to Data and Event Logs.

3 OFF (up position) ON (down position)

Unit of measure for operating conditions are English Imperial units Unit of measure for operating conditions are Metric units


Select when the Air PreHeater option is included. Select when the Air PreHeater option is not included.


Select when the Oil Mist Reclamation option is included. Select when the Oil Mist Reclamation option is not included.


Restores all factory default set point values when powered up from OFF Retains all user established set point values when powered up from OFF

(a) For additional information see the section titled Programming User Established Alarm And Control Set Points


(b) For additional information see the section titled MODBUS COMMUNICATION


The main control board is located in the low voltage controller enclosure. 1. To access the controller enclosure, open the mechanical access door on the left side of the

IVT console cabinet. In side the mechanical compartment and located above the reservoir are two electrical control enclosures. The electrical enclosure located to the right is the controller enclosure.

2. Open the controller enclosure. Locate the I/O expansion board mounted on top of the main controller circuit board. The expansion board is mounted over the main control board using metal spacers. The left side is hinged and swings to the left. Remove the retaining nuts on the left side of the expansion board and swing it away from the main board.

3. Locate the dipswitch package (red) on the main board. Make changes by repositioning the dipswitch.

4. Re-secure the expansion board with the retaining nuts. Close and secure the controller enclosure door and the mechanical compartment door.

5. Turn on the electrical power and remote alarm circuits. The IVT will now accept the program option selected.

36 5 4

ONOFF

12

Dip Switches are located on the main system board.


LOCAL ALARMS, INDICATORS AND READOUT


LOCAL ALARMS, INDICATORS AND READOUT The LubriMist® Model IVT is equipped with sensors, which monitor different operating functions for the Main Oil Mist Generator. The operating status of each of these operating functions is enunciated in several different ways. These are:

<FUNCTION>

Green LED(normal)

Red LED (fault)

Display Message

1 Air Temperature. 4 4 4

2 Oil Temperature (Bulk Oil Reservoir). 4

3 Ambient Temperature. 4

4 Oil Level.(Bulk Oil Reservoir) 4

5 Low Oil Level (Mist Generator Reservoir) 4 4 4

6 Supply Air Pressure. 4 4 4

7 Regulated Air Pressure. 4 4 4

8 Supply Oil Pressure. 4 4 4

9 Mist Pressure. 4 4 4

10 Mist Density 4 4 4

11 High Oil Level, De-misting Reservoir 4

12 Air Pre-heater Temperature 4

The signal from the level switch and nine standard / two optional sensors is fed into conditioning circuits of the controller. The conditioning circuit signal is interpreted and scaled by the program to produce gauge values. See "Reading Unit Operating Conditions" on how to check operating conditions. The program performs an ordered series of control set point checks for the maximum and minimum values of each monitored function. If the current value exceeds a maximum setting (high alarm) or is less than a minimum setting (low alarm), the IVT controller recognizes the fault condition and locally identifies the alarm. The Model "IVT" locally identifies and indicates a fault condition in three ways. They are: 1) individual panel indicators, 2) fault message readout on the liquid crystal display and, 3) red and green externally mounted unit status lights.


LED Panel Indicator Lights

Red and green enunciator lights are provided to indicate the operational status of all operating variables. When the green LED is illuminated normal operation is indicated. The red LED indicates a fault or system failure. Enunciators are provided for air temperature, oil level (main oil mist generator reservoir), supply air pressure, regulated air pressure (main oil mist generator), oil mist pressure, oil supply pressure and mist density.

Liquid Crystal Display In addition to individual status indicators, the IVT controller utilizes a display to monitor an alarm condition. The display is directly above the local panel alarm indicators. See Item 2, Figure 17. When an operating variable reaches an established gauge alarm setting, the alarm function is identified on the display. Provided there is only one alarm condition the controller will identify the current alarm. When the alarm condition is corrected and normal operation resumes, the display will continue to identify the alarm until the display is cleared. This feature is very important in identifying trouble alarms that may fluctuate between normal and alarm condition.

Red And Green External Status Lights LubriMist® Model IVT is equipped with large, highly visible red and green lights that show normal operation (green) or indicate when an alarm has occurred (red). The unit status lights change from green-on to red-on if any alarm condition is detected. The lights remain red-on / green-off until the CLEAR key is pressed twice and all settings are back to normal. Pressing the CLEAR key the first time clears the alarm message. Pressing the CLEAR key a second time reset s the status lights from red-on / green-off to green-on / red-off.

When changing the light bulbs in the RED and Green status lights, ensure that proper replacement bulbs are used. FAILURE TO DO SO MAY CHANGE THE TEMPERATURE CLASSIFICATION AND RESULT IN A HAZARDOUS CONDITION FOR CERTAIN EXPLOSIVE GAS GROUPS.

WARNING

Lubrimist

Green And Red Unit Status Lights

Green LED’s Indicate Normal Condition

Red LED’s Indicate Fault Operation

Liquid Crystal Display Identifies Any Fault Condition And The Current Operating Condition.


Event Log The IVT controller compiles a listing of occurring events and logs them chronologically in an event log. The log maintains in memory up to sixty-three events, adding the most recent and dropping the most aged event once 63 events have been recorded. The type of occurrences recorded in the event log are: 1. Exceeding any high or low alarm set point for any monitored variable. 2. Changing any control set point for any controlled variable. 3. Changing any alarm set point (high or low) for any alarm variable. 4. Resetting or clearing alarm conditions 5. Application of power / Reset - interruption of power 6. Resetting the clock or date 7. Clearing the Event / Alarm Log 8. Refilling the bulk oil reservoir Follow these steps to access and query Event / Alarm Log information from the main oil mist generator keypad. 1) From the normal operating screen on the display press the ENTER key. The LCD will display

a message that reads “EVENT / ALARM LOG” to confirm that the event log has been accessed. The number of events contained in the log will also be displayed.

2) After approximately 3 seconds the screen will automatically display the most recent event. Note that a number is indicated in the lower right corner of the display. This number identifies the order of occurrence. An event numbered as #16 occurred after the previous event numbered #15.

3) The INC and DEC keys can be used to quickly scroll through the events in order of their occurrence.

4) When any recordable event occurs, specific operating data is recorded in the EVENT / ALARM LOG. a) To access operating data at the time of the recorded event press the ENTER key. The

LCD screen once again displays the event number and the time of day that the event occurred. Also displayed is the date the event occurred.

b) Conditions for select system variables are also recorded as each event is recorded. By once again pressing the ENTER key the screen displays select system operating values valid at the time the queried event occurred. Note that the values are not labeled, however they are displayed in a specific order and location on the LCD. The diagram below shows the location for the value of each system variable.

AA = Air Temperature BB = Ambient Temperature CC = Bulk Oil Reservoir Level DD = Supply Air Pressure EE = Regulated Air Pressure FF = Supply Oil Pressure GG = Mist Pressure HH = Mist Density

_ AA __ BB __ CC __ DD _ _ EE __ FF __ GG __ HH _

c) Pressing the ENTER key returns the screen to the event identification screen (step 2). When any event number is being queried, using the ENTER key displays in circular order the event identification screen, the time and date screen system variable screen.

5) From any screen in the event log, using the INC and DEC keys scrolls chronologically through the event log. As event numbers are scrolled the same screen is displayed.

6) To exit the event log mode press the CLEAR key once. 7) To clear the event log, press SET SET CLEAR. Once the data log is cleared data is not

retrievable.


REMOTE COMMUNICATION AND ALARM


REMOTE COMMUNICATION AND ALARM The LubriMist® Model IVT is equipped with an alarm contact and a RS-422/485 data communication terminal. Both can be connected a user provided unit status enunciator located at a remote location. The remote alarm contact is a dry FORM-C that can be used to operate remote annunciation to indicate a unit fault or loss of power alarm. The RS-422/485 is a serial data port, capable of transmitting at a baud rate up to 19200 bits per second.

Remote Alarm Contact A basic on-off closure from the dry FORM-C contact can be connected to a user provided alarm. A user furnished power source must be connected to the common terminal to power the alarm enunciator. The relay contact is part of the same hermetically sealed relay that operates the red and green unit status lights. Each time the unit status lights operate so do the remote alarm contacts. These contacts are located inside of the AC power enclosure located in the left side of mechanical compartment. See Remote Communication And Alarm Connections in the INSTALLATION section of this manual for terminal location and connection information.

WARNING: TO AVOID RISK OF EXPLOSION HAZARD, REMOTE ALARM ELECTRICAL POWER CIRCUITS SHOULD BE NONINCENDIVE

WARNING

The alarm relay contact arrangement in the diagram below is shown in the shelf position. The relay is normally energized and de-energizes to alarm.

The Normally Closed Contact OPENS When The IVT Is Operating Normally. Contact CLOSES at Unit Fault

The Normally Open Contact CLOSES When The IVT Is Operating Normally. Contact OPENS At Unit Fault.

The User Power Source Is Connected To The Common Terminal


Serial Data Port – RS-422/485 The IVT Oil Mist Generator is equipped with a serial data port (RS-422/485). See Remote Communication And Alarm Connections in the INSTALLATION section of this manual for terminal location and connection information. This data port conforms to EIA-485-A and EIA-422-B specifications for balanced data transmission. The RS-422/485 serial port will accept either a two wire or four wire configuration and operate in either single or Tristate mode. The port will support baud rates as high as 19200 baud and. See details below for wire connections.

RS-422/485DATA COMMAND SERVERCOMMUNICATON PORT

2 WIRE CONFIGURATION

R X -

R X +

T X -

T X +

RS-422/485DATA COMMAND SERVERCOMMUNICATON PORT


T X +

T X -

R X +

R X -

OIL MIST GENERATOR

COMMUNICATON PORT

R X +

R X -

T X +

T X -

MODEL IVT

COMMUNICATON PORT

OIL MIST GENERATOR

T X -

T X +

R X -

R X +

MODEL IVT


Connecting To A Personal Computer (PC) The serial communication port can be connected to the serial port of most personal computers or other serial Data Communication Equipment. An RS-232 RS-422/485 interface converter may be required to link to the IVT communication port. Where an RS-232 RS-422/485 interface converter is used, it must be installed in a safe (non-hazardous) location. For RS-422/485 terminal locations, see Remote Communication And Alarm Connections in the section titled INSTALLATION of this manual.

PERSONAL COMPUTER

PERSONAL COMPUTER

R X +

R X -

T X -

T X +

R X +

R X -

T X +

T X -

NON-HAZARDOUS AREA

INTE

RFA

CE

CO

NVE

RTE

R

RE-

232

<-->

RS-

422


R X -

R X +

T X -

T X +

NON-HAZARDOUS AREA

RE-

232

<-->

RS-

422

INTE

RFA

CE

CO

NV

ERTE

R


R X -

R X +

T X -

T X +

COMMUNICATON PORT

OIL MIST GENERATORMODEL IVT

OIL MIST GENERATOR

COMMUNICATON PORTMODEL IVT


Data and Event Log Within the operating program of the IVT controller, the microprocessor polls all operating variables at a specified time interval. All input signals are then scaled according to the selected unit of measure and then posted into the Data Log. As data is posted and accumulated, the result is a historical record of how the IVT Oil Mist Generator operated over the time. Once the data table is full, the most aged record is dropped and the most recent record is added. The data log contains a maximum of 2043 records posted at one-hour intervals. The data log is accessible through the serial data port. Additionally, an Event Log is also generated and held in memory. The event log is a record of all alarms, adjustments and reset events. The all events are posted chronologically, and recorded with a date – time stamp. The event log is also accessible the serial data port. For additional information see Event Log in the section titled LOCAL ALARMS, INDICATORS AND READOUT. The IVT data communication port transmits an ASCII data string when an address character is received. The address to send characters are as follows. 1. To transmit the EVENT LOG, send address character “e” to RX input 2. To transmit the DATA LOG, send address character “d” to RX input

Personal Computer Communication Software This instruction uses Microsoft® Windows 95 / 98, HyperTerminal® as a help example to access and down load the DATA LOG and EVENT LOG from the IVT Oil Mist Generator. We have selected HyperTerminal® because of its wide use and availability. Other communication software is available, however the user must determine its use and compatibility. Lubrication Systems Company does not endorse the use of Microsoft® HyperTerminal®. To connect to a PC using HyperTerminal®: 1. Using Windows 98 select the START, PROGRAMS, ACCESSORIES, COMMUNICATIONS,

HYPERTERMINAL folder. From within this folder select HYPERTERM.EXE file.

From HyperTerminal Folder Execute The HyperTerminal.EXE File.


2. The program will ask you to the name your new connection. This connection should be

descriptive to the area where your IVT is installed. Hyper terminal will also ask you to choose an icon for your connection name. Once a file name and icon have been selected, press “OK”.

c) Select OK

b) Select An ICON

a) Name Your New Connection The Name Should BE Descriptive So That It Can Easily Recognized.


3. Hyper terminal will now setup the connection. Select the appropriate communication port by

selecting from the Connection Using pull down menu. Select Direct to COM1, COM2, or COM3 depending on which communication port you are connected to.

a) Identify The Communication Port That The IVT Oil Mist Generator Is To Be Connected To.

b) Select OK

4. Hyper terminal will now setup the communication port. Make the following selections as listed below. Bits per second: 9600 Data bits: 8 Parity: None Stop bits: 1 Flow control: None Select OK when finished.

a) Set Up The Communication Port

b) Press OK


5. Now it will be necessary to edit the properties of this connection. From under the FILE menu, select PROPERTIES, and then select the SETTINGS tab. Click on the ASCII Setup button. Under the ASCII Receiving section deselect the Wrap lines that exceed terminal width box. Select OK when finished.

IMPORTANT: It is recommended that the connection setup be saved prior to importing data from the IVT Oil Mist Generator. This will ensure that the data is not duplicated and potential confusion is avoided. If either log is viewed prior to saving the setup, each time the connection is executed the data relevant on the setup date will always be displayed. By saving prior to capturing data, the all of the data viewed will be current as of the capture date.

f) Select OK

e) Select OK

d) Deselect “WRAP LINES THAT EXCEED TERMINAL WIDTH”

c) Click The ASCII SETUP Button

b) Select The SETTINGS Tab

a) Select PROPERTIES From Under The FILE Tab

6. Select the FILE – SAVE to save the setup connection. The connection will be saved and displayed at the main HyperTerminal screen according to the inputs that were defined at step number 2. HyperTerminal is now set up to receive the EVENT LOG and the DATA LOG for the IVT Oil Mist Generator.

HyperTerminal is now set up to receive the EVENT LOG and the DATA LOG for the IVT Oil Mist Generator.

Save the Connection Setup before retrieving data from the IVT Oil Mist Generator


7. The next step is to be able to save the data as a text file so that it can be imported into another file format. To accomplish this the data must be “captured”. From the HyperTerminal main screen, locate the connection icon and execute the file. Reference Step 2. To capture the data and save it as a text (.txt) file, under the TRANSFER menu select CAPTURE TEXT. Hyper terminal will ask you for a file name and location. Once selected, the capture heading located at the bottom of the screen will turn bold.

The EVENT LOG and the DATA LOG can now be transferred from the IVT Oil Mist Generator to the PC

d) The CAPTURE Heading Becomes BOLD

c) Press START

b) Enter A File Name And Location Where To Save The File

a) Under The TRANSFER Tab Select CATURE TEXT

8. From the PC keyboard, select the “E” key to view the EVENT LOG. To view the DATA LOG select the “D” key. The data will scroll onto the screen and be viewable from HyperTerminal. As the data is captured, it is also being saved to the file location established at STEP 7. When the HyperTerminal screen stops scrolling data, the log transfer is complete. When finished select TRANSFER, CAPTURE TEXT, STOP. The capture heading and the bottom of the screen will now turn a shaded color.

When finished select TRANSFER, CAPTURE TEXT, STOP.

Data Area Becomes Shaded After Text Capture Is Stopped

The captured LOG is now saved in the file named at STEP 6 and can be imported into different program formats for dissemination. Repeat STEPS 6 through 8 to capture separate data files for the EVENT LOG and the DATA LOG.


MODBUS COMMUNICATION


MODBUS COMMUNICATION The LubriMist® Model IVT is equipped with a Modbus interface and software to allow for sophisticated automatic data exchange with a host computer. The interface implements the standard Modbus protocol originally developed by Gould Modicon and widely used as a control and monitoring of automated equipment. Additional information on Modbus can be obtained at the Modbus User’s Webster (www.modbus.org). Detailed specifications for the Modbus protocol can be found at www.modicon.com/techpubs/toc7.html. Please note that the information contained in this section is not intended as a Modbus tutorial (refer to the above sources for such information) but explains in detail only those aspects that are particular to the IVT Oil Mist Generator. Also, the particular host computer, host computer software, and transmission medium. Please also note that the interface software used to communicate with the IVT Oil Mist Generator in this document uses Modscan, developed and distributed by Win-TECH. Modscan utilizes the standard Windows Multiple-Document-Interface, (MDI), architecture for displaying Modbus data to the user. Additional information on Modscan can be obtained at (www.win-tech.com). The Modbus interface uses the same data communications port described in Remote Communication And Alarm and much of the installation information is applicable.

Overview The Modbus feature allows the intelligent IVT controller to communicate in a sophisticated and automatic way with a supervisory or monitoring host computer. Modbus is a “master-slave” system. The IVT is designed to act as a “slave” with the host computer acting as the “master”. The host computer is responsible for initiating all communication with the slave. The slave is responsible for responding to the particular and varied requests sent by the master. Modbus is a very versatile communication protocol and the IVT implements a very rich set of Modbus features. All operating conditions of the IVT are available to be read via the Modbus. The usefulness and overall capability of the Modbus system depends mostly on the particular host computer and host computer software and the capabilities thereof. The following sections explain how to install and configure the Modbus feature and how it implements the particular functions of Modbus.

Installation Installing and configuring the Modbus feature must follow the steps outlined below and explained in the sections following.

1. Enable Modbus communication via the dipswitch. 2. Connect the IVT to the host computer through an RS232 RS422/485 converter. 3. Configure the Modbus feature via the IVT control panel. 4. Configure the Modbus software (Modscan) on the host computer.

