Hoffman Media EDD-4C manual

Copyright © 2010 Hoffmann & Hoffmann Ltd. Rev. 04, May 2010 1 Dripmaster EDD-4C U.S. Patent No. 5,996,739 & other co untries User Guide Document filename: Dripmaster _EDD-4C_User_Gui de_18May10.doc Important notice: Hoffmann & Hoffmann reserves the righ t to change this docum ent without further notice due to design improvements, funct[...]

2 Revision History Revision Section Notes 01 – Initial document 02 Installation Kit on page 9 Deleted ¼-inch fuel hose as pa rt of installation kit Page 18 Third line of text: ...flow switch to the right ... Page 7 , 10 , 22 , Table 1 , Figure 9 Line power includes 2 20 VAC Table 6 Updated specifications 03 Last page Updated contact information [...]

3 Contents Section 1: In troduction ........................................................................................................ ....................... 5 Overview .......................................................................................................................................... 5 Section 2: In stalla tion .......[...]

4 List of Figures Figure 1: Dripma ster EDD-4C .................................................................................................... ........... 5 Figure 2: Installa tion require ments ............................................................................................ ........... 8 Figure 3: Dripmaster—rear view showing mo[...]

5 Section 1: Intr oduction Overview The Dripmaster is an active ve rtical line-s haft lubrication control an d monitoring device. It automatically stabilizes the oil drip rate so as to comply with pu mp manufacturer's requirements. Figure 1: Dripmaster EDD-4C Constant drip rate is maintained reg ardless of am bient temperature or hydrostatic p[...]

6 End of section[...]

7 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 22 0 VAC), or 24 V AC/DC must be available at the well pump. • An eight-wire control cable (c ontaini ng wires not smaller than 2 2 AWG) needs to[...]

8 Important: The rel ative spacing between the oil tank, t he Dripmaster, and the line-shaft inlet should be according to Figure 2. In order to maintain minimal oi l pressure on the needle valve (especially when the oil tank is al most empty), t he oil inlet should be in the range of 10 to 14 inches below the oil tank. 10 to 14 inches (25.4 to 35.6[...]

9 Installation Kit The Dripmaster is sup plied with the following parts:  1 – oil filter (fuel filter for ¼-inch hose)  4 – mounting bolts  8 – nuts  8 – lock washers  2 – cable bushings (gland s) Make sure that all of the kit items are present. Y ou need to obtain ¼-inch fuel h ose to complete the installation. Mounting [...]

10 Wiring the Power and Control Cables Power and control cables a re routed through the bo ttom of the connection b ox through two strain relief bushings. Power cable e ntry Control cabl e entry Gr e en grou nd w ire connects here Figure 4: Connection box – cable routing Wire the connection box according to Fi gure 5. Connections are descri bed i[...]

11 Caution: External 24 VAC power source must be isolated from ground. 2. Route the power cable through a cabl e strain relief on the left side of the connection bo x (Figure 4) . 3. Connect the green ground wire to a cha ssis sc rew or bolt, preferably usi ng a ring terminal. See Figure 4. 4. Route the control cabl e through the right cable strain[...]

12 Table 2: Pump On/Off conditions Status OK LED on OK LED off Pump on • Drip rate greater than 15 dpm • O.K. relay contacts are closed • Drip rate less than 15 dpm • 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 • O.K. relay contacts are closed • Total lack of [...]

13 Section 3: Operation Controls and Indicators Button and indicator locations o n the Drip master control panel are shown below. Open Va l ve Drip rate Contr o l Mode Close Va lve Drip Rate toggle switch es Tim i ng t ogg le switches 12-sec ond t im er Freeze Display switch Lack of oi l 5 5 6 6 7 7 12 12 13 13 14 14 15 15 16 16 1 1 4 4 Presenc e o[...]

14 Item number (Figure 6) Name Control or Indicator Function 2 OK Green LED Indicates that su fficient 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[...]

15 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) Mod e Drip Rates", starting on page 1[...]

16 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 p reset drip rate. At the end of each 60 second interval, a short correction comman d is given only if there is a deviation from the desi red preset d rip rate. The valve closes if the actual [...]

