Dripmaster EDD-4C U.S. Patent No. 5,996,739 & other countries User Guide Document filename: Dripmaster_EDD-4C_User_Guide_18May10.doc Important notice: Hoffmann & Hoffmann reserves the right to change this document without further notice due to design improvements, functional modifications or quality/reliability amendments. Copyright © 2010 Hoffmann & Hoffmann Ltd. 1 Rev.
Revision History Revision Section 01 – Notes Initial document 02 Installation Kit on page 9 Deleted ¼-inch fuel hose as part of installation kit 03 Page 18 Third line of text: ...flow switch to the right... Page 7, 10, 22, Table 1, Figure 9 Line power includes 220 VAC Table 6 Updated specifications Last page Updated contact information Cover page and Section 7.
Contents Section 1: Introduction ............................................................................................................................... 5 Overview .......................................................................................................................................... 5 Section 2: Installation ................................................................................................................................. 7 General....................................
List of Figures Figure 1: Dripmaster EDD-4C............................................................................................................... 5 Figure 2: Installation requirements ....................................................................................................... 8 Figure 3: Dripmaster—rear view showing mounting centers................................................................ 9 Figure 4: Connection box – cable routing...................................................
Section 1: Introduction Overview The Dripmaster is an active vertical line-shaft lubrication control and monitoring device. It automatically stabilizes the oil drip rate so as to comply with pump manufacturer's requirements. Figure 1: Dripmaster EDD-4C Constant drip rate is maintained regardless of ambient temperature or hydrostatic pressure in the feeding oil tank. This is achieved by monitoring and controlling the drip rate 55 times per hour.
End of section 6
Section 2: Installation General The Dripmaster installation procedure is simple and does not require any special tools, but requires site preparation. Well Site Requirements • Line power (115 VAC or 220 VAC), or 24 V AC/DC must be available at the well pump. • An eight-wire control cable (containing wires not smaller than 22 AWG) needs to be laid between the well pump and the local PLC enclosure. • A sturdy, vertical pole with a welded metal plate should be in close proximity to the well pump.
Important: The relative spacing between the oil tank, the Dripmaster, and the line-shaft inlet should be according to Figure 2. In order to maintain minimal oil pressure on the needle valve (especially when the oil tank is almost empty), the oil inlet should be in the range of 10 to 14 inches below the oil tank. Oil tank 1/4-inch (0.635 cm) copper pipe 10 to 14 inches (25.4 to 35.
Installation Kit The Dripmaster is supplied with the following parts: 1 – oil filter (fuel filter for ¼-inch hose) 4 – mounting bolts 8 – nuts 8 – lock washers 2 – cable bushings (glands) Make sure that all of the kit items are present. You need to obtain ¼-inch fuel hose to complete the installation. Mounting the Dripmaster 1. In order to mount the Dripmaster, drill four 1/4-inch holes in the metal plate that mounts the Dripmaster according to the drilling template shown in Figure 3.
Wiring the Power and Control Cables Power and control cables are routed through the bottom of the connection box through two strain relief bushings. Green ground wire connects here Power cable entry Control cable entry Figure 4: Connection box – cable routing Wire the connection box according to Figure 5. Connections are described in detail in Table 1 on page 11. I J J J Voltage selector switch SW1: 115 VAC / 24 V AC/DC 24VAC/DC S.B.
Caution: External 24 VAC power source must be isolated from ground. 2. Route the power cable through a cable strain relief on the left side of the connection box (Figure 4). 3. Connect the green ground wire to a chassis screw or bolt, preferably using a ring terminal. See Figure 4. 4. Route the control cable through the right cable strain relief (Figure 4). 5. Connect control cable according to Table 1. The connection box power and control line descriptions are shown below.
Table 2: Pump On/Off conditions Status OK LED on OK LED off Pump on • Drip rate greater than 15 dpm • Drip rate less than 15 dpm • O.K. relay contacts are closed • Total lack of oil (OIL LED on) • O.K. relay contacts are open Pump off • Drip rate is equal to or greater than 2 dpm • Total lack of oil (OIL LED on) • O.K. relay contacts are closed • O.K. relay contacts are open 6. Connect an external time-delay relay of approximately four minutes to the O.K. output.
Section 3: Operation Controls and Indicators Button and indicator locations on the Dripmaster control panel are shown below.
Item number (Figure 6) 2 Name Control or Indicator Function OK Green LED Indicates that sufficient oil is delivered whether the well pump is on or off. In the Normal (pump on) mode, this corresponds to oil drip rates in excess of 15 dpm. In the Pre-lube (pump off) mode, the LED lights when the rate is between 1 and 15 dpm. The LED is off when a total lack of oil condition occurs, and the OIL LED lights. A corresponding relay contact closes when the OK LED is on.
Item number (Figure 6) Name Control or Indicator Function 12 Drip Rate Toggle switches Sets the drip rate for the pump-on mode. Choose only one toggle switch, and push it up to the desired dpm value. 13 Timing Toggle switches These switches are set according to the section "Setting Normal (pump on) Mode Drip Rates", starting on page 16. 14 Drip rate 7-segment Display A two-digit display shows the drip rate count 15 12 ' ' Yellow LED Flashes every 12 seconds for timing purposes.
Automatic Control When the Control Mode toggle switch SW17 is in the lower AUTO position (item 8 in Figure 6), the Dripmaster automatically stabilizes the preset drip rate. At the end of each 60 second interval, a short correction command is given only if there is a deviation from the desired preset drip rate. The valve closes if the actual drip rate is 2 drips/minute or more than the preset value. The valve opens if the actual drip rate is 1 drip/minute less than the preset value.