Enable Modbus Communication DIP Switch To enable Modbus communication, dipswitch #2 on the main controller board must be placed in the DOWN position. (The UP position causes the IVT to utilize the serial port for the data and event logs. See Remote Communication and Alarm). The dipswitch is located on the main control board. To set the dipswitch, follow these steps: The main control board is located in the low voltage controller enclosure. 6. To access the controller enclosure, open the mechanical access door on the left side of the

IVT console cabinet. Inside the mechanical compartment and located above the reservoir are two electrical control enclosures. The electrical enclosure located to the right is housing the main controller board.

7. Open the controller enclosure. Locate the I/O expansion board mounted on top of the main controller circuit board. The expansion board is mounted over the main control board using


metal standoffs. The left side is hinged and swings to the left. Remove the thumbscrews on the right side of the expansion board and swing it away from the main board.

8. Locate the dipswitch package (red) on the main board. Place the #2 dipswitch (5th switch from the left) in the DOWN position.

9. Re-secure the expansion board with the thumbscrews. Close and secure the controller enclosure door and the mechanical compartment door.

10. Turn on the electrical power and remote alarm circuits. The IVT Modbus communication serial port is now enable.

Serial Data Port – RS-422 The serial communication port can be connected to the serial port of most computers or other serial Data Communication Equipment. An RS-232 RS-422/485 interface converter is required to link to the IVT communication port. The RS-232 RS-422/485 interface converter must be installed in a safe (non-hazardous) location. It is recommended using (B & B Electronics converter, Model 4WSD9R). Setup in RS-422 mode, ECHO OFF, For a 4 wire or 2 wire configurations. Refer to figures 1 and 2 below.

Connecting To The Host Computer (via 4 wire)

Figure 1

Connecting To The Host Computer (via 2 wire)

Figure 2


Configuring The IVT Oil Mist Generator A number of settings must be configured into the IVT Oil Mist Generator for Modbus communication to work properly. Most of these settings must also be configured into the software of the host computer, see Configuring The Host Computer. Before the configuration can begin, the following information will be needed:

• The particular Modbus slave address to be used by this IVT unit (a number from 1 to 247) • The mode to be used for communication (RTU or ASCII) • The parity to be used for communication (Even, OFF or Odd) • The serial speed to be used for communication (300, 1200, 2400, 4800, 9600 or 19,200

bps) It is recommended that this information be documented in a readily accessible location for future reference. Once this information is known, follow these steps to enter it into the IVT Oil Mist Generator:

1. Press the SET key followed by the ENTER key. 2. Press the ENTER key again to skip over the Unit Number (it does not affect Modbus

communication). The Unit Number should be used if there is more than one IVT connected to the same host computer.

3. The Modbus slave address should now be displayed (001 is the default). If it is not as desired, use the INC and DEC keys to adjust. Press the ENTER key to save the address. If there is more than one IVT connected to the host computer different slave addresses must be used.

4. The Modbus Transmission Mode should now be displayed (RTU and ASCII). If it is not as desired, use the INC and DEC keys to toggle the mode between RTU and ASCII. Press the ENTER key to save the mode. (RTU is the default and Recommended)

5. The Modbus Parity should now be displayed. If it is not as desired, use the INC and DEC keys to toggle the parity mode between Off, Even and Odd. Press the ENTER key to save the parity mode. (EVEN is the default and Recommended)

6. The Serial Speed should now be displayed. If it is not as desired, use the INC and DEC keys to select among the available speeds. Press the ENTER key to save the speed. (9600 Baud Rate is the default and Recommended).

The IVT Oil Mist Generator software is now ready to begin Modbus communication.

Configuring The Host Computer The host computer must be configured according to the specific instructions outlined below for the Modscan screen to send and receive data to the IVT Oil Mist Generator. (See Configuring The IVT Oil Mist Generator): Please note if another host computer Modbus software is to be used all settings must be the same in the IVT Oil Mist Generator as they are in the host computer. Failure to enter the correct parameters will cause a communications error.


Modscan Configuration Start Modscan program in the host computer. See Figure 1

Modscan screen

figure 1

1. The device ID in the Modscan screen has to be the same as the slave address in the IVT. (a) The device ID’s parameters are (1 to 247). (b) The IVT’s parameters are (001 to 247), Note 001 is the same as 1.

2. To set the rest of the parameters in the Modscan screen, click the connection button in the

menu bar and then click Connect. (Connection Detail screen) will appear, fill in all that apply. See Figure 2 Connect Using ----- Select port to be used. Configuration Baud Rate: 9600 --- set the same as IVT

Word length: 8 --- IVT’s default is 8 Parity: Even --- set the same as IVT

Stop Bits: 1 -- IVT’s default is 1


Connection Detail Screen

figure 2

• Hardware Flow Control (leave blank). • Click OK, the Modscan screen will appear and begin polling. • To stop polling click the disconnect button. See figure 3

The Modscan screen can be customized in many different configurations, but for the purpose of this document, only 2 will be covered.

1. Breakdown of each Function Code and it’s HEX Addresses. 2. Viewing the IVT’s values in real time.

Before number 1 can be analyzed, below is a brief description on the Function Codes and the HEX Addresses.

Function Codes There are the four Function Codes that are utilized by the IVT controller program. In that, there are 52 different parameters in the IVT program that can be read by Modscan. Each of the 52 parameters is broken down into their specific Function Codes (01---04). Function Code description Explanation 01 Coil Status has 6 Digital outputs 02 Input Status has 9 Digital inputs 03 Holding Register has 24 Setpoints 04 Input register has 13 Analog inputs To view a particular parameter or a range of parameters select the function code under the (MODBUS Point Type) in the Modscan screen. In the Address (HEX) box select the start address; in the length box select the amount of parameters to be polled. See figure 3


Note; for the purpose of this procedure assume that 0001 is used in the Address (HEX) box and 1 in the length box. Hex Address Base 16 (Hexadecimal) digits 0 thru 9 and A thru F. A represents 10, B represents 11, C-12, D-13, E-14 and F-15. Each number occupies a place value. When F is reached, the value goes to 0 and 1 is added to the next place value, so 10 would be 16 and so on. The original designers of Modbus used 1 as the starting value of Coils, Inputs and Registers, reserving 0 for another use. That is why in the procedure that follows, Address (HEX) 0001in the Modscan screen, will represent 00 in the message frame, 0002 represents 01, 0003- 02, 0004-03 and so on. Refer to figure 4.

Disconnect button

Address (HEX) & Length

Figure 3 Message frame In the Modscan screen there will be 2 sets of numbers in the shaded areas called the (Message Frame). The first set of numbers will be in a light gray area and the second set of numbers will be in a black area, these are the default colors for the Modscan screen. See figure 4

Address Hex Message

Frame

Figure 4 In the light gray area the host computer is sending a message to the IVT controller ([01] [01] [00] [00] [00] [01] [cd] [ca]). In the black area the host computer is receiving the response from the IVT controller ([01] [01] [01] [02] [d0] [49]). From the message frames and the different function codes that follow. Each set of numbers either sending or receiving has meaning. The message frames sent and received will be broken down in individual data groups to show what they mean.


Breakdown of each Function Code and it’s HEX Addresses Coil status: Function Code 01, this refers to the Digital Outputs on the IVT. For a description of the digital outputs refer to (Coil Status Addresses) below. Message frame being sent [01] [01] [00] [00] [00] [01] [fd] [ca] 1) Device I.D. in modscan screen has to be the same as the IVT location

2) In the Modscan screen MODBUS point type & Function code are the same thing.

3) Data sent out, consisting of address (hex) and length

4) Cyclical Redundancy Checking or CRC

[01] [01] ([00] [00]) ([00] [01]) [fd] [ca]

Address (HEX)

Length 1) Device I.D.--- [01] has to be the same as the IVT I.D. (also known as the Slave Address). 2) Modbus point type or function code ---- selecting 01 (Coil Status) from the Modscan screen will determine which values or parameters will be viewed. This is where the function code shows up in the message frame. 3) Data sent---will consist of 2 sets of data ([00] [00]), ([00] [01]), the first two sets of numbers [00] [00] are the address (hex), meaning (Mist tank level, Air heater, Air pre-heater, etc). Remember: In the Modscan screen Address (hex) 0001 means 00 in the message frame, 0002—01, etc. Only one output status value can be polled at anyone time using this format, to view a value, type in the address in the Modscan screen address (hex) box. See Coil Status addresses below. The second set of numbers [00] [01] are the (length). In Coil Status, only one value can be polled at a time, it is recommended to leave the length at 1 when working in Coil Status for this format. 4) Cyclical Redundancy Check--- CRC [fd] [ca], is a number assigned by the computer and cannot be changed by the user. Function code 01—in Modscan screen the address (hex) and the length cannot exceed 11 Or an error will occur in the receiving information from the IVT in the form of ([01] [81] [00] [40] [50]), the [81] being the error code. Coil Status Addresses;There are only 6 addresses (HEX) available in coil status. Address (HEX) Message frame address Description 01 = 00 --- Mist Tank oil Level Air Solenoid 02 = 01 --- Air Heater Element Control 03 = 02 --- Air Pre-heater Element Control 04 = 03 --- Demist Module Motor Starter 05 = 04 --- Overhead light 06 = 05 --- Bulk Oil Tank Fill Solenoid Message frame being received Coil Status, Function code 01, this data will come from the Digital Outputs of the IVT. ([01] [01] [01] [02] [d0] [49]). 1) Device I.D. in Modscan screen has to be the same as the IVT location

2) In the Modscan screen Modbus point type & Function code are the same thing

3) Data Received, consisting of length and the status being polled


[01] [01] ([01]) ([02]) [d0] [49]


The first two sets of numbers are the same as the previous. 1) The device ID (01) 2) The Function code (01). 3) Data Received---Has 2 sets of numbers a [01] and [02]. The [01] represents the number of bites of value status being received (black field), meaning for every single digit added to the length in the Modscan screen the value status received (black field) will increase by two, except in function codes 01 (Coil Status) and 02 (Input Status) in this format. Only one value can be polled at a time, so it is recommended to leave the length at 1 when working in Coil Status 01 in this format. The [02], is the value status of the address being polled. The status of the address being polled doesn’t necessarily mean it is going to come back in the form of a 1 or 0, on or off. It can also come back in the form of Odd # or Even #, but break down those numbers in binary form and they will be 1 or 0. From the IVT, here’s how it breaks down. Even # or O = N.O. normally open --- OFF Odd # or 1 = N.C. normally closed --- ON 4) Cyclical Redundancy Check--- CRC, is a number assigned by the computer and cannot be changed by the user. Input Status, Function Code 02, this data will come from the Digital Inputs on the IVT. For a description of the digital inputs refer to (Input Status Addresses) below. Message frame being sent [01] [02] [00] [00] [00] [01] [b9] [ca] 1) Device I.D. in Modscan screen has to be the same as the IVT location




[01] [02] ([00] [00]) ([00][01]) [b9] [ca] The first two sets of numbers are the same as the previous. 1) Is the device ID 01. 2) The Function code 02. 3) Data sent---will consist of 2 sets of data ([00] [00]), ([00] [01]), the first two sets of numbers [00] [00] are the address (hex), meaning (Loop back of digital outputs, Mist Tank Oil Level Sensor Switch, etc). To poll the value output status, type in the address in the Modscan screen address (hex) box. See Input Status addresses below. Remember: In the Modscan screen Address (hex) 0001 means 00 in the message frame, 0002—01, etc. The second set of numbers [00] [01] are the (length). In Input Status, only one value can be polled at a time, it is recommended to leave the length at 1 when working in Input Status for this format. 4) Cyclical Redundancy Check--- CRC, is a number assigned by the computer and cannot be changed by the user. Function code 02—in Modscan screen the address in HEX and the length cannot exceed 11 Or an error will occur in the receiving information in the form of ([01] [82] [00] [40] [a0]), the [82] being the error code.


Input Status Addresses;There are only 10 addresses (HEX) available in input status. Address (HEX) Message frame address Description

01 = 00 -- Loopback of digital output #1 02 = 01 --- Loopback of digital output #2 03 = 02 -- Loopback of digital output #3 04 = 03 --- Loopback of digital output #4 05 = 04 --- Loopback of digital output #5 06 = 05 --- Loopback of digital output #6 07 = 06 -- Not Used 08 = 07 --- Mist Tank Oil Level Sensor

Switch 09 = 08 --- Mist Tank Low Oil Level

Sensor Switch 0a = 09 --- De-Mist Tank High Oil Level Message frame being received Input Status, Function code 02, this data will come from the Digital Inputs from the IVT ([01] [02] [01] [80] [a0] [28]). 1) Device I.D. in Modscan screen has to be the same as the IVT location




[01] [02] ([01]) ([80]) [a0] [28] The first two sets of numbers are going to be the same as the previous. 1) Is the device ID 01. 2) The Function code 02. 3) Data Received---Has 2 sets of numbers a [01] and [80]. The [01] represents the number of

bites of value status being received (black field), meaning for every single digit added to the length in the Modscan screen the value status received (black field) will increase by two, except in function codes 01 (Coil Status) and 02 (Input Status) in this format. Only one value can be polled at a time, so it is recommended to leave the length at 1 when working in Input Status 02 in this format. The [80] is the value status of the address being polled. The status of the address being polled doesn’t necessarily mean it is going to come back in the form of a 1 or 0, on or off. It can also come back in the form of Odd # or Even #, but break down those numbers in binary form and they will be 1 or 0. From the IVT, here’s how it breaks down The status of components in the Input Status is the opposite of the Coil Status. Even # or 0 = N. C. normally closed or ON Odd # or 1 = N. O. normally open or OFF

4) Cyclical Redundancy Check--- CRC, is a number assigned by the computer and cannot be changed by the user.


Holding Register Function Code 03, Refers to the setpoints of the IVT For a description of the holding registers refer to (Holding Register Addresses) below. Message frame being sent [01] [03] [00] [00] [00] [01] [84] [0a] 1) Device I.D. in Modscan screen has to be the same as the IVT location




[01] [03] ([00] [00]) ([00][01]) [84] [0a] The first two sets of numbers are the same as the previous. 1) Is the device ID 01. 2) The Function code 03. 3) Data sent---will consist of 2 sets of data ([00] [00]), ([00] [01]), the first two sets of numbers [00], [00] are the address (hex). To poll a single value, type in the address in the Modscan screen address (hex) box. See Holding Register addresses below. The second set of numbers [00], [01] are the (length). In Function Code (03) the length can have up to 24 polling places, which will give a hex value of [18], in the sent message frame. Note: In order to poll all 24 Holding Register Address values, the length has to be set at 24 and the Address (HEX) has to be set a 1. The Holding Register Addresses can only be polled in consecutive order. Meaning either from the beginning of the string, anywhere in the middle or the end of the string can be polled. Trying to poll random Holding Register Addresses cannot be done. Example; (02 air temp., 07 supply air press., 09 reg. air press.), cannot be polled as a string. 2) Cyclical Redundancy Check--- CRC, is a number assigned by the computer and cannot be changed by the user. Function code 03—in Modscan screen the combined address HEX and the length cannot exceed 25 Or an error will occur in the receiving information in the form of ([01] [83] [00] [41] [30]), the [83] being the error code.


Holding Registers Addresses; Address (HEX) Message frame Address Description

01 = 00 --- LubriMist Unit Number 02 = 01 --- Air Temp. --- Control SP 03 = 02 --- Air Temp. --- High Alarm SPt 04 = 03 --- Air Temp. --- Low Alarm SPt 05 = 04 --- Air Temp. --- High Temp. Cutout SPt 06 = 05 --- Air Pre Heater Temp. --- Enable SPt 07 = 06 --- Supply Air Press. --- High Alarm SPt 08 = 07 --- Supply Air Press. --- Low Alarm SPt 09 = 08 --- Regulated Air Press. --- High Alarm SPt a = 09 --- Regulated Air Press. --- Low Alarm SPt b = 0a --- Supply Oil Press. --- High Alarm SPt c = 0b --- Supply Oil Press. --- Low Alarm SPt d = 0c --- Mist Press. --- High Alarm SPt e = 0d --- Mist Press. --- Low Alarm SPt f = 0e --- Mist Density --- High Alarm SPt 10 = 0f --- Mist Density --- Low Alarm SPt 11 = 10 --- Bulk Oil Reservoir Temp. --- High Alarm SPt 12 = 11 --- Bulk Oil Reservoir Temp. --- Low Alarm SPt 13 = 12 --- Bulk Oil Reservoir Level --- High Alarm SPt 14 = 13 --- Bulk Oil Reservoir Level --- Low Alarm SPt 15 = 14 --- Air Pre-heater Temp. --- Control SPt 16 = 15 --- Air Pre-heater Temp. --- High Alarm SPt 17 = 16 --- Air Pre-heater Temp. --- Low Alarm SPt 18 = 17 --- Air Pre-heater Temp. --- High Temp Cutout S.P.

Message frame being received Holding Register, Function code 03, Refers to the setpoints from the IVT ([01] [03] [02] [07] [cf] [fa] [20]). 1) Device I.D. in Modscan screen has to be the same as the IVT location




[01] [03] ([02]) ([07] [cf]) [fa] [20] The first two sets of numbers are going to be the same as the previous. 1) Is the device ID 01. 2) The Function code 03. 3) Data Received---Has 3 sets of numbers a [02] and a [07] [cf]. The first set of numbers [02] represent the number of bites of the value status being received (black field), meaning for every single digit added to the length in the Modscan screen two bites of data will be received, so if the length is 1 in the Modscan screen, a [02] is sent back in the message frame being received (black field). If the length in the Modscan screen were 2 the data sent back would be [04], if it were 3 then it would be [06] and so on. The second set of numbers is the value being polled in HEX, Example [07] [cf] in hex is 1999 in decimal, and this is the number identifier for that particular IVT. If the length were 2, in the Modscan screen, from the statement previous, the data received would be [07] [cf] [00] [78]. It would send back the first 2 sets of values in the Holding Registry from Address (HEX) 0001 which are (LubriMist Unit Number meaning [07] [cf] in HEX or 1999 in decimal, and Air Temp. Control Setpoint meaning [00] [78] in HEX or 120 in decimal. So if the length were set at 24, then all the values would be received from the IVT controller, in the black field. Refer to figure 5.


figure 5 4) Cyclical Redundancy Check--- CRC, is a number assigned by the computer and cannot be changed by the user. Note: The value cannot change in the Holding Registers unless the setpoints are changed in the IVT controller. Then the value will reflect in the Holding Registry.