17 35 dpm toggle switch setting 20 25 30 35 40 1248 1 0 40 dpm toggle switch setting 20 25 30 35 40 1248 1 0 The OPEN and CLOSE LEDs indicate whether the n eedle valv e is opening or cl osing. See items 5 and 11 in Figure 6 on page 13. Pre-lube (pump off) Mode To select the Pre-lube mod e, 24 V AC/DC must be ap plied to the S.B. terminals in the co[...]

18 Manua l oil f low sw itch Drip ver ification pe epho le Oil in let Oil outlet Interna l so leno id Figure 7: Dripmaster EDD- 4C Needle Valve Ass embly The internal solenoid is powered by the Dripmaster power source. When powered up, the sol enoid allows oil flow. When powered down, the solenoid bloc ks oil flow. To allow oil flow when the Dripma[...]

19 Section 4: Theory of Operation General The Dripmaster is a gravity-base d oil lubrication system. The common needle valve fed from an oi l tank does not provide an y regulation of the drip rate—the rate varies in response to variations in temper ature (day versus nig ht and time of year) and changes in the tank oil level (hydrostatic pressure)[...]

20 Mechanical Stage Optic Drop Dete cto r Needle Valve Oil Outlet to Shaft Oil In let from Reserv oir Lack of Oil O.K. state Drop Pulses Normal / Pre- lube Mode s Line voltage (115V or 23 0 V) or 2 4V Feed T o S C ADA I nt e rf a c e Control Circuitry Pow er Su pply Servo Mot o r Pr eset S elect ors & Displ ay Figure 9: Dripmaster functional di[...]

21 A built-in, SCADA-compatible report-back m echanism provides the status and alarm info rmation. This information is sent to the local PL C on site. The following si gnals are reported: • OK state – signals that the oil drip rate exceeds a factory-set thre shold. Whenever the oil drip rate falls below this threshold, the OK state is disabled [...]

22 lower limit and the OIL LED lights continuously. The LL relay outlet contact cl oses, transmitting a total lack of oil condition. At this stage, there is no vertical line-shaft lubricatio n 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 [...]

23 Section 5: Maintenance and T roub leshooting 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 • The displayed drip rate is equal to the Norm al (pump on) mode drip rate setting, with[...]

24 Problem Possible Cause Solution The OIL LED is on. • Oil tank is empty • A shut-off valve at the outlet of the oil tank might be closed • Oil flow from the oil tank may be obstructed; the oil filter may be clogged • Oil blockage between the Dripmaster outlet pipe and the line-shaft—excessive oil briefly flows from a built-in overflow h[...]

25 Section 6: Specifications Table 6: Dripmaster EDD-4C specifica tions 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 ?[...]

26 Overall Dimensions 3 . 5 8 i n c h e s ( 9 . 1 c m ) 1 0 . 3 5 i n c h e s ( 2 6 . 3 c m ) 3 . 1 9 i n c h e s ( 8 . 1 c m ) 4 . 8 8 i n c h e s ( 1 2 . 4 c m ) 6.38 inches (16.2 cm) 4.92 inches (12.5 cm) Drip verification peephole Oil outlet 1/4 inch BSP Display w indow Oil inlet 1/4 inch BSP Power cable entry Control cable entry Connection box[...]

27 Section 7: Dripmaster Service P olicy This policy has been establ ished to cover the servi cing of Hoffmann & Hoffmann prod ucts, regardless if it is within or beyond the warra nty period. Installation 1. The installation services requi red for th e Dripmaster inclu des the following: a. Infrastructure (trench diggi ng, cable laying) b. Oil [...]

28 Product within the Warranty Period 1. All Hoffmann & Hoffmann product s have a one year limited warrant y. 2. Hoffmann & Hoffmann Warranty will app ly only to units installed by authorized Rep/Di stributors or by the customer (if Hoffmann & Hoff mann au thorized installation by the customer). 3. Hoffmann & Hoffmann is not re spon[...]

29 2. Return properly packaged item to the address of your local Rep/Distributor o r to Hoffmann & Hoffmann lab. 3. This warranty is limited to the repair or repla c ement of the Hoffmann & Hoffmann product s only. Hoffmann & Hoffmann assumes no othe r responsibility or liability. 4. Hoffmann & Hoffmann reserves the righ t to make c[...]