35 dpm toggle switch setting 20 25 30 35 40 1 2 4 8 10 40 dpm toggle switch setting 20 25 30 35 40 1 2 4 8 10 The OPEN and CLOSE LEDs indicate whether the needle valve is opening or closing. See items 5 and 11 in Figure 6 on page 13. Pre-lube (pump off) Mode To select the Pre-lube mode, 24 V AC/DC must be applied to the S.B. terminals in the connection box (Figure 5). In this mode, the drip rate is automatically set to 2 dpm.
Oil inlet Manual oil flow switch Internal solenoid Oil outlet Drip verification peephole Figure 7: Dripmaster EDD-4C Needle Valve Assembly The internal solenoid is powered by the Dripmaster power source. When powered up, the solenoid allows oil flow. When powered down, the solenoid blocks oil flow. To allow oil flow when the Dripmaster is not powered on, turn the manual oil flow switch to the right 90 degrees. Resetting the Dripmaster There are two ways to reset the Dripmaster: 1.
Section 4: Theory of Operation General The Dripmaster is a gravity-based oil lubrication system. The common needle valve fed from an oil tank does not provide any regulation of the drip rate—the rate varies in response to variations in temperature (day versus night and time of year) and changes in the tank oil level (hydrostatic pressure). Another cause of rate fluctuation is temporary valve blockage. The Dripmaster performs as an automatic needle valve that regulates oil flow (Figure 8).
To SCADA Interface Normal/Pre-lube Drop Pulses Modes O.K.
A built-in, SCADA-compatible report-back mechanism provides the status and alarm information. This information is sent to the local PLC on site. The following signals are reported: • OK state – signals that the oil drip rate exceeds a factory-set threshold. Whenever the oil drip rate falls below this threshold, the OK state is disabled and a relay contact can turn off the well pump directly or signal the SCADA room, which in turn can shut down the pump.
lower limit and the OIL LED lights continuously. The LL relay outlet contact closes, transmitting a total lack of oil condition. At this stage, there is no vertical line-shaft lubrication which means that either the oil tank is empty or there is an oil flow blockage between the oil tank outlet and the Dripmaster inlet. In the case of oil flow blockage in the Dripmaster outlet pipe, excess oil briefly flows from a built-in overflow hose (see Figure 10 above).
Section 5: Maintenance and Troubleshooting Table 4: Routine Maintenance Task Frequency Check for oil leaks Monthly Oil filter change (the oil filter used can be an automotive fuel filter with ¼" fittings) Every six months Check for normal operation Weekly • The displayed drip rate is equal to the Normal (pump on) mode drip rate setting, within a -1, +2 digit tolerance Table 5: Troubleshooting Problem Possible Cause Solution The display and LEDs are not lit. • The unit is not powered.
Problem Possible Cause Solution The OIL LED is on.
Section 6: Specifications Table 6: Dripmaster EDD-4C specifications Power requirements 115 VAC, 10 VA, or 24 V AC/DC 220 VAC, 10 VA or 24 V AC/DC Normal (pump on) mode preset drip rates 20, 25, 30, 35, 40 dpm Pre-lube (pump off) mode drip rate 2 dpm Drip volume 50 drops per 1 cc PULSE relay contact 35 VDC – 0.5 A O.K. relay contact 250 VAC – 10 A AC1 110 VAC – 10 A AC1 110 VDC – 0.3 A 30 VDC – 10 A L.L. (low oil level) relay contact 125 VAC – 0.5 A 110 VDC – 0.2 A 24 VDC – 1 A S.B.
Overall Dimensions Oil inlet 1/4 inch BSP 3.5 8 (9. inch 1 c es m) s he inc ) 5 cm .3 10 6.3 (2 1/4-inch screws (8 places) 6.38 inches (16.2 cm) Display window 4.92 inches (12.5 cm) Drip verification peephole Connection box Control cable entry 3.1 9 (8. inch 1 c es m) s he inc m) 8 4.8 2.4 c (1 Power cable entry Figure 11: Dripmaster dimensions The Dripmaster enclosure is made of painted, cast aluminum.
Section 7: Dripmaster Service Policy This policy has been established to cover the servicing of Hoffmann & Hoffmann products, regardless if it is within or beyond the warranty period. Installation 1. The installation services required for the Dripmaster includes the following: a. Infrastructure (trench digging, cable laying) b. Oil tank stand c. Dripmaster mount d. Cabling (4 pairs) e. 24V power source f. Testing 2.
Product within the Warranty Period 1. All Hoffmann & Hoffmann products have a one year limited warranty. 2. Hoffmann & Hoffmann Warranty will apply only to units installed by authorized Rep/Distributors or by the customer (if Hoffmann & Hoffmann authorized installation by the customer). 3. Hoffmann & Hoffmann is not responsible for damages caused by extreme environmental factors, i.e. temperature extremes. 4. If the failure occurred during the Warranty Period, Hoffmann & Hoffmann will cover the repair cost.
2. Return properly packaged item to the address of your local Rep/Distributor or to Hoffmann & Hoffmann lab. 3. This warranty is limited to the repair or replacement of the Hoffmann & Hoffmann products only. Hoffmann & Hoffmann assumes no other responsibility or liability. 4. Hoffmann & Hoffmann reserves the right to make changes in policy and pricing without notice. Terms & Conditions on reverse The purchaser agrees to the following terms and conditions: 1. Shipping: a.