Input Register Function Code 04, Refers to the analog inputs For a description of the input registers refer to (Input Register Addresses) below. In this example, Address (HEX) 0002 and a length of 1 are used. Note; The Air Pre-heater Enable temp. Address (HEX) 0001 is not always used in an IVT. So if it were used in the Input Register function code 04 below for this example an erroneous value of 65078 for the (Air Pre-heater Enable temp.), would be given. By using Address (HEX) 0002 Bulk Oil Reservoir Level, a reasonable value can be ascertained. Message frame being sent, [01] [04] [00] [01] [00] [01] [60] [0a] 1) Device I.D. in Modscan screen has to be the same as the IVT location




[01] [04] ([00] [01]) ([00][01]) [60] [0a] The first two sets of numbers are the same as the previous. 1) Is the device ID 01. 2) The Function code 04. 3) Data sent---will consist of 2 sets of data ([00] [01]), ([00] [01]), the first two sets of numbers [00] [01] are the address (hex). To poll a single value, type in the address in the Modscan screen Address (HEX) box. See Input Register addresses below. The second set of numbers [00], [01] are the (length). In the Function Code 04 the length can be up to 13, which will give a [0d] in the sent massage frame. (0d hex = 13 in decimal) Note: The length has to be a 1 in order to poll only 1 address. 4) Cyclical Redundancy Check--- CRC, is a number assigned by the computer and cannot be changed by the user. Function code 04—in Modscan screen the address HEX and the length cannot exceed 14. Or an error will occur in the message frame being received in the form of ([01] [84] [00] [43] [00]), the [84] being the error code.


Input Register Addresses Address (HEX) Message frame Address Description

01 = 00 --- Air Pre-heater Enable Temp. 02 = 01 --- Bulk Oil Reservoir Level 03 = 02 --- Ambient Temp. 04 = 03 --- High Air Temp. 05 = 04 --- Air Temp. 06 = 05 --- Mist Density 07 = 06 --- Mist Press. 08 = 07 --- Regulated Air Press. 09 = 08 --- Supply Air Press. a = 09 --- Supply Oil Press. b = 0a --- High Air Pre-heater Temp. c = 0b --- Bulk Oil Reservoir Temp. d = 0c --- Air Pre-heater Temp.

Message frame being received Input Register, Function code 04, this data will come from the IVT ([01] [04] [02] [00] [44] [b9] [03]). 1) Device I.D. in Modscan screen has to be the same as the IVT location




[01] [04] ([02]) ([00][44]) [b9] [03] The first two sets of numbers are the same as the previous. 1) The device ID 01. 2) The Function code 04. 3) Data Received---Has 3 sets of numbers a [02] and a [00] [44]. The first set of numbers [02] represent the number of bites of the value status being received (black field), meaning the length in the Modscan screen is 1 so a [02] is received in the message frame (black field). If the length in the Modscan screen were 2 the data received would be [04], if it were 3 then it would be [06] and so on. The second set of numbers is the value being polled in HEX, Example [00] [44] = 68 in decimal, this is value that’s received for the Bulk Oil Reservoir Level. (This would be in gallons) If the length were 2 in the Modscan screen and the starting HEX Address were 02, then from the previous statement. The data received would be [00] [44] [00] [46]. The first two bites of data [00] [44] bulk Oil Reservoir Level would have a decimal value of 68 in gallons and the second set of data bites [00] [46] would be the Ambient Temp. with a decimal value of 70 (this would be degrees in Fahrenheit). 4) Cyclical Redundancy Check--- CRC, is a number assigned by the computer and cannot be changed by the user.


Viewing the IVT’s values in real time.

To view the IVT’s values in real time from the message frame in the Modscan screen, click the Show Data button and then the Integer button in the Modscan screen. Refer to figure 6.

Integer Button

Show Data Button

Figure 6 Note, the Show data and the Integer buttons can also be established from the menu bar. Click setup and then highlight (Display Options) then place a check mark next to Show Data and Integer. When reading real-time values in the message frame area, its Hex Address will show up on the left side of the real-time values, which can be referenced to their descriptions from the previous sections. Refer to figure 7

Hex Addresses

Figure 7


Remember; the Hex Addresses can only be read in a string (Beginning, Middle or End). Warning; As in section (1), when placing values in the Address (HEX) and Length boxes in the Modscan screen, the values cannot exceed their specified limits for each function code. Function Codes 01 Coil Status----—----Address (HEX) and Length cannot exceed 11 or Modscan will stop receiving data and lock on to the previous values. 02 Input Status --------- Address (HEX) and Length cannot exceed 11 or Modscan will stop receiving data and lock on to the previous values 03 Holding Register---- Address (HEX) and Length cannot exceed 25 or Modscan will stop receiving data and lock on to the previous values 04 Input Register-------- Address (HEX) and Length cannot exceed 14 or Modscan will stop receiving data and lock on to the previous values

General Information All Modbus transmitted values consist of one or more 16-bit binary “words”. These are used in various ways to represent the particular item or value as determined by the message context. The format used for Coil Status or Input Status is explained first followed by that for Holding Registers or Input Registers. Coil Status or Input Status is transmitted in what is sometimes called a “packed-bit” format. This refers to the fact that the individual status values are “packed” into the individual bits of a larger 16-bit data word. Specifically, the individual bits are arranged in increasing numeric order, according to their data address, and starting at bit number zero.

High byte of 16-bit value Low byte of 16-bit value 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 S15 S14 S13 S12 S11 S10 S9 S8 S7 S6 S5 S4 S3 S2 S1 S0 S0 = Status bit transmitted with lowest address number … S15 = Status bit transmitted with highest address number Note that if a particular transmission request involves less than 16 individual status addresses, then the upper bits will be unused. The Modbus specification allows for many more than 16 status bits to be transmitted at one time using multiple 16-bit words but the IVT Oil Mist Generator has no need to ever transmit more than ten (10) at one time. Holding Registers or Input Registers are transmitted as 16-bit words with one analog numeric value per word. The format used is what is referred to as “twos-complement” integer form. Each 16-bit value is treated as a 15-bit integer with a 1-bit sign. This allows for the transmission of negative numbers for those registers that may need to represent values below zero. Fifteen integer bits plus sign allow for numeric values in the range –32768 to +32767.

High byte of 16-bit value Low byte of 16-bit value 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 S V14 V13 V12 V11 V10 V9 V8 V7 V6 V5 V4 V3 V2 V1 V0

V0 = Least significant bit (LSB) of 15-bit integer value V14 = Most significant bit (MSB) of 15-bit integer value S = Sign bit


These values are transmitted as “twos-complement” integer numbers. This is a standard method used in computers to represent signed integers. The following table shows how common values would be represented in twos-complement form.

16-bit Twos-Complement Representation Signed Decimal

Number Binary Decimal Hexadecimal -32,768 1000000000000000 32768 8000 -32,767 1000000000000001 32769 8001

-1 1111111111111111 65535 FFFF 0 0000000000000000 0 0000 1 0000000000000001 1 0001

32,766 0111111111111110 32766 7FFE 32767 0111111111111111 32767 7FFF

Although this representation may appear strange at first, it is useful and numerically correct because simple addition and subtraction yield correct results and it is the most commonly used format for that reason. The actual values transmitted for a given analog input or set point are an exact replica of what is seen on the control panel in the selected units (English or metric) with an implied decimal point where applicable. For example, those values with two digit positions to the right of the decimal point would be transmitted as a numeric value of one hundred times (100x) the reading seen on the control panel. So the value 123.45 would be transmitted as 12,345 and the host software will need to scale accordingly. Note that this only affects those data values representing metric units of Bars such as supply air pressure, regulated air pressure and supply oil pressure and their related high and low alarm set points. It does not apply to any values when using English units since all are displayed with no digits to the right of the decimal point.


BULK OIL SUPPLY RESERVOIR


Bulk Oil Supply Reservoir

General Description and Use: The IVT Oil Mist Generator console includes an integral bulk oil supply reservoir. As oil is consumed during the normal process of providing oil mist lubrication to the serviced equipment the volume of oil in the bulk oil reservoir will decrease. The decrease in volume is monitored in two ways. An oil level sight glass is located behind the front cabinet door. The operating level can easily be check and monitored from this location. Second, the bulk oil reservoir is equipped with an oil level transmitter that is interfaced with the IVT controller. Additional information on read outs and remote monitoring can be found elsewhere in this manual. .

Commission The Auxiliary Oil Mist Generator Before oil can be added to the bulk oil supply reservoir, the main oil mist-generating unit must be shut down and the auxiliary unit must be commissioned. This being because the air space above the oil levels in the bulk oil reservoir and the main oil mist generator is common. During normal operation, mist flows from the main oil mist generator into the bulk oil reservoir before exiting the IVT Oil Mist Console. This feature provides an oil mist purge on the bulk oil reservoir and keeping it clean. Instructions for changing from the main to the auxiliary oil mist generator can be found in the section of titled AUXILIARY OIL MIST GENERATOR.

Lubrimist

Bulk Oil Reservoir Fill Cap Oil Level Gauge


Adding Oil To The Bulk Oil Reservoir Once the main oil mist generator has been removed from service and the auxiliary oil mist generator has been started oil can be added to the bulk oil reservoir. Oil may be pumped directly from drums or other bulk supply source through a supply hose. A clean 10-micron (nominal) oil filter should be used while filling the bulk supply reservoir. To fill the reservoir, follow these steps.

a) Open the operator compartment door. Verify that the Drain valves for the bulk oil reservoir, the main oil mist generator reservoir and the auxiliary oil mist generator are in the closed position. Valves are closed when their handles are rotated to the full clock-wise position. Valves should have drain plugs installed and secure.

b) Locate the bulk oil reservoir fill cap. The cap is located to the right of the spin-on oil filter. Loosen and unscrew the oil fill cap and set aside. Note that the cap is connected to the reservoir with a chain to discourage misplacing.

c) Check the end of the oil fill hose for contamination. Clean away any dirt and grit that may be in or on the hose end nozzle. Insert the hose into the fill connection and fill the reservoir. Initial fill should be a minimum of 55-gallon drum.

While filling the bulk oil supply reservoir, monitor the oil level gauge. DO NOT OVER FILL.

The total reservoir capacity is approximately 75 gallons maximum. Overfilling will result in oil overflowing out of the fill connection and onto the ground.

WARNING

d) Once filling is complete, remove the oil supply hose and reinstall the oil fill cap. The cap

is threaded and seals with an o-ring. Care should be taken to ensure proper thread alignment and engagement. The cap needs only to be firmly tightened by hand. The oil hose should be wiped clean and stored in a manor to avoid contamination. It will be needed in the future for refilling the oil reservoir.

Take care when installing the oil fill cap. Ensure that threads are clean prior to installing. Take care to ensure that threads are started straight and that no cross threading occurs when installing. Do not use pliers or any other hand tool to grip and tighten the oil fill cap. Tighten hand tight. DO NOT OVER TIGHTEN.

Commission The Main Oil Mist Generator Once filling of the bulk oil reservoir is complete, remove the auxiliary oil mist generator from service and commission the main oil mist generator. Instructions for changing from the auxiliary to the main oil mist generator can be found in the section of titled AUXILIARY OIL MIST GENERATOR.


AUXILIARY OIL MIST GENERATOR


Auxiliary Oil Mist Generator

General Description and Use: The IVT Oil Mist Generator console includes an integral auxiliary oil mist generator. The auxiliary unit is provided for use when maintenance or repair operations are being performed on the main oil mist generator

IMPORTANT: The auxiliary oil mist generator is intended for intermittent use only. When operated for purposes other than to perform routine maintenance or repair of the main oil mist generator, it should be checked at the beginning of every shift for proper operation.

The auxiliary oil mist generator is operator accessible from the operator panel. The controls for the auxiliary oil mist generator are located on the right side of the operator panel. A separate electrical power switch is provided in the NEC configuration of the IVT Oil Mist Generator. In the ATEX version the three-position selector switch switches power from the main to the auxiliary oil mist generator. Reference the descriptions in the Operator Panel section of the PRODUCT DESCRIPTION for additional information. A low air pressure switch is located in the mechanical compartment. Mist pressure and reservoir oil level gauges are provided to locally monitor the mist pressure and reservoir oil level once the unit has been placed into operation. A plugged reservoir drain valve is provided for draining and cleaning the reservoir as needed. Just as the main oil mist generator, the auxiliary oil mist generator includes an integral air oil heater. The heater controls are accessible from the operator panel. Also located on the operator panel are two manually operated toggle valves for filling the auxiliary oil reservoir from the bulk oil supply tank.

Terminal Enclosure with Solid State Relays, Fuses and Terminal Strip

Air Pressure Regulator

Heater Controller

Air Block Valve

Air / Oil Heater and Mist Generator.

Mist Outlet Valve

Toggle Valves

Mist Pressure Gauge

Pop Off Valve

Oil Level Gauge Manual Fill Port

Plugged Drain Valve Regulated Air

Pressure Gauge Plugged Drain Valve

The Right side mechanical compartment encloses the air oil heater, the mist-generating head, the low air pressure switch and the air temperature sensors. The heater element is interlocked with the low air pressure switch and is inoperable if the regulated air pressure is less set less than 10 PSIG. This ensures that airflow is established before power is applied to the element. A regulated air pressure gauge is mounted on the mist generator head to indicate the regulated air pressure being supplied to the mist generator. A manual reservoir fill port and a non-adjustable pressure pop off valve are also provided. The oil mist discharge is automatically switched between the main and auxiliary oil mist generator as the air supplies are adjusted.


Auxiliary Oil Mist Generator Start-Up Using the auxiliary oil mist generator is made possible by following only a few simple steps. 1) Check the reservoir oil level and fill if necessary. The reservoir is normally filled from the bulk

oil reservoir using the air operated oil transfer pump. Filling the reservoir is accomplished by manually opening and holding BOTH toggle valves in the open position. The toggle valves have lever type handles with spring return. The valves will revert to the closed position if they are not manually held in the open position. This is to prevent inadvertent overfilling

IMPORTANT: The air supply valve to the auxiliary oil mist generator should be opened prior to filling the reservoir. This will operate the mist outlet valve and allow the air volume in the reservoir to vent through the mist outlet as the oil fills the reservoir space. Also ensure that the reservoir drain valve is closed and the plug secure.

Pulling UP or pressing DOWN on the valve lever opens the valves. The toggle valve located toward the left supplies air pressure to the oil transfer pump. The toggle valve located on the right opens the pump discharge to the auxiliary oil mist generator reservoir. Open and hold the air and oil toggle valves in the OPEN position. When the AIR toggle valve is opened, the transfer pump will start to operate and the oil passes through the oil filter. If the OIL toggle valve is not held in the open position, the oil pressure opens the check valve located on the main oil mist generator reservoir and begins to fill the main oil mist generator reservoir. When the OIL toggle valve is held in the open position, the check valve spring pressure forces the oil to flow through the Oil toggle valve to fill the auxiliary oil mist generator reservoir. While filling, monitor the oil level in the oil level gauge. The reservoir should be filled to approximately 2/3 full.

CAUTION: Do not overfill the auxiliary oil mist generator reservoir. An air space must be maintained above the oil level for mist generation and flow between the mist generator and the mist outlet. If your system includes auto drain legs allowance must be made to collect the return oil volume.

The oil transfer pump speed should be limited to approximately 200 cycles per minute. Adjusting the air pressure regulator to the oil transfer pump controls the pump speed. If the pump fails to operate, ensure that the air supply block valve is in the open position. Pump speed increases when the air pressure regulator knob is turned clock-wise. The pump speed decreases when the regulator knob is adjusted in the counter-clock wise direction. When the auxiliary oil mist generator is initially filled from a dry reservoir, the fill time to 2/3 full is approximately 10 minutes. The pump discharge rate at 200 cycles per minute is approximately 0.71 GPM (2.9 liters per minute).

Lubrimist

The Right Toggle Valve Opens Oil Flow Into The Auxiliary Oil Mist Generator Reservoir

Open The Auxiliary Oil Mist Generator Air Supply Block Valve Before Filling The Reservoir.

Use The Air Pressure Regulator To Limit The Oil Transfer Pump Cycle Speed To 200 Cycles Per Min.

Ensure That The Air Supply Block Valve For The Oil Transfer Pump Is In the Open Position

The Left Toggle Valve Controls The Air Supply To The Transfer Pump

Monitor Oil Level In The Oil Level Gauge. Fill To 2/3 Full.

Ensure That The Drain Valve Is Closed And Plugged.


IMPORTANT: The main oil mist generator may be allowed to continue to operate while the auxiliary oil mist generator is allowed to fill. If the main unit is allowed to operate, place the air pressure regulator for the auxiliary oil mist generator in the closed or full counter-clock wise position prior to opening the supply air valve. Failure to do so may result in a high mist pressure condition.

2) Turn OFF the electrical power to the main oil mist generator

a) The electrical power switch is located in the top of the operator panel. Separate power switches are provided for the main and auxiliary oil mist generators in NEC configured units. The main oil mist generator switch is located on the left side. Move the switch to the OFF position.

b) For ATEX configured units, power is supplied through a three-position selector switch. To turn power OFF to the main oil mist generator move the selector switch to the center position.( I O II )

3) Turn OFF the air supply to the main oil mist generator. a) Adjust the air pressure regulator to the closed position. Turning the adjustment knob on

the air pressure regulator in the full counter clockwise position places it in the closed position. The mist pressure will bleed to zero.

b) Close the air supply block valve to the main oil mist generator. If the air supply to the auxiliary unit is ON, the mist outlet valve will operate to close the mist outlet to the main oil mist generator.

