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

REVISION 05

April 2007

P/N 77740224

LubriMist® Model IVT Oil Mist Generator

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LubriMist® Model IVT Oil Mist Generator

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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

LubriMist® Model IVT Oil Mist Generator

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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

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

LubriMist® Model IVT Oil Mist Generator

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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

Voltage Panel Wiring Diagram / Cold Ambient Option - Cabinet heating – 230 VAC - ATEX

176

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

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

LubriMist® Model IVT Oil Mist Generator

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LubriMist® Model IVT Oil Mist Generator

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UNIT IDENTIFICATION AND LABELING

LubriMist® Model IVT Oil Mist Generator

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LubriMist® Model IVT Oil Mist Generator

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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 info@lsc.com

LubriMist® Model IVT Oil Mist Generator

Page 9 of 212

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

Model IVT Oil Mist Generator is available to ATEX II 3G EEx nC IIC T4. •

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.

WARNING WARNING
WARNING
WARNING

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

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

LubriMist® Model IVT Oil Mist Generator

Page 10 of 212

Model Code Designation Key LubriMist® Model IVT Oil Mist Generator

Option Description

Option Code

 

Description

Electrical Standard

C

ATEX

ATEX
II 3G EEx nC IIC T4.

II 3G EEx nC IIC T4.

N

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

Inlet Power

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)

B

230

VAC 50/60 HZ SINGLE PHASE & METRIC MEASURING UNITS

Labeling

E

ENGLISH and SPANISH

X

NOT LISTED - CONSULT FACTORY FOR AVAILABILITY

Oil Mist Reclamation

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)

F

NEMA MOTOR: 250 VAC 50 HZ 1 PHASE; EXPLOSION PROOF CLASS

1

DIV. 2 GROUP C/D T3C (1)

Cabinet Accessories

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)

K

ATEX - BOTH WARM & COLD AMBIENT OPTIONS

Special

 

NON-REQUIRED FIELD.

CONSULT FACTORY IF FIELD INCLUDES ENTRY

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

LubriMist® Model IVT Oil Mist Generator

Page 11 of 212

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.

LubriMist® Model No Serial No. Series No. Volts AC 50 / 60 Hz Amps Listed
LubriMist®
Model No
Serial No.
Series No.
Volts AC
50 / 60 Hz
Amps
Listed Oil Mist Generator for Hazardous Locations
Class I Division 2 Groups B, C, D - T
Class I, Zone 2, Group IIB + H2, T
U ® L
C
US
LISTED
23 PN
Operating Temperature
-40°C < T amb < +60°C
Max Inlet Air Pressure; 150 PSIG
/
10.3 Bar
Lubrication Systems Co.
Houston Texas
713/464-6266l e-mail Info@LSC.COM
l Fax 713/464-
Data Ref. Description Example Model Code Per Cust. P.O. & LSC Job Order See ”
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
115
230
κ NOTE: Ratings do not include electric motor drivers for “Oil Mist Reclamation” option.
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:
15.5
7.8
Machinery for use at 115 VAC
Machinery for use at 230 VAC
22.9
11.5
κ NOTE: Ratings do not include electric motor drivers for “Oil Mist Reclamation” option.

LubriMist® Model IVT Oil Mist Generator

Page 12 of 212

LubriMist® Model IVT Oil Mist Generator Page 12 of 212 Certificate Of Conformance NEC Construction The

Certificate Of Conformance

NEC Construction

The Manufacturer:

Hereby declares that

The product:

Lubrication Systems Company 1740 Stebbins Dr. Houston, Texas 77043 USA

Model IVT -

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

-_ Oil Mist Generator

Has been evaluated to the requirements of the following standards:

UL 508 C22.2 No. 14 UL 1604

C22.2 No. 213-M1987

Standard for Industrial Control Equipment Canadian Standard for Industrial Control Equipment Electrical Equipment for use in Class I and Class II, Div. 2 and Class III Hazardous (Classified) Locations 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

USL, CSL

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

USL

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. Indicates Listing to U.S. Standards

CNL

Indicates Listing to Canadian Standards

Signed By:

Title:

Date:

Charles Ehlert

to Canadian Standards Signed By: Title: Date: Charles Ehlert Director of Quality and New Product Development

Director of Quality and New Product Development

August 2004

LubriMist® Model IVT Oil Mist Generator

Page 13 of 212

Tag Detail for ATEX Model IVT

LubriMist® IVT Oil Mist Generators manufactured compliant with the ATEX Directive

