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Dripmaster EDD-4C
U.S. Patent No. 5,996,739 & other countries
User Guide
Document filename: Dripmaster_EDD-4C_User_Guide_18May10.doc
Important notice: Hoffmann & Hoffmann reserves the right to change this document without further notice due
to design improvements, functional modifications or quality/reliability amendments.
1
Rev. 04, May 2010
Copyright © 2010 Hoffmann & Hoffmann Ltd.
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Revision History Revision Section Notes 01 – Initial document 02 Installation Kit on page 9 Deleted ¼-inch fuel hose as part of installation kit 03 Page 18 Third line of text: ...flow switch to the right... Page 7, 10, 22, Table 1, Figure 9 Line power includes 220 VAC Table 6 Updated specifications Last page Updated contact information 04 Cover page and Section 7. Updated company logo and contact information 2
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Contents Section 1: Introduction ............................................................................................................................... 5 Overview .......................................................................................................................................... 5 Section 2: Installation................................................................................................................................. 7 General.....................
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List of Figures Figure 1: Dripmaster EDD-4C............................................................................................................... 5 Figure 2: Installation requirements ....................................................................................................... 8 Figure 3: Dripmaster—rear view showing mounting centers................................................................ 9 Figure 4: Connection box – cable routing...................................
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Section 1: Introduction Overview The Dripmaster is an active vertical line-shaft lubrication control and monitoring device. It automatically stabilizes the oil drip rate so as to comply with pump manufacturer's requirements. Figure 1: Dripmaster EDD-4C Constant drip rate is maintained regardless of ambient temperature or hydrostatic pressure in the feeding oil tank. This is achieved by monitoring and controlling the drip rate 55 times per hour. There are two modes of operation: • N
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End of section 6
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Section 2: Installation General The Dripmaster installation procedure is simple and does not require any special tools, but requires site preparation. Well Site Requirements • Line power (115 VAC or 220 VAC), or 24 V AC/DC must be available at the well pump. • An eight-wire control cable (containing wires not smaller than 22 AWG) needs to be laid between the well pump and the local PLC enclosure. • A sturdy, vertical pole with a welded metal plate should be in close proximity to the wel
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Important: The relative spacing between the oil tank, the Dripmaster, and the line-shaft inlet should be according to Figure 2. In order to maintain minimal oil pressure on the needle valve (especially when the oil tank is almost empty), the oil inlet should be in the range of 10 to 14 inches below the oil tank. Oil tank 1/4-inch (0.635 cm) copper pipe 10 to 14 inches (25.4 to 35.6 cm) Oil filter 1/4-inch flexible copper tubing Lineshaft Figure 2: Installation requirements 8
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Installation Kit The Dripmaster is supplied with the following parts: 1 – oil filter (fuel filter for ¼-inch hose) 4 – mounting bolts 8 – nuts 8 – lock washers 2 – cable bushings (glands) Make sure that all of the kit items are present. You need to obtain ¼-inch fuel hose to complete the installation. Mounting the Dripmaster 1. In order to mount the Dripmaster, drill four 1/4-inch holes in the metal plate that mounts the Dripmaster according to the drilling template shown in Figu
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Wiring the Power and Control Cables Power and control cables are routed through the bottom of the connection box through two strain relief bushings. Green ground wire connects here Power cable entry Control cable entry Figure 4: Connection box – cable routing Wire the connection box according to Figure 5. Connections are described in detail in Table 1 on page 11. 24VAC/DC S.B. - Pre-lube (pump off) mode LL - Total lack of oil PULSE - Drip indication Voltage selector switch SW1:
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Caution: External 24 VAC power source must be isolated from ground. 2. Route the power cable through a cable strain relief on the left side of the connection box (Figure 4). 3. Connect the green ground wire to a chassis screw or bolt, preferably using a ring terminal. See Figure 4. 4. Route the control cable through the right cable strain relief (Figure 4). 5. Connect control cable according to Table 1. The connection box power and control line descriptions are shown below. Table 1:
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Table 2: Pump On/Off conditions Status OK LED on OK LED off Pump on • Drip rate greater than 15 dpm • Drip rate less than 15 dpm • O.K. relay contacts are closed • Total lack of oil (OIL LED on) • O.K. relay contacts are open Pump off • Drip rate is equal to or greater than 2 dpm • Total lack of oil (OIL LED on) • O.K. relay contacts are closed • O.K. relay contacts are open 6. Connect an external time-delay relay of approximately four minutes to the O.K. output. This is necessary to e
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Section 3: Operation Controls and Indicators Button and indicator locations on the Dripmaster control panel are shown below. Dripmaster window Presence of oil 2 2 3 3 Pre-lube (pump off) mode area Lack of oil 1 1 Drip rate 4 4 5 5 Valve opening Display switch 17 17 6 6 Open Valve 7 7 Valve fully open Freeze 16 16 Control Mode 8 8 12-second timer 15 15 9 9 Manual Operation Drip rate display 14 14 10 10 Close Valve 11 11 Valve Closing Drip Rate toggle 12 12 Timing toggle 13 13 switches swi
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Item Name Control or Function number Indicator (Figure 6) 2 Green LED Indicates that sufficient oil is delivered OK whether the well pump is on or off. In the Normal (pump on) mode, this corresponds to oil drip rates in excess of 15 dpm. In the Pre-lube (pump off) mode, the LED lights when the rate is between 1 and 15 dpm. The LED is off when a total lack of oil condition occurs, and the OIL LED lights. A corresponding relay contact closes when the OK LED is on. The terminal for t
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Item Name Control or Function number Indicator (Figure 6) 12 Drip Rate Toggle switches Sets the drip rate for the pump-on mode. Choose only one toggle switch, and push it up to the desired dpm value. 13 Timing Toggle switches These switches are set according to the section "Setting Normal (pump on) Mode Drip Rates", starting on page 16. 14 Drip rate 7-segment A two-digit display shows the drip rate count Display 15 12 ' ' Yellow LED Flashes every 12 seconds for timing purposes. You
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Automatic Control When the Control Mode toggle switch SW17 is in the lower AUTO position (item 8 in Figure 6), the Dripmaster automatically stabilizes the preset drip rate. At the end of each 60 second interval, a short correction command is given only if there is a deviation from the desired preset drip rate. The valve closes if the actual drip rate is 2 drips/minute or more than the preset value. The valve opens if the actual drip rate is 1 drip/minute less than the preset value. Setting
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35 dpm toggle switch setting 20 25 30 35 40 1248 10 40 dpm toggle switch setting 20 25 30 35 40 1248 10 The OPEN and CLOSE LEDs indicate whether the needle valve is opening or closing. See items 5 and 11 in Figure 6 on page 13. Pre-lube (pump off) Mode To select the Pre-lube mode, 24 V AC/DC must be applied to the S.B. terminals in the connection box (Figure 5). In this mode, the drip rate is automatically set to 2 dpm. Manual Control This mode permits emergency operation in the rar
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Oil inlet Manual oil flow switch Internal solenoid Oil outlet Drip verification peephole Figure 7: Dripmaster EDD-4C Needle Valve Assembly The internal solenoid is powered by the Dripmaster power source. When powered up, the solenoid allows oil flow. When powered down, the solenoid blocks oil flow. To allow oil flow when the Dripmaster is not powered on, turn the manual oil flow switch to the right 90 degrees. Resetting the Dripmaster There are two ways to reset the Dripmaster: 1. By d
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Section 4: Theory of Operation General The Dripmaster is a gravity-based oil lubrication system. The common needle valve fed from an oil tank does not provide any regulation of the drip rate—the rate varies in response to variations in temperature (day versus night and time of year) and changes in the tank oil level (hydrostatic pressure). Another cause of rate fluctuation is temporary valve blockage. The Dripmaster performs as an automatic needle valve that regulates oil flow (Figure 8).
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To SCADA Interface Normal/Pre-lube Drop O.K. Lack of Oil Inlet Pulses state Oil from Reservoir Modes Mechanical Stage Control Circuitry Needle Servo Valve Motor Preset Selectors & Display Optic Drop Power Detector Supply Oil Outlet to Shaft Line voltage (115V or 230 V) or 24V Feed Figure 9: Dripmaster functional diagram A two-digit display is visible in the Dripmaster display window (see Figure 6 on page 13)—this is a drip counter that freezes for six seconds for each one minute interval and