4) Turn ON the air supply to the auxiliary oil mist generator and adjust the mist pressure. The air supply block valve must be in the open position. Turning the air pressure regulator adjustment knob makes adjustments to the mist pressure. Turning the knob in the clock-wise direction increases mist pressure. Turning it in the counter-clock wise direction decreases the mist pressure. Monitor the mist pressure gauge as adjustments are made. Normal mist pressure setting is 20 inches of water / 50 m BAR.

5) Turn ON the electrical power to the auxiliary oil mist generator a) The electrical power switch is located in the top of the operator panel. Separate power

switches are provided for the main and auxiliary oil mist generators in NEC configured units. The auxiliary oil mist generator switch is located on the right side. Move the switch to the ON position.

b) For ATEX configured units, power is supplied through a three-position selector switch. To turn power ON to the auxiliary unit move the selector switch to the right position.( I O II )

Once the auxiliary oil mist generator has been commissioned, check the air oil heater for operation and proper set point.

Operation Once the auxiliary oil mist generator has been placed in operation, maintenance and repair to the main oil mist generator can be performed. The main oil mist generator should be placed back in service as soon as possible. If the auxiliary oil mist generator remains in operation for an extended time period, it should be monitored to ensure that the oil level, air temperature and mist pressure is maintained. As oil is consumed, refilling the reservoir can be done with the unit in full operation by holding both toggle valves in the open position while monitoring the rising level in the oil level sight glass. Reference step no. 1 above.


Air / Oil Heater Operation And Temperature Adjustment. The auxiliary oil mist generator is equipped with an integral air oil heater. This is the same as the heater assembly installed on the main oil mist generator reservoir. A separate solid state controller controls the heater element for the auxiliary oil mist generator. See the section titled Auxiliary Oil Mist Generator in the PRODUCT DESCRIPTION section for further description of the heater and its controls.

IMPORTANT: The heater element controls are interlocked with the low air pressure switch. The heater remains inoperable until the regulated air pressure increases above 10 PSI. This is to ensure that airflow over the element has been established before electrical power is applied. To check the regulated air pressure, open the right side mechanical compartment door to view the regulated air pressure gauge. The gauge is mounted on the right side of the mist generating head body.

Readout and parameter management is performed through the LED display and membrane panel key switches. When the power is shut off, or in case of power failure, control parameters are saved in non-volatile memory. The components are specified for operation from –40 to +180° F / -40 to +82° C) The controller is a dual thermocouple unit with solid state relay voltage drive outputs for control and alarm functions. The control uses type K thermocouples. The temperature control thermocouple provides the signal for switching the electrical power via a solid state relay. A second type K thermocouple is used for a high temperature alarm and heater cutout.

Controller Operation The control begins operation as soon as power is applied and shows the process temperature display. The control output (SSR1) will be fully ON if the temperature of the control thermocouple (#1) is below the programmed bandwidth, fully OFF above the programmed bandwidth and proportional within the bandwidth. If the temperature of the cutout thermocouple (#2) is below the programmed cutoff Set-point, the cutout output (SSR2) will be ON. If the temperature of the #2 thermocouple is above the programmed cutoff Set-point, SSR2 will be OFF. If the temperature of thermocouple #2 falls below the programmed Low Alarm Set-point, the “Ξ” LED on the front panel will be illuminated. If either thermocouple sensor becomes open circuited, the display will read “EEEE” and both SSR outputs will be held in OFF until the problem is corrected. If the regulated air pressure switch contacts are OPEN (low pressure), the HEAT and CUTOFF outputs will be held OFF. When the regulated air pressure exceeds 10 PSIG, these outputs function normally.

Programming And Changing Set-points

The default control set point for the auxiliary air / oil heater is 120° F / 49° C. The high temperature cutout is preset at 140° F / 60° C. The low temperature alarm setting is 100° F / 38° C. All temperature settings can be viewed or changed by following the following procedure.

Push the SET key once. The display will show the current heater control Set point and the rightmost digit will display “1”. The Up and DOWN arrow keys will adjust the process control Set-point between the limits of 100 - 140° F / 38 - 60° C. Pushing SET again will advance to the next parameter, but if the key is not pressed for 10 seconds, the control will automatically return to the temperature display and control screen.


Push the SET key again. The display will show the current BANDWIDTH and the rightmost digit will display “b”. The UP and DOWN keys will adjust the bandwidth between the limits of 0.5 and 20.0° F / 0.3 – 11.1° C. Bandwidth is the effective gain of the controller. A small bandwidth will approach ON-OFF type control while a large bandwidth will accommodate thermal systems with more time lag. The factory set default is 0.5, however optimizing heater operation to suit site conditions may be done in the field. Pushing SET again will advance to the next parameter, but if the key is not pressed for 10 seconds, the control will automatically return to the temperature display and control screen.

Push the SET key again. The display will show the current temperature cutoff Set-point and the rightmost digit will display “2”. The UP and DOWN keys will adjust the temperature cutoff between the limits of 100° - 190° F ( 38° - 87° C ). Pushing SET again will advance to the next parameter, but if the key is not pressed for 10 seconds, the control will automatically return to the temperature display and control screen.

Push the SET key again. The display will show the current alarm Set-point and the rightmost digit will display “3”. The UP and DOWN keys will adjust the alarm Set-point between the limits of 60° - 100°F ( 16° - 38° C ). Pushing SET again will advance to the temperature display and control screen, but if the key is not pressed for 10 seconds, the control will automatically return to the temperature display and control screen anyway.

The air / oil heater will now resume control at the new control and alarm settings.

SET

Use SET Key To Navigate Between Screens

1 2

Illuminates When The Control Temperature Setting Is Being Displayed

Illuminates When The High Temperature Cutout Setting Is Being Displayed *

“ALARM” LED Illuminates 1) For High Temperature Alarm 2) For Low Temperature Alarm 3) When Setting Low Temperature

Setting In Program Mode.

In The Normal Mode, The Temperature Units Are Displayed F = Fahrenheit C = Celsius In Program Mode The Function Variable Is Displayed 1= Control Temperature Setting 2= High Temperature Cutout Setting 3= Low Temperature Alarm Setting b= Bandwidth Settings

Temperature Values Are Indicated On LED Readout

DOWN Key Decreases Values

UP Key Increases Values


Switching From The Auxiliary Oil Mist Generator To The Main Oil Mist Generator. Once the main oil mist generator has been serviced or repaired, it should be put back in service. 1) Turn OFF the electrical power to the auxiliary oil mist generator The electrical power switch is

located in the top of the operator panel a) Separate power switches are provided for the main and auxiliary oil mist generators in

NEC configured units. The auxiliary oil mist generator switch is located on the right side. Move the switch to the OFF position.

b) For ATEX configured units, power is supplied through a three-position selector switch. To turn power OFF to the auxiliary unit move the selector switch to the center position.( I O II )

2) Turn OFF the air supply to the auxiliary oil mist generator. a) Adjust the air pressure regulator to the closed position. Turning the adjustment knob on

the air pressure regulator in the full counter clockwise position places it in the closed position. The mist pressure will bleed to zero.

b) Close the air supply block valve to the auxiliary oil mist generator 3) Commission the main oil mist generator as described in the section titled COMMISSIONING

in this manual.

Mist Outlet Switching Valve The Model IVT Oil Mist Generator console is equipped with a pneumatically operated switching valve that automatically connects the mist outlet of either the main or auxiliary oil mist generator to the mist outlet pipe. When the air pressure is being supplied to the main oil mist generator the mist outlet is open to the main oil mist generator and closed to the auxiliary unit. When the auxiliary oil mist generator is operating the mist outlet valve automatically opens to the discharge of the auxiliary oil mist generator and blocks the outlet to the main oil mist generator. If air is being supplied to both the main and the auxiliary units, both outlet connections are open and both units discharge mist into the distribution header system.

IMPORTANT: The main and auxiliary oil mist generators should not be operated in parallel. The fail open design is intended to safe guard against unintentional improper switching between the main and auxiliary oil mist generator. Failure to properly follow instructions may result in a high mist pressure condition.


The valve uses the supply and regulated air pressure being supplied to the main and auxiliary mist generators to operate. The following operating sequence assumes the air block valves are closed and the air pressure regulator adjustments are at zero for both oil mist generators. 1) When the main oil mist generator air block valve is opened, the air pressure signal down

stream of the valve increases to the supply pressure setting (150 PSI maximum). Air pressure is applied to the bottom of the main air cylinder, moving the valve poppet UP, thus opening the mist outlet to the main oil mist generator. As the regulated air pressure setting increases, air pressure is applied to the top of the auxiliary air cylinder. The air cylinder moves the valve poppet to the auxiliary unit discharge DOWN and presses it against the seat.

AIR SUPPLYTO MAIN UNIT

AIR SUPPLY BLOCK VALVEMAIN OIL MIST GENERATOR

MAIN OIL MIST GENERATORAIR PRESSURE REGULATOR

MIST OUTLETFROM MAIN UNIT

INLET AIR

MIST OUTLET


2) When the auxiliary oil mist generator is put on line, the supply air pressure opens the outlet to

the auxiliary oil mist generator discharge and the regulated air pressure closes the discharge to the main unit.

TO AUXILIARY UNITAIR SUPPLY

AUXILIARY OIL MIST GENERATORAIR SUPPLY BLOCK VALVE

AUXILIARY OIL MIST GENERATORAIR PRESSURE REGULATOR

MIST OUTLETFROM AUXILIARYUNIT

MIST OUTLET

INLET AIR

3) If the block valves to both oil mist generators are inadvertently placed in the open position at

the same time, because the supply air pressures are higher than the regulated air pressures, both valve poppets move up to the open position.

MAIN OIL MIST GENERATORAIR SUPPLY BLOCK VALVE

AUXILIARY OIL MIST GENERATORAIR PRESSURE REGULATOR

AUXILIARY OIL MIST GENERATOR

MIST OUTLET

INLET AIR

AIR SUPPLY BLOCK VALVE

MAIN OIL MIST GENERATORAIR PRESSURE REGULATOR

FROM AUXILIARYUNIT

MIST OUTLETFROM MAIN UNITMIST OUTLET

TO AUXILIARY UNITAIR SUPPLYAIR SUPPLY

TO MAIN UNIT


CONTROLLING THE MIST


Adjusting Air / Oil Ratio LubriMist® Vortex oil mist generation technology allows for maximum control and adjustment of oil mist properties. There are four basic controls for adjusting the oil output of the mist generator.

1. The AIR PRESSURE REGULATOR is used to adjust the volume of air flowing into the Vortex chamber, which in turn controls oil mist volume. The air pressure regulators are located on the operator panel. The volume of oil mist is proportioned to each bearing or application point by the reclassifier. With the air bypass valve (described below) closed, the air pressure regulator setting must be high enough for oil mist production. Regulated air pressure should be adjusted to maintain proper mist pressure. Since changes in regulated air pressure affect the volume of oil mist produced, it also affects oil consumption. Separate air pressure regulators are provided for the main and auxiliary oil mist generators.

2.

Lubrimist

The AIR / OIL HEATER controls the temperature of the oil as it is being converted from a liquid into oil mist particles. Because oil viscosity has a definite influence on oil mist generation, increasing and decreasing the oil temperature effects a change in the mist density as the oil temperature is varied. Generally, when the air / oil heater is operating, the oil temperature runs approximately 10-12° F (5-7°C) cooler than the air temperature. An increase in temperature will increase oil output. Decreasing the temperature will cause the oil output to also decrease. See Programming User Established Alarm And Control Set Points in the OPERATING GUIDE section of this manual for instruction on changing set points for the main oil mist generator. Adjusting the heater controls for the auxiliary oil mist generator is covered in the AUXILIARY OIL MIST GENERATOR section of this manual.

Use Auxiliary Oil Mist Generator Control Panel To Manage Auxiliary Air / Oil Heater Setpoint

Use Main Oil Mist Generator Control Panel To Manage Main Unit Air / Oil Heater Setpoint

Air Pressure Regulator To Control Main Oil Mist Generator Mist Volume

Air Pressure Regulator To Control Auxiliary Oil Mist Generator Mist Volume

IMPORTANT: The oil/air ratio or mist density is also dependent on the characteristics of the oil, oil temperature and supply air temperature. Density decreases with lower temperatures and higher oil viscosity.


3. The OIL FLOW VALVE controls oil mist density (oil/air ratio). Its normal position is fully

closed. By turning it counter-clockwise (opening the bypass) the mist density can be reduced when leaner density oil mist is desired. It should not be opened more than three turns. Adjustments to the oil flow valve do not affect oil mist pressure. The oil flow valve is located on the front of the mist generating head body. Separate mist generating heads are provided for the main and the auxiliary oil mist generators.

4. The AIR BY-PASS VALVE controls mist pressure without effecting oil output. Its normal position is fully closed, but by turning it counter clockwise more air will be added to the oil mist leaving the generator. This essentially dilutes the air / oil ratio by adding more air. Without reducing the regulated air pressure setting, adjusting the air by-pass valve increases mist pressure and reduces the oil/air ratio. Velocity of mist through the distribution lines and reclassifiers will also increase when this valve is opened. The air by-pass valve is located on the right of the mist generating head body. Separate mist generating heads are provided for the main and the auxiliary oil mist generators

Oil Flow Valve

Air By-Pass Valve

IMPORTANT: The oil / air ratio or mist density is reduced by opening the air by-pass valve. However, oil output is not affected.


Changing The Mist Generating Capacity A qualified person should make replacement of parts. The IVT Oil Mist Generator is designed to provide oil mist lubrication for systems over a wide range of oil mist flow requirements. The IVT package can easily be set up to service oil mist systems with mist capacity requirements from 1.2 to 30 SCFM. The mist generators of the same capacity are always installed in the main and auxiliary mist units. When system flow requirements change due to the addition or deletion of mist application points, the mist generating capacity of the IVT Oil Mist Generator must be verified. If necessary a new mist generator insert kit can be easily installed to keep up with the new mist generating requirements. The IVT Oil Mist Console is shipped as one of four different mist-generating capacities. The four different capacities are listed in the table below. Reference Tag Detail For NEC Model IVT and Tag Detail For ATEX Model IVT in the UNIT IDENTIFICATION AND LABELING section of this manual for additional information.

Mist Generating Range Mist Generator Size

US UNITS METRIC UNITS

Number Of Machined Groves In Vortex Plate

60 Bearing 0.60 - 1.80 SCFM 1.02 – 3.06 M3 / Hr 1

213 Bearing 1.75 – 6.40 SCFM 2.97 – 10.87 M3 / Hr 2

475 Bearing 2.48 – 14.30 SCFM 4.21 – 24.30 M3 / Hr 3

933 Bearing 5.70 – 28.0 SCFM 9.68 – 47.57 M3 / Hr 4

Separate mist generating cartridge kits are available for changing the mist flow requirements when the new mist flow is outside of the specified mist generating range. The mist generator cartridge size can be identified by making note of the number of machined rings found on the vortex plate of each cartridge assembly. The number of rings for each capacity oil mist generating cartridge is shown in the above table. See the figure below for location of markings. Kits include parts to change both the main and auxiliary oil mist generators. Consult Lubrication Systems Company Houston Texas USA for further information.

Mist Generating Heads Are Located On Top Of the Main And Auxiliary Oil Mist Generator Reservoirs

The Mist Generator Capacity Is Indicated By The Number Of Machined Groves In the Vortex Plate. Reference The Above Table For Identification.


ROUTINE MAINTENANCE Note: A qualified person should make replacement of spare parts.


ROUTINE MAINTENANCE Whenever equipment is provided with pure (dry sump) oil mist lubrication, it is important to insure constant, uninterrupted operation of the oil mist lubrication systems. If a malfunction occurs, early detection and corrections are important. The daily operation of the oil mist system for the process operator has been reduced to checks of the IVT Oil Mist Generator and lubricated equipment and to emergency procedures in the event of a major malfunction. Except for emergencies, routine adjustment of the oil mist generator is not required. Each oil mist system, once installed and balanced, supplies a constant amount of oil mist to a number of lubrication points. Any change in the oil mist pressure or in the regulated air pressure (load pressure) from the initial set points is an indication that some component has failed. Minor adjustments that might offset the failure symptoms may lead to more serious problems before detection and corrections can be made. Keeping system adjustments to a minimum is intended to make the oil mist systems more reliable and to insure proper operation. It is not meant to discourage the natural troubleshooting initiative of the process technician. Operators should be familiar with "Model IVT Operating Guide", knowing how to read gauge values and alarm settings before attempting these procedures.

1) DAILY OIL MIST GENERATOR CHECKS

a) Check mist header pressure setting @ 20 inches H2O / 50 m BAR

b) Check low mist pressure alarm setting (Factory setting is 10 inches H2O / 25 m BAR

c) Check high mist pressure alarm setting (Factory setting is 30 inches H2O / 75 m BAR

Low pressure may indicate a leak in system, reclassifiers removed from the system or broken lines.

High pressure may indicate plugged mist fittings of an open bypass valve.

Surging pressure may indicate an oil pocket in the distribution header or inlet air pressure not constant.

d) Check regulated air pressure and the supply air pressure. This regulated air pressure is preset and should not be adjusted to regulate mist header pressure.

Generator will not operate properly below 10 PSIG - 0.7 BAR regulated air pressure.

Supply air pressure should be approximately 20 PSIG – 1.5 BAR) above the regulated air pressure.

e) Check for proper air temperature setting (Factory setting is 120° F - 49° C).

f) Check oil level in the main generator reservoir.

g) Check general unit condition for leaks, broken gauges, etc. and repair as needed.

2) WEEKLY CHECKS

a) Check all control and alarm set points.

b) Clean inside of generator console and correct any leaks.