LubriMist ® Model No. IVT- Serial No. Volts AC 50 / 60 Hz Amps 1
LubriMist
®
Model No. IVT-
Serial No.
Volts AC
50 / 60 Hz
Amps
1 PH
Oil Mist Generator for Hazardous Locations
3 G EEx nC IIC T
Y.O.M.
DEMKO ** ATEX ******
EPSILON 03 ATEX 1272
Operating Temperature
°C < T amb <
°C
Max Inlet Air Pressure; 150 PSIG
/
10.3 Bar
Lubrication Systems Co.
Houston Texas
USA
713/464-6266 l
e-mail Info@LSC.COM l Fax 713/464-9871
Data Ref. Description Example Model Code Per Cust. P.O. & LSC Job Order See ”
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
115
230
κ NOTE: Ratings do not include electric motor drivers for “Oil Mist Reclamation” option.
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
8.1
4.1
9.0
κ NOTE: Ratings do not include electric motor drivers for “Oil Mist Reclamation” option.

LubriMist® Model IVT Oil Mist Generator

Page 14 of 212

LubriMist® Model IVT Oil Mist Generator Page 14 of 212 EU Certificate of Conformity The Manufacturer:

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

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:

Title:

Date:

Charles Ehlert

of Protection “n”. Signed By: Title: Date: Charles Ehlert Director of Quality and New Product Development

Director of Quality and New Product Development

August 2004

LubriMist® Model IVT Oil Mist Generator

Page 15 of 212

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

LubriMist® Model IVT Oil Mist Generator

Page 16 of 212

PRODUCT DESCRIPTION

LubriMist® Model IVT Oil Mist Generator

Page 17 of 212

LubriMist® Model IVT Oil Mist Generator

Page 18 of 212

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

Sensor E-E 28 Oil Pressure Transducer C-C 29 Auxiliary Oil Mist Generator H-H 30 IVT Plan

IVT Plan View

LubriMist® Model IVT Oil Mist Generator

Page 19 of 212

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
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.
5.
Power Selector Switch
5. Power Disconnect Switches
NEC Version
ATEX
Version
4.
2. Air Supply Ball Valves
Lubrimist
• Main Oil Mist Generator
• Oil Supply Pump
• Auxiliary Oil Mist Generator
Auxiliary Oil Mist
Generator Air/Oil Heater
Controller
6.
1. Operator Keypad And
Toggle Valves For
Manual Oil Filling Of
Reservoirs
Display
7.
Auxiliary Oil Mist
3. Air Pressure Regulators
• Main Oil Mist Generator
• Oil Supply Pump
• Auxiliary Oil Mist Generator
Generator Mist Pressure
Gauge
9.
Bulk Oil Reservoir
Threaded Fill Port
8.
Oil Mist Generator Reservoir
Level Gauge (typical)
9.
Spin On Oil Filter
8.
Oil Mist Generator Drain
Valve w/ Drain Plug (typical)
8.
Bulk Oil Reservoir Drain
Valve w/ Drain Plug

View B-B

LubriMist® Model IVT Oil Mist Generator

Page 20 of 212

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.

2. Air Distribution Manifold Inlet Air Connection ½ 150 # RF T-304 Flange 2. Air
2. Air Distribution Manifold
Inlet Air Connection
½ 150 # RF T-304 Flange
2. Air Distribution Manifold
1. Air Filter
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 H-H

View G-G

LubriMist® Model IVT Oil Mist Generator

Page 21 of 212

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 Out Cabinet Seal Mist Outlet Switching Valve View F-F Mist Generator Head With Air
Mist
Out
Cabinet
Seal
Mist Outlet
Switching Valve
View F-F
Mist Generator Head With Air / Oil Heater

The oil mist generating heads (main and auxiliary) are mounted inside of the mechanical compartment of the IVT. Each uses oil held in separate reservoirs. Both mist generating heads are mechanically identical. Each mist head features an inline air heater element for heating and maintaining the air supply at a controlled temperature. The air heater element is installed through the top of the mist head body (a block of machined aluminum) and attaches with a ½ NPT thread. The heater cartridge extends into a second manifold made of machined aluminum rod.