3) MAINTENANCE CHECKS

The following maintenance procedures should be performed at least on a semi-annual basis to help insure proper system operation. If your “IVT” is installed in an extremely dusty or humid environment or if you are concerned about the quality of your compressed air supply, the maintenance schedule should be accelerated. Consult with the nearest LSC office/service center for further discussion and recommendations.

a) Change oil filter element (P/N 77-500-487).

b) Inspect and clean the oil suction screen (P/N LS0205120).

c) Replace air filter element (P/N 77780352).

d) Inspect and thoroughly clean the interior of the oil mist generator reservoirs.


e) Check and verify operation of the high and low set points of all alarms.

f) Check the operation of the remote alarm circuit if one has been installed.

g) Make an overall assessment of the “IVT” and mist distribution system and correct obvious deficiencies and problems.


TROUBLE SHOOTING GUIDE


The following information is designed for identifying potential problems and possible solutions on the LubriMist® model “IVT” Oil Mist Generator. For complete operating instructions, parts list, electrical schematics and component locations refer to LubriMist® Model “IVT” Oil Mist Generating System Installation and Operating Manual The alarm message or problem is described in the column on the left. Troubleshooting techniques as well as possible solutions are listed in the column to the right. The Troubleshooting steps as well as solutions are listed in order of severity. If the first solution does not clear the alarm, then proceed on to the next possible solution. If the alarm condition still exists, the severity of the alarm or problem may be beyond the possible solutions listed in this guide. Please contact Lubrication Systems Company 800-800-5823 for further information and servicing options. All listed alarm settings are factory values. If customers assigned values have substituted factory values, please use customer assigned values instead. Alarms that warrant switching mist generation to Auxiliary Unit are as follows. • LOW MIST DENSITY • LOW AIR TEMPERATURE • HIGH AIR TEMPERATURE • MIST TANK TAKING TOO LONG TO FILL • LOW OIL LEVEL MIST TANK LEVEL • HIGH AIR CUTOFF AIR TEMPERATURE • LOW OIL SUPPLY PRESSURE • HIGH OIL SUPPLY PRESSURE

When switching to the Auxiliary unit, please follow instructions located on interior of IVT cabinet door. If procedure is not available, please refer to AUXILIARY OIL MIST GENERATOR section of LubriMist® Model “IVT” Oil Mist Generating System Installation and Operating Manual.


Main Unit ALARM

MESSAGE / PROBLEM

SOLUTION

LOW MIST DENSITY Oil Mist Density is below Low Alarm Setting – Oil Mist quality has been compromised. (10%)

1. Turn mist inspection valve. Visually inspect oil mist quality. 2. Check oil level in mist tank. Confirm Oil Supply Level alarm on front of keypad is

not in active. Verify that the operating oil level is in the normal operating range. Loss of oil results in loss of oil mist production.

3. Press Air Temp key. Confirm air temperature is at control set point (120°F - 49°C). If customer assigned values replace factory values: To check control setting press key combination Set, Air Temp. When finished, press the Clear key to return to normal operating mode. Note: Decline in Air Temperature will cause the oil viscosity to increase resulting in a decrease in mist production.

4. Confirm mist head oil flow valve has not been adjusted further than 3 turns. See mist head adjustment screw locations below. Closing the oil flow valve increases the oil mist output. Note: Excessive adjustment to this valve may compromise the oil mist heads ability to produce quality oil mist.

5. Confirm mist head air bypass valve is not over adjusted. Note: Excessive adjustment to this valve may over dilute the oil mist with clean air. Closing the air by-pass valve decreases dilution. Note that adjustments using the air bypass valve varies mist pressure.

6. Check the oil suction screen for obstruction. • Switch to Auxiliary Unit. See instructions located on interior of IVT cabinet

door. • Open the left IVT cabinet door. Locate oil suction screen holder on the side of

the mist head. Remove the oil suction screen and clean thoroughly, reinstall when through.

• Switch mist generation back to main oil mist generator.

Mist Head Front View Mist Head Right Side View

Air Bypass Valve Suction Screen

Holder

Oil Flow Valve


HIGH MIST DENSITY Oil Mist Density is above High Alarm Setting – Unit is generating high concentrations of oil mist. (90%)

1. Press Air Temperature key. Temperature must be at control set point (120°F - 49°C). If customer assigned values replace factory values: To check control setting press key combination Set, Air Temp. When finished, press the Clear key to return to normal operating mode. Note: Increase in Air Temperature will cause the oil viscosity to decrease resulting in an increase in mist production.

2. Perform oil consumption test on oil mist console. Adjust oil consumption to .65 cu. in oil/Hour/SCFM air using mist head adjustments. See troubleshooting instructions for LOW MIST DENSITY above for adjustment locations.

3. Once optimal oil consumption is achieved, refer to instructions for Oil Mist Monitor. Select sensitivity adjustment to obtain a mist density reading of near 50%.

LOW MIST PRESSURE Oil Mist Header Pressure is below Low Alarm Setting (10in H2O – 25mBar)

1. Press Mist Pres key. Normal mist pressure is 20 In H2O / 50mBar. Verify that the low mist pressure alarm setting. Note whether customer assigned values have been programmed to the replace the factory values. Press the key combination Set, Mist Pres. to read the low alarm setting. Press the Clear key to return to normal operating mode.

2. If the mist pressure is near the Low Alarm Setting (10in H2O – 25mBar) check the oil mist header systems for broken mist lines or pipes and IVT oil mist generator for leaks.

3. Verify that the regulated air pressure has not been changed from the original setting established at commissioning. When adjustments are made, the EVENT LOG records the event. See the section titled Event Log under LOCAL ALARMS, INDICATORS AND READOUT in the Installation and Operating Manual for instruction on how to access the event log. If it is determined that the regulated air pressure has been changed, and that the Low Mist Pressure alarm is due the change in regulated air pressure correct the setting. Adjust the air regulator to achieve 20in H2O oil mist pressure, ensuring not to exceed 65PSI – 4.48Bar Regulated Air Pressure. If regulated pressure does not increase with adjustments to air regulator. The air regulator is defective and should be replaced (LSC part no. 77780127).

4. If adequate mist pressure cannot be achieved with a functional air regulator, the capacity of the mist head has been exceeded. This situation occurs when the mist system is expanded to service additional equipment and bearings. If the oil mist system has been expanded, verify that the mist head vortex size is adequate for the service load. If the mist generating capacity has been exceeded, the vortex cartridge will need to be replaced to next larger size. See table in IVT Operating Instruction Manual section CONTROLLING THE MIST for part numbers, mist head sizes and replacement instructions.


HIGH MIST PRESSURE Oil Mist Header Pressure is above High Alarm Setting (30in H2O – 75mBar)

1. Confirm supply air ball valve for Auxiliary unit is closed. Main Unit and Auxiliary Unit cannot be operated at the same time.

2. Check for plugged reclassifiers. Paraffin based oils can develop a wax buildup through reclassifiers as the ambient temperature drops below freezing. Please refer to oil manufacturers product data sheet for oil specifications.

3. Check the oil mist distribution header and branch lines for sags or low points that can collect oil and obstruct the mist flow. Mist pipe blockages will result in a surging mist pressure

4. Verify that the regulated air pressure has not been changed from the original setting established at commissioning. When adjustments are made, the EVENT LOG records the event. See the section titled Event Log under LOCAL ALARMS, INDICATORS AND READOUT in the Installation and Operating Manual for instruction on how to access the event log. If it is determined that the regulated air pressure has been changed, and that the High Mist Pressure alarm is due the change in regulated air pressure correct the setting. Decrease the regulated air pressure to achieve 20in H2O oil mist pressure, ensuring not to decrease below 10PSI – .69Bar. If regulated pressure does not decrease with adjustments to air regulator. The air regulator is defective and should be replaced (LSC part no. 77780127). Note: Oil mist generating head will not produce oil mist with a regulated air pressure below 10PSI - .69Bar

5. If adequate mist pressure cannot be achieved while maintaining the minimum regulated air pressure, the system oil mist flow requirement is less than the minimum operating capacity of the mist head. This situation occurs when the mist system is reduced and equipment is removed from the system. If the oil mist system has been downscaled, verify that the mist head vortex size is correct for the service load. If the mist generating capacity is over capacity, the vortex cartridge will need to be replaced to next smaller size. See table in IVT Operating Instruction Manual section CONTROLLING THE MIST for part numbers, mist head sizes and replacement instructions.


LOW REGULATED PRESSURE Regulated Air Pressure to mist generating head is below Low Alarm Setting (10PSI - .69BAR) Note: Oil mist generating head will not produce oil mist with a Regulated Air Pressure below 10PSI - .69BAR

1. Check the supply air shut off valve for main unit located at the operator panel, ensure the valve is in the full open position.

6. Verify that the air supply source has sufficient capacity to service the oil mist demand. Check the supply air piping system to ensure that all block valves are fully opened and that piping is sufficiently sized to eliminate unacceptable pressure drop at operating conditions.

2. Verify that the regulated air pressure has not been changed from the original setting established at commissioning. IMPORTANT: CARE MUST BE TAKEN WHEN ADJUSTMENTS TO THE REGULATED AIR PRESSURE SETTING IS MADE. MAKE CERTAIN THAT ALL RECLASSIFIER FITTINGS ARE NOT PLUGGED AND THAT ALL DISTRIBUTION HEADER AND BRANCH PIPING IS FREE FROM OBSTRUCTIONS AND TRAPS. CHANGING THE REGULATED AIR PRESSURE CHANGES THE TOTAL MIST VOLUME (SCFM) BEING PRODUCED AND DISTRIBUTED TO THE EQUIPMENT BEING SERVICED. When adjustments are made, the EVENT LOG records the event. See the section titled Event Log under LOCAL ALARMS, INDICATORS AND READOUT in the Installation and Operating Manual for instruction on how to access the event log. If it is determined that the regulated air pressure has been changed, and no occurrence of a High Mist Pressure is recorded, then the setting may be corrected. Increase the regulated air pressure to achieve 20in H2O oil mist pressure. If regulated pressure does not change with adjustments to air regulator. The air regulator is defective and should be replaced (LSC part no. 77780127). If a High Mist Pressure alarm is recorded in the Event Log, then it possible that adjustments to the regulated air pressure setting were made to correct the mist pressure alarm. Correct the source of the high mist pressure alarm. Note: Oil mist generating head will not produce oil mist with a regulated air pressure below 10PSI - .69Bar

3. 4. If installed, confirm that all collection containers have been properly drained and

checked. Also, confirm that all Automatic Drain Leg reservoirs installed in oil mist systems are draining correctly. Note: Overfilled collection containers or drain leg reservoirs will produce a higher oil mist pressures condition.

5. If adequate regulated air pressure adjustment cannot be achieved to maintain the normal operating mist pressure, the system oil mist flow requirement may be less than the minimum operating capacity of the mist head. This situation occurs when the mist system is reduced and equipment is removed from the system. If the oil mist system has been down scaled, verify that the mist head vortex size is correct for the service load. If the mist generating capacity is over capacity, the vortex cartridge will need to be replaced to next smaller size. See table in IVT Operating Instruction Manual section CONTROLLING THE MIST for part numbers, mist head sizes and replacement instructions.


HIGH REGULATED PRESSURE Regulated Air Pressure to mist generating head is above High Alarm Setting (65PSI – 4.48BAR)

1. Verify that the regulated air pressure has not been changed from the original setting established at commissioning. IMPORTANT: CARE MUST BE TAKEN WHEN ADJUSTMENTS TO THE REGULATED AIR PRESSURE SETTING IS MADE. MAKE CERTAIN THAT ALL RECLASSIFIER FITTINGS ARE PROPERLY INSTALLED. CHECK ALL DISTRIBUTION HEADER AND BRANCH PIPING FOR BREAKS AND LEAKS WHERE MIST FLOW CAN ESCAPE. CHANGING THE REGULATED AIR PRESSURE CHANGES THE TOTAL MIST VOLUME (SCFM) BEING PRODUCED AND DISTRIBUTED TO THE EQUIPMENT BEING SERVICED. When adjustments are made, the EVENT LOG records the event. See the section titled Event Log under LOCAL ALARMS, INDICATORS AND READOUT in the Installation and Operating Manual for instruction on how to access the event log. If it is determined that the regulated air pressure has been changed, and no occurrence of a Low Mist Pressure is recorded, then the setting may be corrected. Increase the regulated air pressure to achieve 20in H2O oil mist pressure. If regulated pressure does not change with adjustments to air regulator. The air regulator is defective and should be replaced (LSC part no. 77780127). If a Low Mist Pressure alarm is recorded in the Event Log, then it possible that adjustments to the regulated air pressure setting were made to correct the mist pressure alarm. Correct the source of the low mist pressure alarm.

2. Press Mist Pres key. If pressure is near Low Alarm Setting (10in H2O – 25mBar) check the oil mist header systems for broken mist lines or pipes. Note whether customer assigned values have been programmed to the replace the factory values. To check low alarm setting press key combination Set, Mist Pres. Press the Clear key to return to normal operating mode.

1. If adequate regulated air pressure adjustment cannot be achieved to maintain the normal operating mist pressure, the system oil mist flow requirement may be greater than the operating capacity of the mist head. This situation can occur when the mist system has been expanded and equipment is added to the system. If the oil mist system has been expanded, verify that the mist head vortex size is correct for the service load. If the mist generating capacity is under capacity, the vortex cartridge will need to be replaced to a larger size See table in IVT Operating Instruction Manual section CONTROLLING THE MIST for part numbers, mist head sizes and replacement instructions.


LOW AIR TEMPERATURE Heated Air Temperature is below Low Alarm Setting (100°F - 38°C)

1. Press the Air Temp key and observe the displayed operating air temperature value. Confirm that the temperature is above Low Alarm Setting (100°F - 38°C)and the Air Heater Set temperature (120°F - 49°C) is above the low alarm setting. Actual displayed values may vary if customer assigned values have been assigned to replace factory values: To check air heater set temperature key combination Set, Air Temp. Press the Enter key twice to view low alarm setting. Press Clear key to return to normal operating mode.

2. Ensure that the minimum regulated air supply pressure is being maintained. The IVT solid state controller will not permit the air heater element to energized if the Regulated Air Pressure is below Low Alarm Setting (10PSI - .69Bar). Press the Reg Air Pres key and observe the displayed operating regulated air pressure value.. Increase pressure above low alarm setting. See Troubleshooting solutions for LOW REGULATED PRESSURE.

3. Check mist tank reservoir level. The oil level must be above low-level switch alarm set point (approx. 1” above LOW mark on sight gauge). Low level alarm is indicated by red light on the keypad adjacent to Oil Supply Level heading. The IVT solid state controller will not permit the air heater element to energize if the mist tank reservoir level is below low alarm point.

4. Check the operation of the Air heater element (H-1) and the solid state relay (SSR-1). Open AC electrical enclosure, and observe the green LED located on the SSR-1. The LED indicates the operating status of relay. When the LED is ON power is being applied to the air heater element. Confirm whether the LED is lit while the air temperature is below the control set point.

5. If relay LED is on and air temperature is not increasing, check the 10A fuse at fuse block number #10 and replace if the fuse is open. (LSC part no. 77780155). If the fuse is good and power is being supplied to the heater element, check and replace the air heater element if needed.

6. If repair is not possible, switch mist generation to Auxiliary. See procedure located on interior of IVT cabinet door.

HIGH AIR TEMPERATURE Heated Air Temperature is above High Alarm Setting (140°F - 60°C)

1. A High Air Temperature alarm can occur if the ambient temperature is warmer that the High Air Temperature alarm setting. To check the ambient temperature reading press the Amb Temp key. If the ambient temperature is above or near the High Air Temp. Alarm Setting (140°F - 60°C), site operating conditions may require that the High Air Temperature alarm setting be increased to eliminate a nuisance alarm situation.

2. Confirm Air Heater Set temperature (120°F - 49°C) is below high alarm setting. Actual displayed values may vary if customer assigned values have been assigned to replace factory values: To check air heater set temperature key combination Set, Air Temp. Press the Enter key once to view high alarm setting. Press Clear key to return to normal operating mode.

3. Check the operation of the air heater solid state relay SSR-1. Open AC electrical enclosure, and observe the green LED located on the SSR-1. The LED indicates the operating status of relay. When LED is ON the air heater element is energized. Confirm that the LED is OFF when air temperature at or above control set point. Replace the SSR-1 relay if the green LED remains ON. LSC part number 77780152.



MIST TANK TAKING TOO LONG TO FILL Transfer rate of oil from bulk oil reservoir to mist tank has exceeded 5 minutes. Normally this alarm is initiated before the LOW OIL LEVEL MIST TANK LEVEL alarm is active.

1. From the front operator panel, check the Oil Supply Pump air shut off valve. Ensure the valve is in the full open position. Air pressure must be applied to the oil supply pump to make it operate

2. Check the bulk oil supply reservoir and ensure that it has not been depleted. Refill the bulk oil reservoir if additional oil supply is needed.

3. Check Regulated air pressure for supply oil pump. Pressure must be set at 35- 40 PSI. The pressure indicator is mounted adjacent to the solenoid operated air valve, and located behind the right side maintenance access door.

4. Check Oil Filter element F-2. A dirty oil filter will not permit oil to pass through. Replace if necessary. LSC part number 77500489.

5. Reset the console by turning main power OFF then ON. Confirm operation of the solenoid operated air valve S-1. As the solenoid is energized you will hear a clicking sound. If solenoid does not energize, verify the operation of the oil level control switch in the main misting reservoir. As oil level falls, the switch closes to energize the solenoid. As oil level rises, the switch should open and de-energize the solenoid valve. With the level switch in the closed position the solenoid should be energized (open) and oil level should rise. Check to ensure that 24 VDC power is applied to the solenoid terminals. If the solenoid does not energize it should be replaced. LSC part number 77780131.

6. Confirm operation of air operated pump. When solenoid is energized and adequate regulated air pressure is applied to the pump, the pump will start automatically. The pump can be manually operated by pressing and holding the manual air toggle valve in the open position. The air toggle valve is located on the front operator panel. Replace pump if necessary. LSC part number 77780134.


LOW OIL LEVEL MIST TANK LEVEL Oil Level within mist generating tank is below low alarm point. Normally this alarm is initiated after the MIST TANK TAKING TOO LONG TO FILL alarm is active.

1. Confirm low oil level through sight glass. The Low oil level alarm is initiated if oil level in mist tank is less than 1” from Low mark on sight glass.

2. From the front operator panel, check the Oil Supply Pump air shut off valve. Ensure the valve is in the full open position. Air pressure must be applied to the pump to make it operate


4. Check Regulated air pressure for supply oil pump. Pressure must be set at 35- 40 PSI. The pressure indicator is mounted adjacent to the solenoid operated air valve, and located behind the right side maintenance access door.


6. Reset the console by turning main power OFF then ON. Confirm operation of the solenoid operated air valve S-1. As the solenoid is energized you will hear a clicking sound. If solenoid does not energize, verify the operation of the oil level control switch in the main misting reservoir. As oil level falls, the switch closes to energize the solenoid. As oil level rises, the switch should open and de-energize the solenoid valve. With the level switch in the closed position the solenoid should be energized (open) and oil level should rise. Check to ensure that 24 VDC power is applied to the solenoid terminals. If the solenoid does not energize it should be replaced. LSC part number 77780131.

7. Confirm operation of air operated pump. When solenoid is energized and adequate regulated air pressure is applied to the pump, the pump will start automatically. The pump can be manually operated by pressing and holding the manual air toggle valve in the open position. The air toggle valve is located on the front operator panel. Replace pump if necessary. LSC part number 77780134.



LOW SUPPLY PRESSURE Supply Air Pressure to IVT is below Low Alarm Setting (25PSI – 1.7BAR)

1. Check supply air pressure at the source, compare to IVT supply pressure reading. To obtain the Supply Air Pressure reading at the IVT, press Sup Air Pres key.

2. If the IVT supply air pressure reading is lower than the pressure reading at the air source, check for any shut-off valves installed within the supply airline to the IVT. Confirm these valves are in the full open position.

3. Check air filter element F-1. A dirty or clogged filter element will result in a difference in pressure readings from the air source to the IVT. Change filter element if necessary. LSC part no. 77780124.

4. Increase supply air pressure at the source above Low Alarm Setting (25PSI – 1.7BAR).

HIGH SUPPLY PRESSURE Supply Air Pressure to IVT is above High Alarm Setting (150PSI – 10.3BAR)

1. Check supply air pressure at the source, compare to IVT supply pressure reading. To obtain the Supply Air Pressure reading at the IVT, press Sup Air Pres key.

2. Reduce supply air pressure at the source below High Alarm Setting (150PSI – 10.3BAR).

HIGH AIR CUTOFF AIR TEMPERATURE Heated Air Temperature is above High Cutoff Alarm Setting (150°F - 65°C) Note: High Air Cutoff alarm is designed to act as a failsafe feature for the Air Heater Element. The temperature sensor that controls the high air cutoff alarm is separate from the sensor used to control air temperature.

1. Confirm that the Air Heater Set temperature (120°F - 49°C) is below high air cutoff alarm setting (150°F - 65°C). See the IVT Operating Instructions for instructions on how to program user specified alarm and control set point values. Note whether customer assigned values have been programmed to the replace the factory values. To check air heater high cutoff temperature press key combination Set, Air Temp. Press the Enter key three times to view high cutoff alarm setting. Press Clear key to return to normal operating mode.

2. Press Air Temp key. If temperature measurement is low (90°F - 100°F), the sensor TE-2 that controls air temperature is failing and should be replaced. LSC part number 77700941.

3. Check the operation of the Air heater solid state relay SSR-1. Open AC electrical enclosure, and observe the LED located on the SSR-1. The LED indicates the operating status of relay. When LED is ON the air heater element is energized. When LED is OFF the air heater element is de-energized. Confirm LED is OFF when air temperature at or above control set point. If the air temperature is above the control set point and the relay SSR-1 is ON, replace the relay. LSC part number 77780152.



LOW OIL SUPPLY PRESSURE Oil Supply Pressure is below Low Alarm Setting (10PSI - .69BAR)

1. From the front operator panel, check the Oil Supply Pump air shut off valve. Ensure the valve is in the full open position. Air pressure must be applied to the oil supply pump to make it operate

2. Check Regulated Air Pressure for supply oil pump. Pressure must be set 35- 40 PSI. The pressure indicator is mounted adjacent to the solenoid operated air valve, and located behind the right side maintenance access door.


4. Oil pump operation can be initiated by pressing the key combination Set - Clear. The Air Operated oil pump should start. Note: Supply oil pressure must exceed low alarm setting within 5 seconds to continue operating.

5. Reset the console by turning main power OFF then ON. Confirm operation of the solenoid operated air valve S-1. As the solenoid is energized you will hear a clicking sound. If solenoid does not energize, verify the operation of the oil level control switch in the main misting reservoir. As oil level falls, the switch closes to energize the solenoid. As oil level rises, the switch should open and de-energize the solenoid valve. With the level switch in the closed position the solenoid should be energized (open) and oil level should rise. Check to ensure that 24 VDC power is applied to the solenoid terminals. If the solenoid does not energize , it should be replaced. LSC part number 77780131.

6. Confirm operation of air operated pump. When solenoid is energized and adequate regulated air pressure is applied to the pump, the pump will start automatically. . The pump can be manually operated by pressing and holding the manual air toggle valve in the open position. The air toggle valve is located on the front operator panel. Replace pump if necessary. LSC part number 77780134.


HIGH OIL SUPPLY PRESSURE Oil Supply Pressure is above High Alarm Setting (150PSI – 10.34BAR)

1. Confirm Regulated air pressure for supply oil pump is correctly adjusted to 35-40 PSI (2.4 – 2.8 BAR)

2. Confirm operation of thermal expansion relief valve TRV. Set pressure @150PSI – 10.34BAR. If supply oil pressure exceeds high alarm setting and relief valve does not relieve pressure, the valve should be replaced. LSC part number 77600966.



LOW OIL LEVEL BULK TANK LEVEL Bulk Oil Level is below Low Alarm Setting (10Gal – 38Lt.)

1. Add required lube oil to Bulk Oil Reservoir through the Threaded Fill Port located on the front operator panel. Normal operating level is 70Gallons – 265Liters.

2. To read the operating level in the bulk oil reservoir press the Oil Level key. Visually compare IVT Bulk Oil Level reading to bulk oil level in sight glass.

3. If IVT bulk oil level reading is significantly lower than level in bulk oil sight glass, replace Oil Level Transmitter LT-1. LSC part number 77780141.

HIGH OIL LEVEL BULK TANK LEVEL Bulk Oil Level is above High Alarm Setting (75Gal – 284Lt.)

1. The Bulk Oil Reservoir has been overfilled. Visually confirm the reservoir level indicated by the oil level sight gauge. Normal operating level is 70Gallons – 265Liters.

2. Drain any excess oil through Bulk Oil Reservoir Drain Valve. 3. To read the operating level in the bulk oil reservoir press the Oil Level key.

Visually compare IVT Bulk Oil Level reading to bulk oil level in sight glass. 4. If IVT bulk oil level reading is significantly higher than level in bulk oil sight glass,

replace Oil Level Transmitter LT-1. LSC part number 77780141. LOW OIL TEMP Bulk Oil Temperature is below Low Alarm Setting (10°F - -12°C)

1. Confirm ambient temperature is above Oil Temp Low Alarm Setting. 2. If minimum ambient temperatures in geographical location fall below 15°F/10°C,

IVT unit should be equipped with Air Pre-Heater option.


HIGH OIL TEMP Bulk Oil Temperature is above High Alarm Setting (160°F – 71°C)

1. Confirm ambient temperature is below Oil Temp High Alarm Setting. 2. If maximum ambient temperature in geographical location exceeds 140°F/60°C,

IVT unit should be equipped with Air Cooling option.

Auxiliary Unit The “ ” is illuminated The temperature of thermocouple TE-5 is below Low Alarm Setting (100°F - 38°C)

1. Confirm that the operating air temperature is above Low Alarm Setting (100°F – 38°C), and that the Air Heater Set temperature (120°F - 49°C) is above low alarm setting. The operating air temperature is normally displayed on the controller readout during operation. To check air heater set temperature press key Set, the rightmost digit will display “1”. The displayed value is the set temperature for the air heater. Normal operation of controller display will automatically resume after 10 seconds.

2. Check the regulated air pressure being supplied to the auxiliary unit mist head. The minimum regulated air pressure is 10 PSI. Increase pressure above interlock setting 10PSI - .69BAR. The IVT Auxiliary Controller will not permit the air heater element to energized if the regulated air pressure is below interlock setting 10PSI - .69BAR. A low air pressure switch is utilized to provide the interlock contacts. The switch contacts are arranged to close on increasing pressure. Verify that the pressure switch operates at 10 PSI, and replace if it is malfunctioning.

3. Check the operation of the Air heater element H-2 and solid state relay BU-SSR-1. Open the electrical enclosure to auxiliary unit. and observe the green LED located on the BU-SSR-1 relay. The LED indicates the operating status of relay. When LED is ON the air heater element is energized. Confirm that the LED is lit when air temperature is below control set point (120°F - 49°C)

4. If relay LED is on and the air temperature is not increasing, replace the 10A fuse at fuse block number #2. LSC part no. is 77780155. If IVT is a 240VAC, the 10A fuse at number #5 should also be replaced. If the Air temperature is below the control air temperature setting, replace the SSR-1 relay if the green LED remains OFF.

5. If the fuses and the solid state relay are functional, check and replace the heater element if necessary.

Display reads “EEEE” Thermocouple lead is loose or disconnected

1. Confirm which thermocouple is generating “EEEE” reading. Check wiring into controller. Reference electrical wiring diagram.

2. Replace suspected thermocouple if necessary. LSC part number 77700941

Temperature reading of thermocouple 2 is much higher that thermocouple 1 Heated Auxiliary air temperature has exceeded High Cutout Alarm Setting. (150°F - 65°C)

1. Confirm that the Air Heater Set temperature (120°F - 49°C) is below high air cutoff alarm setting (150°F - 65°C). See the IVT Installation and Operating Manual for instructions on reading set point values.

2. The High Air Cutoff alarm is designed to act as a failsafe device for the Air Heater Element. The temperature sensor that controls the high air cutoff alarm is separate from the sensor used to control air temperature.

3. If temperature measurement #1 is low (90°F - 100°F), the sensor TE-4 that controls air temperature is failing and should be replaced. LSC part number 77700941.

4. To check the operation of the air heater solid state relay BU-SSR-1. Open the electrical enclosure to auxiliary unit and observe the green LED located on the BU-SSR-1 relay. The LED indicates the operating status of relay When the LED is ON the air heater element is energized. When LED is OFF the air heater element is de-energized. Confirm LED is OFF when air temperature at or above control set point.

5. If the air temperature is above the control set point and the relay BU-SSR-1 is ON, replace the relay. LSC part number 77780152.


Optional Equipment AIR PRE-HEATER LOW AIR PRE-HTR TEMPERATURE Heated Pre-heater Air Temperature is below Low Alarm Setting (30°F - -1°C)

1. The IVT solid state controller will not permit the air pre-heater element to operate if the regulated air pressure is below Low Alarm Setting (10PSI - .69BAR). To observe the regulated air pressure reading, press the Reg Air Pres key. If the regulated air pressure is less that 10 PSI / 0.69 BAR, increase the pressure above the low alarm setting. See Troubleshooting solutions for LOW REGULATED PRESSURE.

2. Press key combination Set – Set – Air Temp to view temperature of Supply Air. This temperature must be above -40°F for pre-heater to maintain set temperature.

3. Press the key combination Set – Set – Pre Heater to view the Pre-Heater Temperature control setting. Confirm that the temperature is above Low Alarm Setting (30°F - -1°C). Determine if customer assigned values have been installed to replace the factory values: To check the air pre-heater low alarm temperature setting, press the key combination Set, Pre Heater. Press the Enter key two times to view low alarm setting. Press Clear key to return to normal operating mode.

4. Check mist tank reservoir level. The oil level must be above low-level switch alarm set point (approx. 1” above LOW mark on sight gauge). Low level alarm is indicated by red light on the keypad adjacent to the Oil Supply Level heading. The IVT solid state controller will not permit the air pre-heater element to energize if the mist tank reservoir level is below low alarm point.

5. Check the operation of the Air Pre-heater element (H-3) and solid state relay (SSR-2). Open the AC electrical enclosure, and observe the green LED located on the SSR-2. The LED indicates the operating status of relay. When the LED is ON power is being applied to the air heater element. Confirm LED is lit while the air temperature is below control set point.

6. If relay LED is ON and the Pre-heater air temperature is not increasing, check the 10A fuse at fuse block number #11 and replace if the fuse is open.. (LSC part no. 77780155). If the fuse is good and power is being supplied to the heater element, check and replace the air heater element if needed.

HIGH AIR PRE-HTR AIR TEMPERATURE Heated Pre-Heater Air Temperature is above High Alarm Setting (80°F - 27°C)

1. A High Air Temperature alarm can occur if the inlet air temperature is warmer that the PreHeater High Air Temperature alarm setting. Press the key combination Set – Set – Air Temp to view the inlet temperature of Supply Air. This temperature must be below the High Alarm Setting.

2. Press the key combination Set – Set – Pre Heater to view the pre heater temperature setting. Confirm that the temperature is below the High Alarm Setting.Determine if customer assigned values have been installed to replace factory values: To check air pre-heater high alarm temperature setting, press key combination Set, Pre Heater. Press the Enter key once to view high alarm setting. Press Clear key to return to normal operating mode.

3. Check the operation of the Air Pre-heater solid state relay SSR-2. Open AC electrical enclosure, and observe the green LED located on the SSR-2. The LED indicates the operating status of relay. When LED is ON the air heater element is energized. Confirm that the LED is OFF when air temperature is at or above the control set point. Replace the SSR-2 relay if the green LED remains ON. LSC part number 77780152.


HIGH PREHTR CUTOFF AIR TEMPERATURE Heated Pre-Heater Air Temperature is above High Cutoff Alarm Setting (100°F - 38°C)

1. Press the key sequence Set – Set – Pre Heater to view pre heater temperature. Confirm that the air pre-heater set temperature (60°F - 16°C) is below the high air pre-heater cutoff alarm setting (100°F - 38°C). Determine if customer assigned values have been installed to replace factory values: To check air pre-heater high cutoff temperature setting press key combination Set, PreHeater. Press the Enter key three times to view high cutoff alarm setting. Press Clear key to return to normal operating mode.

2. Press the key sequence Set – Set – Pre Heater to view the pre heater temperature. If temperature measurement is low (30°F - 40°F), the sensor TE-7 that controls air temperature is failing and should be replaced. (LSC part number- 77700941).

3. Check the operation of Air Pre-heater solid state relay SSR-2. Open AC electrical enclosure, and observe the green LED located on the SSR-2. The LED indicates the operating status of relay. When LED is ON the Air Pre-heater element is energized. When LED is OFF the air heater element is de-energized. Confirm that the LED is OFF when the air Pre-heater temperature is at or above the control set point. If the air temperature is above the control set point and the relay SSR-2 is ON, replace the relay. (LSC part number 77780152).

IVT Am bient Conditioners

-40

-20

0

20

40

60

80

100

120

140

0 5 10 15 20 25 30

M ist F low (SCFM )

Am

bien

t Tem

p (F

)

Am b< -4F (-20C), Cabinet Heating Required - ATEX

Am bient > 120F (50C), Cabinet Cooler Reqd - NEC

Am bient > 104F (40C) , Cabinet Cooler Reqd - ATEX

Am b< 15F (-10C), A ir P re-Heater Required - NEC and ATEX


PARTS LIST / DRAWINGS / SCHEMATICS

EXPLOSION HAZARD – Substitution of components may impair suitability for Class I, Division 2. WARNING


Spare Parts Lists MAINTENACE SPARE PARTS Quantity of IVT Oil Mist Generators

(ITEMS TO BE REPLACED EVERY SIX MONTHS) 1 5 10 15 20 25 30 35 40 45 50Quan./ IVT Part Number Description Recommended Quantity

1 77500487 ELEMENT, OIL FILTER SPIN-ON 4 9 13 15 18 20 22 24 25 27 281 77780352 ELEMENT, AIR FILTER 4 9 13 15 18 20 22 24 25 27 282 77500861 GASKET, RESERVOIR CLEANOUT 8 18 25 31 36 40 44 47 51 54 572 77800092 GASKET, RESERVOIR CLEAN OUT 8 18 25 31 36 40 44 47 51 54 57

REPAIR AND OPERATION SPARE PARTS 1 5 10 15 20 25 30 35 40 45 50

Quan./ IVT Part Number Description Recommended Quantity 2 77600087 GAUGE, PRESS. MIST SS 2 4 6 8 9 10 11 12 13 13 142 77600088 GAUGE, PRESS AIR SS 2 4 6 8 9 10 11 12 13 13 141 77600966 VALVE, RELIEF 1 2 3 4 4 5 5 6 6 7 71 77710826 RELAY 24 VDC COIL 10A/240V CONTACT 1 2 3 4 4 5 5 6 6 7 72 77780111 GAUGE, OIL LEVEL 8" LONG 2 4 6 8 9 10 11 12 13 13 142 77780119 CYLINDER, AIR 2 4 6 8 9 10 11 12 13 13 142 77780120 SIGHT, WINDOW W/GASKET 2 4 6 8 9 10 11 12 13 13 142 77780121 SEAL, POLYPACK 2 4 6 8 9 10 11 12 13 13 141 77780131 VALVE, SOLENOID 24VDC 1/4 NPT S.S. 1 2 3 4 4 5 5 6 6 7 71 77780134 PUMP, OIL TRANSFER 1 2 3 4 4 5 5 6 6 7 71 77780136 VALVE, CHECK 3/8"TX3/8"P 100PSI SS 1 2 3 4 4 5 5 6 6 7 71 77780147 GAUGE, OIL LEVEL 24" LONG 1 2 3 4 4 5 5 6 6 7 72 77780965 FUSE, 1.6AMP @ 250VAC 5 X 20MM 2 4 6 8 9 10 11 12 13 13 143 77780152 RELAY, SOLID STATE 240VAC @ 25A MAX 3 7 9 12 13 15 16 18 19 20 214 77780153 FUSE, 1AMP @ 250VAC 5 X 20MM 4 9 13 15 18 20 22 24 25 27 284 77780154 FUSE, 4AMP @ 250VAC 5 X 20MM 4 9 13 15 18 20 22 24 25 27 284 77780155 FUSE, 10AMP @ 250VAC 4 9 13 15 18 20 22 24 25 27 281 77780269 VALVE, RELIEF 3/4"P SS , 2.4 PSI 1 2 3 4 4 5 5 6 6 7 7

77780179 HEATER, 850W 115VAC SJO LEAD CORD (ATEX) 2 4 6 8 9 10 11 12 13 13 1477780180 HEATER, 850W 230VAC SJO LEAD CORD (ATEX) 2 4 6 8 9 10 11 12 13 13 1477780181 HEATER, 850W 115VAC 2-LEAD (NEC) 2 4 6 8 9 10 11 12 13 13 14

2 (*) 77780182 HEATER, 850W 230VAC 2-LEAD (NEC) 2 4 6 8 9 10 11 12 13 13 14

(*) Select the correct heater element for the purchased IVT construction –Reference the section titled “UNIT IDENTIFICATION AND LABELING”.