Air Heater Element (typical 2 places) Mist Head Body (typical 2 places) Heater Manifold (typical
Air Heater Element
(typical 2 places)
Mist Head Body
(typical 2 places)
Heater Manifold
(typical 2 places)
Auxiliary Oil Mist
Main Oil Mist Generator
Generator Reservoir
View I-I
Reservoir

LubriMist® Model IVT Oil Mist Generator

Page 22 of 212

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.

Mist Generating Head w/ Air/Oil Heater Thermocouple For Air Temperature Measurement, Heater Control, And High
Mist Generating Head w/
Air/Oil Heater
Thermocouple For Air Temperature
Measurement, Heater Control, And
High / Low Alarm Signals.
Thermocouple For High Air
Temperature Heater Cutout
Measurement, Heater Control, And High / Low Alarm Signals. Thermocouple For High Air Temperature Heater Cutout

View A-A

LubriMist® Model IVT Oil Mist Generator

Page 23 of 212

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.

The switch assembly mounts through the top of the reservoir. The oil level for the auxiliary

LubriMist® Model IVT Oil Mist Generator

Page 24 of 212

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 Power Voltage Enclosure View A-A
Control Voltage Enclosure
Power Voltage Enclosure
View A-A

LubriMist® Model IVT Oil Mist Generator

Page 25 of 212

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 Supply Air Pressure Transducer Air Distribution Manifold Ambient Air Sensor View G-G
Plan View
Supply Air Pressure Transducer
Air Distribution Manifold
Ambient Air Sensor
View G-G

LubriMist® Model IVT Oil Mist Generator

Page 26 of 212

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
Regulated Air Pressure
Transducer
ion the signal is used to provide an operating regulated air pressure value. Regulated Air Pressure

View A-A

LubriMist® Model IVT Oil Mist Generator

Page 27 of 212

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
reservoir. High and low alarms are active when the oil temperature is not within a prescribed
operating range.
Bulk Oil Reservoir
Level Transmitter
Mist Pressure
Transducer
Bulk Oil
Thermocouple
View E-E
View D-D

LubriMist® Model IVT Oil Mist Generator

Page 28 of 212

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.

Mist Density Monitor View E-E
Mist Density Monitor
View E-E

LubriMist® Model IVT Oil Mist Generator

Page 29 of 212

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.

Oil Pressure Transducer Pump Outlet Manifold
Oil Pressure
Transducer
Pump Outlet
Manifold

View G-G

View C-C

LubriMist® Model IVT Oil Mist Generator

Page 30 of 212

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.

Heater Controller Terminal Strip w/ Fuses Solid State Relays Low Air Pressure Switch Auxiliary Oil
Heater
Controller
Terminal Strip
w/ Fuses
Solid State Relays
Low Air Pressure
Switch
Auxiliary Oil Mist Generating Head w/
• Air / Oil Heater
View H-H
• Heater Control Thermocouple
• High Temperature Thermocouple

LubriMist® Model IVT Oil Mist Generator

Page 31 of 212

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

LubriMist® Model IVT Oil Mist Generator

Page 32 of 212

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.

IVT Oil Mist Generator

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

Air Vent to Atmosphere

Centrifugal

Coalescer w/

Motor Driver

High Level

Alarm Switch

Over Flow

Connection.

Oil Level Gauge

Enclosure Contains

Pump Controls

Bulls 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.

to interlock with the motor driver control circuit. NOTE: SEPARATE MOTOR DRIVER STARTER AND CONTROL CIRCUITRY

NOTE: SEPARATE MOTOR DRIVER STARTER AND CONTROL CIRCUITRY ARE TO BE PROVIDED AND INSTALLED BY THE USER.

LubriMist® Model IVT Oil Mist Generator

Page 33 of 212

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

Block Valve

IVT Inlet Air Connection

Air

Air

generator Block Valve IVT Inlet Air Connection Air Air Vortex Cold Air Generator Introduced Chilled Air

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

Pressure Regulator w/ Air

Pressure Gauge For Controlling

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.

LubriMist® Model IVT Oil Mist Generator

Page 34 of 212

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.

Temperature Switch

Vortex Cold Air Generator Solenoid Operated Air Valve Power Disconnect Air Inlet Switch Block Valve
Vortex Cold Air
Generator
Solenoid
Operated Air
Valve
Power
Disconnect
Air Inlet
Switch
Block Valve
Air Temperature
Gauge
Air Pressure
Regulator w/ Air
Pressure Gauge
For Controlling Air
Flow
774321G
55G
1
2
3
4
66
9 1010988
1 111

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.

LubriMist® Model IVT Oil Mist Generator

Page 35 of 212

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.

is supplied to the interior of the IVT Controller enclosure. Instrument Block Valve For Servicing Rotometer

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.

LubriMist® Model IVT Oil Mist Generator

Page 36 of 212

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.

Air Preheater
Air Preheater

Inlet Air

Heater Control And Cutout Sensors Are Located In The Heater Discharge

Inlet Air Temperature Sensor

Connection

LubriMist® Model IVT Oil Mist Generator

Page 37 of 212

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.

Air Preheater
Air Preheater

Inlet Air

Heater Control And Cutout Sensors Are Located In The Heater Discharge

Inlet Air Temperature Sensor

Connection

Cold Ambient Option (Air Preheating) - ATEX constructions

LubriMist® Model IVT Oil Mist Generator

Page 38 of 212

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.

no additional user connections or installation is required. Cold Ambient Option (Cabinet H eating) - ATEX

Cold Ambient Option (Cabinet Heating) - ATEX constructions

LubriMist® Model IVT Oil Mist Generator

Page 39 of 212

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.

Block Valve

Solenoid Operated Oil Valve Supply Oil Pressure Gauge
Solenoid
Operated Oil
Valve
Supply Oil
Pressure
Gauge

Spin-on Oil

Filter

Check Valve

LubriMist® Model IVT Oil Mist Generator

Page 40 of 212

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).

LubriMist® Model IVT Oil Mist Generator

Page 41 of 212

LubriMist® Model IVT Oil Mist Generator

Page 42 of 212

LubriMist® Model IVT Oil Mist Generator Page 42 of 212 Location / Mounting Choose a central
LubriMist® Model IVT Oil Mist Generator Page 42 of 212 Location / Mounting Choose a central

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.

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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

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.

When threaded flanges are use to connect to the header

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.

maximum mist output capacity is shown in the tables below. INLET AIR SUPPLY SYSTEM MUST BE

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.

IVT Mist

Generator Size

Mist Generating Flow Range

US Units

Metric Units

60

BI

0.60 - 1.80 SCFM

1.02 – 3.06 M 3 / Hr

213

BI

1.75 – 6.40 SCFM

2.97 – 10.87 M 3 / Hr

475

BI

2.48 – 14.30 SCFM

4.21 – 24.30 M 3 / Hr

933

BI

5.70 – 28.0 SCFM

9.68 – 47.57 M 3 / Hr

IVT Mist

Generator Size

Minimum Recommended Air Supply Capacity

US Units

Metric Units

60

BI

5 SCFM @ 65 PSIG

8.5 M 3 /HR @4.5 BAR

213

BI

10 SCFM @ 65 PSIG

17 M 3 /HR @4.5 BAR

475

BI

18 SCFM @ 65 PSIG

31 M 3 /HR @4.5 BAR

933

BI

32 SCFM @ 65 PSIG

55 M 3 /HR @4.5 BAR

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

the airflow requirement needed to operate the oil transfer pump. NOTE: MAXIMUM AIR SUPPLY PRESSURE IS

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

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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

WARNING
WARNING

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

switched off or the area is known to be non- hazardous. 1-1/4 Conduit Two Places Power
1-1/4 Conduit Two Places Power Terminal Enclosure Right Side View Rear View Model IVT Oil
1-1/4 Conduit
Two Places
Power Terminal
Enclosure
Right Side View
Rear View
Model IVT Oil Mist Generator –
NEC Construction
Power Terminal
Enclosure
Right Side View
20 mm Entrance
Connection w/
Stopping Plug –
2 places

Rear View

Model IVT Oil Mist Generator – ATEX Construction

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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.

rating either with or without the Cold Ambient Options. IMPORTANT: ALL ELECTRICAL CONNECTIONS SHOULD BE MADE
rating either with or without the Cold Ambient Options. IMPORTANT: ALL ELECTRICAL CONNECTIONS SHOULD BE MADE

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:

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

3 G EEx nC IIC T4

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

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.

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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.

FORM-C contact can be connected to a user sourced alarm. CAUTION: TO AVOID RISK OF EXPLOSION

CAUTION:

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

2. An RS-422/485 serial connection is available for data transmission to the users remote located personal computer (PC) or DCS.

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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
also operate.
WARNING

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.