ADDITIONAL SPARES AVAILABLE THROUGH LSC Quan./ IVT Part Number Description

4 77700941 THERMOCOUPLE,TYPE K 3/16 OD 4 IN LG 1 77710711 BOARD, DISPLAY 1 77780124 AIR FILTER 1/2 NPT 3 77780127 REGULATOR 1/2"NPT 0-60 PSI 2 77780130 VALVE, TOGGEL SPRING RETURN 3/8T S.S 2 77780138 TRANSDUCER, PRESS.0-150 PSI 1/4 NPT 1 77780139 TRANSDUCER, PRESS.0-100 PSI 1/4 NPT 1 77780140 TRANSDUCER, PRESS.0-5 PSI 1/4 NPT 1 77780141 TRANSMITTER, LEVEL CONTROL 1 77780142 RTD,1/4 OD X 4 LG. ELEMENT 1 77780143 SWITCH, PRESS.ADJ.1-12 PSI 1 77780144 PID HEATER CONTROLLER 1 77780145 SWITCH, DUAL LEVEL 1 77780148 THERMOCOUPLE,TYPE K 3/16 OD 33IN LG 1 77780156 BOARD, EXPANSION 1 77780157 BOARD, MAIN (WITH PROGRAMMED EPROM) 1 77780158 KEYPAD, CONTROLLER IVT 1 77780159 TRANSFORMER 120/240VAC X 24VAC 75VA 1 77780186 EPROM, PROGRAMMED FOR IVT 1 77780195 DETECTOR, MIST MONITOR ASSY (IVT) 1 77780265 TRANSDUCER, TEMP. (PREHEATER)


Process & Instrument Diagrams IVT Oil Mist Generator

PRESSURE TRANSDUCER-SUPPLY AIR PRESSUREPRESSURE TRANSDUCER-SUPPLY OIL PRESSURETEMPERATURE SENSOR-SUPPLY OIL RESERVOIR (TC)TEMPERATURE CONTROL- H-1 AIR / OIL HEATER (TC)

PRESSURE TRANSDUCER-REGULATED AIR PRESSURE

TEMPERATURE CONTROL- H-2 AIR / OIL HEATER (TC)

AIR / OIL HEATER, AUXILLIARY OIL MIST GENERATOR

TEMPERATURE SENSOR - AMBIENT AIR TEMPERATURE (TC)

AIR PRESSURE REGULATOR - OIL PUMP AIR SUPPLY

PRESSURE POP OFF VALVE - OIL MIST RESERVOIR

MIST PRESSURE INDICATOR, 0-100 IN H20 (0-7.3 mm Hg)MIST PRESSURE INDICATOR, 0-100 IN H20 (0-7.3 mm Hg)

TEMPERATURE SENSOR - H-1 AIR / OIL HEATER CUT-OUT (TC)

TEMPERATURE SENSOR - H-2 AIR / OIL HEATER CUT-OUT (TC)

THERMAL RELIEF VALVE, 150 PSI (10.3 BAR) CRACKING PRESSURE

PRESSURE TRANSDUCER-MIST PRESSURE

AIR PRESSURE REGULATOR - AUXILIARY UNIT

AIR / OIL HEATER, MAIN OIL MIST GENERATOR

AIR PRESSURE REGULATOR - MAIN UNITAIR PRESSURE INDICATOR, 0-100 PSI (0-6.9 BAR)

GREEN LOCAL UNIT STATUS LIGHT-NORMAL

AIR PRESSURE INDICATOR, 0-100 PSI (0-6.9 BAR)

PT-4

TE-6H-1

PCV-1

PCV-3PCV-2

H-2

PI-1

TE-3TE-2

TE-5TE-4

TE-1

TRV

XL-1PV

PI-3PI-4

PI-2

PT-3PT-2PT-1

ITEM DESCRIPTION

SYMBOL IDENTIFICATIONS

CUSTOMEROPTIONAL

INDICATION

T-304 S.S. FLANGE1/2" 150# RFINLET AIR

DCSCUSTOMER

AMBIENT

RUN(GREEN) (RED)

ALARM

XL-2 RED LOCAL UNIT STATUS LIGHT-FAULT

ATM.

LEVEL INDICATOR

LEVEL TRANSMITTER

OIL LEVEL GAUGE - BULK OIL RESERVOIROIL LEVEL GAUGE - MAIN UNIT MIST TANK

OIL LEVEL GAUGE - AUXILIARY MIST TANK

PRESSURE SWITCH - LOW AIR PRESSURESOLENOID OPERATED AIR VALVE - OIL PUMP CONTROL

INLET AIR FILTERLOW OIL LEVEL SWITCH

OIL SUPPLY FILTER

INSTRUMENT AIR SUPPLYOIL MIST DENSITY SENSOROIL LEVEL CONTROL SWITCH

T-304 S.S. FLANGE2" 150# RF

MIST SUPPLY

D-1

LSLLS

F-2F-1

LIIA

LG-3

PSL

LT-1

LG-2LG-1

S-1

LubriMist® Model IVT Oil Mist Generator Page 167 of 212 Optional Equipment • De-misting Unit • Warm Ambient Option - Cabinet Cooling • Cool Ambient Option -Air Pre-Heater for NEC construction

-Air Pre-Heater with Cabinet Heaters for ATEX construction • Air Purge (Rotometer) • Auto Bulk Oil Fill

H-4 CABINET HEATER w/ T-STAT- OPERATOR ACCESS - ATEX ONLYH-5 CABINET HEATER w/ T-STAT- MECH. COMPARTMENT - ATEX ONLYTI TEMPERATURE GAUGE - CABINET INTERIORTS-1 TEMPERATURE SWITCH - CABINET INTERIOR

SOLENOID OPERATED AIR VALVE - ATEX CABINET COOLERS-3

LO

0.69 BAR10 PSI

DESCRIPTIONAIR PREHEATER ELEMENT

HIGH OIL LEVEL SWITCH

INSTRUMENT AIR SUPPLY

SUPPLY OIL PRESSURE GAUGESOLENOID OPERATED OIL VALVE

AIR PRESSURE REGULATOR - DEMISTER PUMP

SYMBOL IDENTIFICATIONS

START TEMPERATURE SENSOR, - H3 AIR PREHEATER (TT)TEMPERATURE CONTROL- H3 AIR PREHEATER (TC)TEMPERATURE SENSOR - H-3 AIR PRE-HEATER CUT-OUT (TC)AIR PRESSURE REGULATOR - AIR COOLER

OIL LEVEL GAUGE - AUXILIARY MIST TANKOIL LEVEL GAUGE - BULK OIL RESERVOIROIL LEVEL GAUGE - MAIN MIST TANKOIL LEVEL GAUGE - DEMISTER TANKOIL LEVEL GAUGE - BULLS EYE SIGHT

ITEM

INLET AIR1/2" 150# RFT-304 S.S. FLANGE

2" 150# RFT-304 S.S. FLANGE

MIST RETURN

IA

S-2PI-5

PCV-5PCV-4

H3TE-9TE-7TE-8

LSHF-1

IA

F-3

LO

LG-5LG-4LG-3LG-2LG-1

INLET AIR FILTERINLET OIL FILTER

LUBE OIL SUPPLY

LubriMist® Model IVT Oil Mist Generator Page 168 of 212 Electrical Wiring Diagrams And Schematics / IVT – NEC Construction

Ladder Diagram / 115 VAC Supply Voltage / IVT – NEC Construction

LubriMist® Model IVT Oil Mist Generator Page 169 of 212 Voltage Panel Wiring Diagram / 115 VAC Supply Voltage / IVT – NEC Construction

OFF

ON

AUXILIARY UNIT ELECTRICAL PANEL

INPUT INPUTBU-SSR-2BU-SSR-1

OUTPUT OUTPUT

2 3

++

1 64 7

3

54

678

21

1 4

MAIN UNIT AC POWER ELECTRICAL PANEL

EC-2

SWITCH

HEATERAIR/OIL

SEE DETAIL

LOW PRESSURE

6

5

PSL

3 H-2

87

10131 54 11

OUTPUT

INPUT

SSR-1

T-1

H4

H2

H3

H112

8

+2

17163

14

123

54

6

X2

X1

15

-

10

11

12

13

151617

9

14+-

OUTPUTSSR-2

INPUT

78

AUXILIARY UNITPOWER SWITCH

AUXILIARY UNIT ELECTRONIC CONTROLLER

10

HEATER

(OPTIONAL EQUIP)AIR PREHEATER

LOCAL UNITSTATUS LIGHTS

24VAC TO SOLID STATE CONTROLLER

24VDC FROM SOLID STATE CONTROLLER

6 H-157 H-3

1514

13

164

9

179

AIR/OIL

G

R

XL-1

XL-2

POWER SWITCHMAIN UNITOFF

ON

6

AC VOLTAGE COMPONENTS

INCOMING POWER115 VAC 1PH

2L1

2L21L2

1L1

DC VOLTAGE COMPONENTS

LubriMist® Model IVT Oil Mist Generator Page 170 of 212 Ladder Diagram / 230 VAC Supply Voltage / IVT – NEC Construction

LubriMist® Model IVT Oil Mist Generator Page 171 of 212 Voltage Panel Wiring Diagram / 230 VAC Supply Voltage / IVT – NEC Construction

AUXILIARY UNIT ELECTRICAL PANEL

OUTPUTBU-SSR-1

INPUT

2

12

876

4

5

3

41

+

3

POWER SWITCHMAIN UNIT

SEE DETAIL

AIR/OILHEATER

78

35

6

7H-2

PRESSURE

PSLLOW

OUTPUT

INPUT

SWITCH+BU-SSR-2

69

9164

17

141513

8

10

1716

1514

13

12

11

9

6

7

54321

57

6SSR-2

-+

17

OUTPUT

INPUT

16

SSR-1

X1

X2

T-1H1

H3

H4

H2

-

OUTPUT

INPUT+

14

15

2

3

12

8

413 10 11 51

MAIN UNIT AC POWER ELECTRICAL PANEL

ON

OFFPOWER SWITCH

CONTROLLER

AUXILIARY UNIT

AUXILIARY UNIT

ELECTRONIC

EC-2

1 4

ON

10 6

OFF

AIR/OIL

LOCAL UNITSTATUS LIGHTS

AIR PREHEATER(OPTIONAL EQUIP)

HEATER

XL-2

XL-1G

R

H-3

H-1

24VDC FROM SOLID STATE CONTROLLER

24VAC TO SOLID STATE CONTROLLER

INCOMING POWER230 VAC 1PH

2L21L22L11L1

AC VOLTAGE COMPONENTS DC VOLTAGE COMPONENTS

LubriMist® Model IVT Oil Mist Generator Page 172 of 212 Electrical Wiring Diagrams And Schematics / IVT –ATEX Construction


Ladder Diagram / 115 VAC Supply Voltage / IVT – ATEX Construction Voltage Panel Wiring Diagram -115 VAC Supply Voltage / IVT – ATEX Construction

LubriMist® Model IVT Oil Mist Generator Page 174 of 212 Ladder Diagram / 230 VAC Supply Voltage / IVT – ATEX Construction


Voltage Panel Wiring Diagram -230 VAC Supply Voltage / IVT – ATEX Construction

LubriMist® Model IVT Oil Mist Generator Page 176 of 212 Voltage Panel Wiring Diagram / Warm Ambient Option – Cabinet Cooling – 115 or 230 VAC - ATEX Construction Only


Voltage Panel Wiring Diagram / Cold Ambient Option - Cabinet heating – 230 VAC - ATEX Construction Only


Auxiliary Oil Mist Generator Controller Wiring Connection Detail

LubriMist® Model IVT Oil Mist Generator Page 179 of 212 Component Power Requirements And Identification NEC Constructions

Full Load Amperes Description 115 VAC 230 VAC

Main Oil Mist Generator Air/Oil Heater (850 watts) 7.4 Amperes 3.7 Amperes Electronic Controller 0.7 Amperes 0.4 Amperes Air Pre-Heater (850 watts) 7.4 Amperes 3.7 Amperes Auxiliary Oil Mist Generator Air/Oil Heater (850 watts) 7.4 Amperes 3.7 Amperes Electronic Controller 40mA 40mA ATEX Constructions

Full Load Amperes Description 115 VAC 230 VAC

Main Oil Mist Generator Air/Oil Heater (850 watts) 7.4 Amperes 3.7 Amperes Electronic Controller 0.7 Amperes 0.4 Amperes Air Pre-Heater (850 watts) 7.4 Amperes 3.7 Amperes Cabinet Heater - Operator Access Compartment Not Available 0.6 Amperes Cabinet Heater - Mechanical Compartment Not Available 0.6 Amperes Auxiliary Oil Mist Generator Air/Oil Heater (850 watts) 7.4 Amperes 3.7 Amperes Electronic Controller 40mA 40mA


Component Identification Tag Description PT-1 Pressure Transducer – Mist Pressure PT-2 Pressure Transducer – Regulated Air Pressure PT-3 Pressure Transducer – Supply Air Pressure PT-4 Pressure Transducer – Supply Oil Pressure TE-1 Temperature Sensor – Supply Oil Reservoir (TC) TE-2 Temperature Control – H-1 Air / Oil Heater Control (TC) TR-3 Temperature Sensor – H-1 Air / Oil Heater Cut-Out (TC) TE-4 Temperature Control – H-2 Air / Oil Heater Control (TC) TE-5 Temperature Sensor – H-2 Air / Oil Heater Cut-Out (TC) TE-6 Temperature Sensor - Ambient Air TE-7 Temperature Control – H-3 Air Pre-Heater Control (TC) TE-8 Temperature Sensor – H-3 Air Pre-Heater Cut-Out (TC) TE-9 Temperature Start Sensor – H-3 Air Pre-Heater (TT) H1 Air / Oil Heater, Main Oil Mist Generator H2 Air / Oil Heater, Auxiliary Oil Mist Generator H3 Air Pre-Heater H4 Cabinet Heater w/ Thermostat – Operator Access Compartment – (ATEX only) H5 Cabinet Heater w/ Thermostat –Mechanical Compartment – (ATEX only) XL-1 Green Local Status Light – Normal XL-2 Red Local Status Light – Fault PSL Pressure Switch – Low Regulated Air Pressure – Auxiliary Unit S-1 Solenoid Operated Air Valve – Oil Supply Pump Control S-2 Solenoid Operated Air Valve – Auto Bulk Fill S-3 Solenoid Operated Air Valve – Cabinet Cooler Control (ATEX only) LT-1 Level Transmitter – Bulk Oil Reservoir D-1 Oil Mist Density Sensor LS Oil Level Control Switch LSL Low Oil Level Switch LSH High Oil Level Switch – Demisting Reservoir T-1 Power Transformer 120/240 VAC x 24 VAC 75 VA UY-1 Relay –Unit Status – Hermetically Sealed EC-1 Electronic Controller – Main Oil Mist Generator EC-2 Electronic Controller – Auxiliary Oil Mist Generator TS-1 Temperature Switch – Cabinet Cooler Control (ATEX only)

LubriMist® Model IVT Oil Mist Generator Page 181 of 212 IVT Low Voltage Controller Layout

MAIN BOARDANALOG INPUT (AI)

MAIN BOARDDIGITAL INPUT (DI)

MAIN UNIT ELECTRONIC CONTROLLER

EC-1

UN-REGULATED26VDC

24VACINPUT

MAIN SYSTEM BOARD

24VAC FROM TRANSFORMER

10 PIN RIBBONCABLE

DATA CONN

DATA CONN24VDC

REGULATED 24VDC TO AC VOLTAGE PANEL

EXPANSION BOARD

EXPANSION BOARDANALOG INPUT (AI)

RS-232

RS-422

DISPLAY CONNECTION

RS-422 DATA COMMUNICATION

MAIN BOARDDIGITAL OUTPUT (D0)

CABLERIBBON34PIN

CABLE

DISPLAY BOARD

RIBBON34PIN

LubriMist® Model IVT Oil Mist Generator Page 182 of 212 Main Board Analog Input Terminal Strip

LT1-2WHITE

3A

MAIN BOARDANALOG INPUT (AI)

OIL LEVEL TRANSMITTER

THERMOCOUPLE (TYPE K)MIST HEAD - HIGH AIR TEMP

MIST HEAD - AIR TEMPTHERMOCOUPLE (TYPE K)

TEMPERATURE (100OHM RTD)

BULK OIL RESERVOIR

AI #7

AI #8

AI #6

AI #5

YELLOW

YELLOW

TE2-1B

TE3-1

TE2-2

BA

FERRITE

FERRITE

RED

RED

RED

TE6-2

TE3-2

TE6-1

AB

LT1-1

AB

RED

FERRITE

FERRITE

RED

TE-3TE

-2TE

-6

AMBIENT

1

PRE-HEATER - START TEMPTEMPERATURE TRANSDUCERAI #2

WHITETE9-1B

TE9-2A

FERRITE

RED

TE-9

LubriMist® Model IVT Oil Mist Generator Page 183 of 212 Main Board Digital Input Terminal Strip

MAIN BOARDDIGITAL INPUT (DI)

DI #10

WHITE

RED

LSH-1

LSH-2

-

+

HIGH LEVEL SWITCHDEMISTING MODULE

DI #9

DI #8

GREEN

RED

WHITE

BLACKLSL-1

LSL-2

-

+

LS-1

LS-2

-

+

MIST GENERATION TANKLOW LEVEL SWITCH

MIST GENERATION TANKLEVEL CONTROL SWITCH

LSH

LSL

LS


Main Board Digital Output Terminal Strip

MAIN BOARDDIGITAL OUTPUT (D0)

AIR PRE-HEATER RELAY

REMOTE SIGNAL

STATUS LIGHT RELAY

AIR PUMP SOLENOID

BULK OIL SOLENOID

UY-1 R2

S-1

+RELAYS.S.