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.

through Close and secure the AC power enclosure door. Locate The AC Power Enclosure Conduit For

Locate The AC Power Enclosure

Conduit For Remote Alarm Wiring

Remote Alarm Connection ¾ Inch Conduit

1 - COM 2 - N.O. 3 - N.C. For NEC Constructions, Connect The Remote
1 - COM
2 - N.O.
3 - N.C.
For NEC Constructions,
Connect The Remote Alarm Wiring To
Terminal Numbers 1 - 2 - 3

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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
WARNING

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.

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.

1 - COM 2 - N.O. 3 - N.C. For ATEX Constructions, Connect The Remote
1 - COM
2 - N.O.
3 - N.C.
For ATEX Constructions,
Connect The Remote Alarm Wiring To Terminal
Numbers 1 - 2 - 3
Locate The Remote
Alarm Terminal Enclosure
Connect The Remote Alarm Wiring To Terminal Numbers 1 - 2 - 3 Locate The Remote

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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 WARNING
WARNING
WARNING

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

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.

3. Close and secure the controller enclosure door. Locate The Controller Enclosure Conduit For Wiring Remote
3. Close and secure the controller enclosure door. Locate The Controller Enclosure Conduit For Wiring Remote

Locate The

Controller Enclosure

Conduit For Wiring

Remote Alarm Connection ¾ Inch Conduit

RX+ RX- TX+ TX- See page 97 for wiring instructions
RX+ RX- TX+ TX-
See page 97 for wiring instructions

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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
WARNING

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.

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. 4 = RX- 5 =
3. Close and secure the remote alarm circuit enclosure cover.
4 = RX-
5 = RX+
6 = TX-
7 = TX+
TX+
TX-
RX+
RX-
See page 97 for wiring instructions
Locate The Remote
Alarm Terminal Enclosure

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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 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.IMPORTANT: All customer furnished mo

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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

2)

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. Locate the high oil level overflow connection located on the right side of the reservoir.

3)

Connect the oil over flow connection to a suitable drain. The connection size is ¾ NPT. 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. Remote Alarm Connection Connect Return Oil Mist
d) Close and secure the controller enclosure door.
Remote Alarm
Connection
Connect Return Oil
Mist Header To 2-1/2
Inch Return
Connection
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

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For ATEX Constructions

1)

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

2)

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. Locate the high oil level overflow connection located on the right side of the reservoir.

3)

Connect the oil over flow connection to a suitable drain. The connection size is ¾ NPT. 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.

#4 +). d) Close and secure the controller enclosure cover. For ATEX Constructions, Connect the motor
For ATEX Constructions, Connect the motor interlock wiring to terminal number 10 (DO#4-) and terminal
For ATEX Constructions,
Connect the motor interlock wiring
to terminal number 10 (DO#4-) and
terminal number 11 (DO#4+)

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

Electric Motor

Connect ¾ Inch Overflow Connection To Drain

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LubriMist® Model IVT Oil Mist Generator Page 54 of 212 COMMISSIONING CAUTION: For ATEX construction IVT

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.

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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.

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.

1)

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

WARNING
WARNING

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

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 ool 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
WARNING

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Lubrimist
Lubrimist

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

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

Be Closed And Plugged

Use The Air Pressure Regulator To Adjust Pump Speed.

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

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

Place Air Block Valve In

The

OPEN Position By Turning The Handle To The Full Clock-Wise Position

The Auxiliary Oil Mist Generator Reservoir Drain Valve Should

Before

Filling The Bulk Oil Reservoir.

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

Commissioning The Bulk Oil Supply

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Starting The Model IVT Oil Mist Generator

Page 58 of 212 Starting The Model IVT Oil Mist Generator CAUTION: For IVT Oil Mist
Page 58 of 212 Starting The Model IVT Oil Mist Generator CAUTION: For IVT Oil Mist

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

IVT oil mist generator is equipped with electrical devices that interrupt the electrical power to either

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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

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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.

NEC Power Switch Location

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

ATEX Power Switch Location

Should Be In The OFF Position. ATEX Power Switch Location 2) Place The Three Position Selector

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

Operator Panel Lubrimist 1) Turn ON The Air Supply To The Main Oil Mist Generator
Operator Panel
Lubrimist
1) Turn ON The Air Supply To
The Main Oil Mist Generator Air
Block Valve
3) Use The Main Oil Mist
Generator Air Pressure Regulator
To Set The Mist Pressure

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.

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

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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 tempora