SSR-1

-INPUT

+RELAYSSR-2

S.S.

-

INPUT

AIR/OIL HEATER RELAY

+-

CUSTOMER REMOTE SIGNAL24VDC@1A MAX.

DEMISTER

2

S-2

7

S1-2

S1-1

DO #1

-+

-

H3-1

H1-2

H1-1

H3-2

DO #2

-+

DO #3+

UY1-2

DO #4+

DO #5

-+

UY1-1

S2-2

S2-1

DO #6

-+

-


Expansion Board Analog Input Terminal Strip

BPT4-1

ATE7-2

EXPANSION BOARDANALOG INPUT (AI)

FERRITEPRE-HEATER - AIR TEMPTHERMOCOUPLE (TYPE K)

TE-7

YELLOWBTE7-1

AI #8

FERRITETHERMOCOUPLE (TYPE K)

BULK TANK - OIL TEMPTE-1BTE1-1

YELLOW

RED

ATE1-2RED

AI #7

FERRITETHERMOCOUPLE (TYPE K)

PRE-HEATER - HIGH AIR TEMPTE-8

BTE8-1YELLOW

AI #6

TE8-2 ARED

RED

2 GREEN4D1-3 +15

APT2-2

AI #4FERRITEPT-3 TRANSDUCER

FERRITESUPPLY OIL PRES.PT-4 TRANSDUCER

BLACK

APT4-2

AI #5

BPT3-1RED

FERRITE

SUPPLY AIR PRES.

TRANSDUCERREGULATED AIR PRES.PT-2

APT3-2BLACK

BPT2-1RED

AI #3

FERRITETRANSDUCERMIST PRESSUREPT-1

BPT1-1

BLACK

RED

APT2-2BLACK

AI #2

FERRITE

3

32TB1

1

DI-1

5D1-2

D1-1 +5RED

AWHITE

AI #1

OIL MIST DENSITY

5TB2

DETECTOR 4

1

D1-4 GNDBLACK

BROWN-15D1-5


RS-422/485 Data Communication Terminal Strip

TX-

TX++

-

RS-422/485 DATA COMMUNICATION

RX+

RX-

+

-

LubriMist® Model IVT Oil Mist Generator Page 187 of 212 Bill Of Materials – IVT / NEC Construction. ITEM PART NUMBER QUANTITY DESCRIPTION

1 77500489 1 SPIN-ON OIL FILTER 2 77600087 2 MIST PRESSURE GAUGE 3 77600088 2 REGULATOR PRESSURE GAUGE 4 77780130 2 TOGGLE VALVE 5 77780111 2 OIL LEVEL GAUGE, 8 INCHES LONG 6 77780120 2 WINDOW SIGHT GLASS 7 77780147 1 OIL LEVEL GAUGE, 20 INCHES LONG

8 76050031 2 PLUG, ½ “ 150 / 3000# - T-304 SS 9 77700320 2 BALL VALVE ½” T-304 SS

10 77700321 1 BALL VALVE, ¾”, ROUND HANDLE, SS 11 76050040 1 PLUG, ¾“ 150 / 3000# - T-304 SS 12 77600966 1 RELIEF VALVE 13 77780386 1 OIL TRANSFER PUMP 14 77780140 1 PRESSURE TRANSDUCER, 0-5 PSI 15 77780139 1 PRESSURE TRANSDUCER, 0-100 PSI 16 77780138 2 PRESSURE TRANSDUCER, 0-150 PSI 17 77780145 1 DUAL LEVEL SWITCH 18 77780131 1 AIR SOLENOID VALVE, 24 VDC, ¼ NPT, SS BODY 19 77780126 3 BALL VALVE, ½”, LEVER HANDLE, SS 20 77780127 3 PRESSURE REGULATOR, 0-60 PSI, ½” NPT 21 77780141 1 LEVEL TRANSMITTER 22 77780148 1 THERMOCOUPLE, TYPE K, 33 “ LONG 23 73160138 1 FLANGE, 2” 150# THRD., T-304 SS 24 77780124 1 AIR FILTER, ½” NPT 25 77780034 1 MIST OUTLET VALVE ASSEMBLY 26 77780269 2 POP OFF VALVE, 2.4 PSI, ¾ NPT 27 2 MIST GENERATING KIT (SIZE PER MIST CAPACITY) 28 77780195 1 OIL MIST MONITOR DETECTOR ASSEMBLY 29 77780142 1 AMBIENT TEMPERATURE SENSOR, RTD, 100 OHM 30 77710711 1 DISPLAY 31 77710441 1 CONDUIT OUTLET BOX 32 77780143 1 PRESSURE SWITCH, ADJ. 1-12 PSI 33 77780144 1 TEMPERATURE CONTROLLER 34 77710826 1 RELAY, HERMETICALLY SEALED 24 VDC COIL 35 36 77780149 2 SWITCH, FACTORY SEALED 2-POLE, FEED THRU 37 77780136 1 CHECK VALVE, 100 PSI CRACKING PRESS 38 77780152 3 (a) SOLID STATE RELAY 39 77780159 1 CONTROL TRANSFORMER 40 77780119 2 AIR CYLINDER 41 77780153 1 / 2 (d) FUSE, 1 AMP 42 77780154 1 / 1 (d) FUSE, 4 AMP 43 77780155 2 / 4 (d) FUSE, 10 AMP 44 77780156 1 EXPANSION BOARD, ANALOG INPUT 45 77780157 1 ELECTRONIC CONTROLLER BOARD 46 77780337 1 KEYPAD 47 77700941 4 (b) THERMOCOUPLE, TYPE K 4” LONG 48 77780181

77780182 2 (c) 2 (c)

AIR / OIL HEATER ELEMENT 115 VAC 850 WATT AIR / OIL HEATER ELEMENT 230 VAC 850 WATT

49 77780965 1 FUSE, 1.6 AMP 50 77780265 1 TRANSDUCER, TEMPERATURE (PRE-HEATER OPTION

ONLY) 51 77780331 1 SUPPRESSOR, TRANSIENT 52 77780313 1 / 2 (d) FUSE, 8 AMP 53 77780327 1 LED LIGHT CLUSTER – GREEN – 24 V 54 77780328 1 LED LIGHT CLUSTER – RED – 24 V

(a) Quantity is 4 when Air Pre-heater option is included (b) Quantity is 6 when Air Pre-heater option is included (c) Quantity is 3 when Air Pre-heater option is included (d) Quantity shown is for 115 Volt / 230 Volt


General Arrangement Drawings – IVT / NEC Construction

Operator Panel

10 11

OPERATOR INTERFACEFRONT

46

DETAIL "A"

DETAIL "D"

OIL TRANSFER PUMP MANUAL AIR VALVE

8 9

7

4

5

1

30

BULK OILFILL PORT

8 9

4

2

5

DETAIL "D"

DETAIL "A"

AUXILIARY RESERVOIRMANUAL OILREFILL

DETAIL "A"

DETAIL "A"

53 54


Main Oil Mist Generator Access, (left door)


Auxiliary Oil Mist Generator Access, (right door)


Top View

DETAIL "F"

16

47

TOP VIEW

28

31

47

4848


Electrical Power Switches


Oil Transfer Pump / Oil Mist Discharge


Air Supply Components


Electrical Control Components

AC PANEL COMPONENTS - NEC 230VAC

AC PANEL COMPONENTS - NEC 115VAC

43

38

49

38

32 3838

33

39

41

43

52

41

43

38

49

43

38

32

34

38 38

33

39

42

4243

(INCLUDED WITH AIR PREHEATER OPTION)


51

52

34

51

42

42

LubriMist® Model IVT Oil Mist Generator Page 196 of 212 Bill Of Materials – IVT / ATEX Construction. ITEM PART NUMBER QUANTITY DESCRIPTION

1 77500489 1 SPIN-ON OIL FILTER 2 77600087 2 MIST PRESSURE GAUGE 3 77600088 2 REGULATOR PRESSURE GAUGE 4 77780130 2 TOGGLE VALVE 5 77780111 2 OIL LEVEL GAUGE, 8 INCHES LONG 6 77780120 2 WINDOW SIGHT GLASS 7 77780147 1 OIL LEVEL GAUGE, 20 INCHES LONG 8 76050031 2 PLUG, ½ “ 150 / 3000# - T-304 SS 9 77700320 2 BALL VALVE ½” T-304 SS

10 77700321 1 BALL VALVE, ¾”, ROUND HANDLE, SS 11 76050040 1 PLUG, ¾“ 150 / 3000# - T-304 SS 12 77600966 1 RELIEF VALVE 13 77780386 1 OIL TRANSFER PUMP 14 77780140 1 PRESSURE TRANSDUCER, 0-5 PSI 15 77780139 1 PRESSURE TRANSDUCER, 0-100 PSI 16 77780138 2 PRESSURE TRANSDUCER, 0-150 PSI 17 77780145 1 DUAL LEVEL SWITCH 18 77780131 1 AIR SOLENOID VALVE, 24 VDC, ¼ NPT, SS BODY 19 77780126 3 BALL VALVE, ½”, ROUND HANDLE, SS 20 77780127 3 PRESSURE REGULATOR, 0-60 PSI, ½” NPT 21 77780141 1 LEVEL TRANSMITTER 22 77780148 1 THERMOCOUPLE, TYPE K, 33 “ LONG 23 73160138 1 FLANGE, 2” 150# THRD., T-304 SS 24 77780124 1 AIR FILTER, ½” NPT 25 77780034 1 MIST OUTLET VALVE ASSEMBLY 26 77780269 2 POP OFF VALVE, 4 PSI, ¾ NPT 27 2 MIST GENERATING KIT (SIZE PER MIST CAPACITY) 28 77780195 1 OIL MIST MONITOR DETECTOR ASSEMBLY 29 77780142 1 AMBIENT TEMPERATURE SENSOR, RTD, 100 OHM 30 77710711 1 DISPLAY 31 77780246 1 TERMINAL ENCLOSURE, SUPPLY POWER CONN. 32 77780143 1 PRESSURE SWITCH, ADJ. 1-12 PSI 33 77780144 1 TEMPERATURE CONTROLLER 34 77710826 1 RELAY, HERMETICALLY SEALED 24 VDC COIL 35 77780239 TERMINAL ENCLOSURE, REMOTE ALARM CONN. 36 77780247 1 SELECTOR SWITCH, 3-WAY 37 77780136 1 CHECK VALVE, 100 PSI CRACKING PRESS 38 77780152 3 (a) SOLID STATE RELAY 39 77780159 1 CONTROL TRANSFORMER 40 77780119 2 AIR CYLINDER 41 77780153 1 / 2 (d) FUSE, 1 AMP 42 77780154 1 / 1 (d) FUSE, 4 AMP 43 77780155 2 / 4 (d) FUSE, 10 AMP 44 77780156 1 EXPANSION BOARD, ANALOG INPUT 45 77780157 1 ELECTRONIC CONTROLLER BOARD 46 77780337 1 KEYPAD 47 77700941 4 (b) THERMOCOUPLE, TYPE K 4” LONG 48 77780179

77780180 2 (c) 2 (c)

AIR / OIL HEATER ELEMENT 115 VAC 850 WATT AIR / OIL HEATER ELEMENT 230 VAC 850 WATT

49 77780965 1 FUSE, 1.6 AMP 50 77780265 1 TRANSDUCER, TEMPERATURE (PRE-HEATER OPTION

ONLY) 51 77780331 1 SUPPRESSOR, TRANSIENT 52 77780313 1 / 2 (d) FUSE, 8 AMP

(a) Quantity is 4 when Air Pre-heater option is included (b) Quantity is 6 when Air Pre-heater option is included (c) Quantity is 3 when Air Pre-heater option is included (d) Quantity shown is for 115 Volt / 230 Volt

LubriMist® Model IVT Oil Mist Generator Page 197 of 212 General Arrangement Drawings – IVT / ATEX Construction

Operator Panel

FRONT

1110

BULK OILFILL PORT

98

DETAIL "A"

AUXILIARY RESERVOIRMANUAL OILREFILL

2

4

5

DETAIL "A"

DETAIL "D"

DETAIL "A"

STATUS LIGHTRED & GREEEN

OIL TRANSFER PUMP MANUAL AIR VALVE

DETAIL "D"

9

7

8

4

5

1

DETAIL "A"

46

30

OPERATOR INTERFACE


Main Oil Mist Generator Access, (left door)

027

17

2

12

LEFT SIDEMAIN ACCESS

DETAIL "G"44

15

45


Auxiliary Oil Mist Generator Access, (right door)


Top View

TOP VIEW

16

47

28

DETAIL "F"

48 48

47


Electrical Power Switches


Oil Transfer Pump / Oil Mist Discharge


Air Supply Components


Electrical Control Components

39

52

41

43

41

42

43

42

3838

34

AC PANEL COMPONENTS - CENELEC 115VAC


38

49

43

AC PANEL COMPONENTS - CENELEC 230VAC

32

38

34

38 38

33

51

52

43

4238

43

49

38

32

34

33

38

51 39

42


Optional Equipment

Cold Ambient Option - Air Preheating - NEC and ATEX Constructions ITEM PART NUMBER QUANTITY DESCRIPTION

1 77780265 1 TRANSDUCER, TEMPERATURE (PRE-HEATER OPTION ONLY)

2 77780179

77780180

77780181

77780182

1

AIR / OIL HEATER ELEMENT 115 VAC 850 WATT –ATEX CONSTRUCTION AIR / OIL HEATER ELEMENT 230 VAC 850 WATT - ATEX CONSTRUCTION AIR / OIL HEATER ELEMENT 115 VAC 850 WATT –NEC CONSTRUCTION AIR / OIL HEATER ELEMENT 230 VAC 850 WATT - NEC CONSTRUCTION

3 77700941 4 (b) THERMOCOUPLE, TYPE K 4” LONG

PRE-HEATER OPTION

( HEATER CONTROL )

( HEATER CUTOUT )

( HEATER START )1

2

3

3


Cold Ambient Option - Cabinet heating – ATEX only ITEM PART NUMBER QUANTITY DESCRIPTION

1 77780442 1 CABINET HEATER – 130 WATT w/ THERMOSTAT 2 77780445 1 TEMPERATURE GAUGE

LubriMist® Model IVT Oil Mist Generator Page 207 of 212 Air Purge Option ITEM PART NUMBER QUANTITY DESCRIPTION

1 51052525 1 PLUG VALVE 2 77700287 1 ROTOMETER, INSTRUMENT AIR PURGE 3 77700288 1 VENT, ENCLOSURE AIR PURGE

LubriMist® Model IVT Oil Mist Generator Page 208 of 212 Warm Ambient Option – Cabinet Cooling – NEC Construction ITEM PART NUMBER QUANTITY DESCRIPTION

1 77700320 1 BALL VALVE, ½ “ SS 2 77500473 1 AIR FILTER / PRESSURE REGULATOR 3 77600863 1 VORTEX COOLER 4 77600566 1 PRESSURE GAUGE, 1-160 PSIG

LubriMist® Model IVT Oil Mist Generator Page 209 of 212 Warm Ambient Option – Cabinet Cooling – ATEX Construction ITEM PART NUMBER QUANTITY DESCRIPTION

1 77780443 1 AIR PRESSURE REGULATOR 2 77780444 1 VORTEX COOLER 3 77780448 1 TEMPERATURE SWITCH 4 77780335 1 SOLENOID OPERATED AIR VALVE 5 77600566 1 AIR PRESSURE GAUGE, 0-160 PSIG 6 77780445 1 TEMPERATURE GAUGE

71111

988

91010

664

32

1G

55G

12

34

7


Optional Demisting Unit ITEM PART NUMBER QUANTITY DESCRIPTION

1 77500843 1 OIL TRANSFER PUMP 2 77780127 1 AIR PRESSURE REGULATOR 3 77600088 1 GAUGE, REGULATED AIR PRESSURE 4 1 VENT CAP 5 77780344 1 CHECK VALVE, 10 PSI 6 77780198 1 HIGH LEVEL ALARM SWITCH 7 77780105 1 GASKET, LEVEL SWITCH ADAPTER 8 77780011 1 OIL LEVEL GAUGE 9 77600853 1 LEVEL OPERATED AIR SWITCHING VALVE

10 77500875 1 BULLS EYE SIGHT


Optional Auto Bulk Oil Fill ITEM PART NUMBER QUANTITY DESCRIPTION

1 77700321 1 BALL VALVE, S.S. ¾” NPT. 2 77780335 1 SOLENOID OIL VALVE – 24VDC 3 77500487 1 OIL FILTER ELEMENT, 10 MICRON – SPIN-ON 4 77780344 1 CHECK VALVE, 10 PSI 5 77600565 1 PRESSURE GAUGE, 0-300 PSI (0-21 BAR)

LubriMist® Model IVT Oil Mist Generator Page 212 of 212 NOTES: ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ __________________________________________________________________________________________________________________________________________________________

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