Smart 2 Pump User Manual
Contents
1. 5 2 Oil Lubrication Electro Pump SW ver 1 10 User and Maintenance Manual Warranty information TABLE OF CONTENTS INTRODUCTION GENERAL DESCRIPTION PRODUCT MACHINE IDENTIFICATION TECHNICAL SPECIFICATIONS MACHINE COMPONENTS UNPACKING AND INSTALLING THE MACHINE INSTRUCTIONS FOR USE TROUBLESHOOTING MAINTENANCE PROCEDURE 10 DISPOSAL 11 ORDERING INFORMATION 12 DIMENSIONS 13 HANDLING AND TRANSPORTATION 14 OPERATING HAZARDS 15 PRECAUTIONS 16 WARRANTY INFORMATION 17 DECLARATION OF COMPLIANCE WITH STANDARDS 18 DROPSA LOCATIONS ID po X OX Ora Co Tu Manufacturer DropsA SpA Product SMART2 Certification Manual drawn up in accordance with C2084IE WK 06 05 EC Directive 98 37 Annex l paragraph 1 7 4 1 INTRODUCTION This User and Maintenance Manual refers to SMART2 Oil Lubrication Electro Pump You can find additional copies and newer revisions of this document from our website http www dropsa com Alternatively contact one of our Sales Offices This manual contains important information on health and safety issues for the personnel It is recommended to attentively read this manual and carefully keep it in good condition so that it is always available to personnel requiring to consult it 2 GENERAL DESCRIPTION Oil lubrication pump SMART2 has been designed for industry machine tools The electric gear pump was designed to work w2. 58 158 5 MACHINE COMPONENTS The following main components are assembled to the baseplate A reservoir made of transparent plastic material Q An electric gear pump with high performance and minimum power consumption A SAMBA level sensor which indicates lubricant minimum level via a N O electric contact reservoir empty To reverse to N C please contact Dropsa Eng Dept A pressure gauge A N O Pressure switch which detects system in pressure A PCB user interface 5 1 MANUAL SMART2 The electronic board located under the cover of manual SMARTS2 allows pressure switch and electric level contact management both indipendent and serial On the front panel there are Push button for manual control MANUAL LED indicator for PUMP ON 5 1 AUTOMATIC SMART2 VIPO5 Controller located under the cover of automatic SMART2 allows pump total autonomy both in cycle times alarms or checks On the front panel there are a LCD display 16x2 types Push buttons three for control management and one RESET button 6 UNPACKING AND INSTALLING THE PUMP 6 1 UNPACKING Once a suitable location has been found to install the unit remove the pump from package Check the unit has not been damaged during transportation or storage No particular disposal procedures are necessary as package materials are no dangerous for health or environment However package should be disposed of in
3. switch terminal M2 External proximity micro switch AMO alarm eonmnec tons V V input signal 8 Mc alarm output 220 V 110 V Mil ui C lt Input output electrical specifications Power See 4 1 General technical specifications Input signal NPN or PNP proximity or N C free contacts input Alarm Output Free contact 250VAC 150 mA 125VAC 110VDC 300 mA 30VDC 1A 6 4 3 POWER SUPPLY SWITCH VARIABLE RESISTOR AND BATTERY a VARIABLE AION RESISTOR BATTERY 87 eh m E 00000000G JUMPER POWER SUPPLY SWITCH 6 4 3 1 POWER SUPPLY SWITCH gt For 220V switch rightwards For 110V switch leftwards 6 4 3 2 VARIABLE RESISTOR It allows to regulate display brightness 6 4 3 3 BATTERY ACTIVATION The controller is provided with a three pin jumper to activate battery backup of Date and Time when the equipment is powered off To short circuit the board and activate the battery insert the bridge only into two pins see above picture WARNING Each time the bridge is removed or powerfailure occurs Date and Time are reset It is recommended to setup Date and Time each time the bridge is removed and then put back in place In order to make a complete reset of the machine remove the bridge and switch off the machine 6 4 4 PRECAUTIONS BE TAKEN DURING CONNECTING PROCEDURE Prior to any operation verify the volta
4. N DESCRIPTION 3600241 SMART2 ELECTRO PUMP 110VAC 60 Hz 3600242 SMART2 ELECTRO PUMP 220VAC 50 Hz 11 2 AUTOMATIC SMART2 PART N DESCRIPTION 11 3 SPARE PARTS PART N DESCRIPTION 3132725 Control kit for automatic SMART2 3132726 Control kit for manual SMART2 3600903 Motor unit for SMART2 110V 50Hz automatic and manual 3600904 3600904 Motor unit for SMART2 110V 60Hz automatic and manual 3600905 Motor unit for SMART2 220V 50Hz automatic and manual 6770033 3292053 6770070 3130101 Refilling filter 3291048 12 DIMENSIONS Weight 4 00 Kg 8 8 Ibs i i IAN Bi LI DIL OUTLET NL ISIL ee Sine Ss Leur DlDroweA OGG To an 13 HANDLING AND TRANSPORTATION Prior to shipping the equipment is carefully packed in cardboard package During transportation and storage always maintain the pump the right way up as indicated on the box On receipt check that package has not been damaged Then storage the machine in a dry location Due to machine contained weight and size it is not necessary the use of material handling equipment Anyway we recommend to lift the equipment observing the right way up shown on the cardboard package 14 OPERATING HAZARDS WARNING It is necessary to carefully read about the instructions and the risks involved in the use of lubrication machines The operator mu
5. accordance with regulations that may be in force in your area or state 6 2 INSTALLING THE PUMP gt n order to facilitate any maintenance intervention to avoid unnatural posture for personnel during machine operation or the possibility of sustaining impacts install the machine in a comfortable and easy to reach location Allow sufficient space for the installation leaving minimum 100 mm 3 9 in around the unit Do not install the unit in aggressive or explosive inflammable environments or on vibrating surfaces To install the pump use only the supplied bracket provided with two holes for 6 mm 0 2 in screws see Dimensions ch 12 VN ON 6 3 HYDRAULIC CONNECTION Connect SMART2 to the system via the hydraulic connection located on the baseplate on the right side of the pump standard thread BSP 6 4 ELECTRIC WIRING 6 4 1 ELECTRIC DIAGRAM Here follows the general electric diagram for both automatic and manual SMART PCB user connections only refers to automatic SMART2 PRESSURE SAMBA LEVEL G P MOTOR SWITCH SWITCH PUMP ll _ LH FEMALE or v ot PRESSURE log OIL LEVEL EXTERNAL L CN2 eecccccocco ej T 220 VAC RE LLE gt e E e PS 110 VAC O e is man ual or P2 4 L e e OV l P e A PENA e NTERFAC
6. clean the valve or dirty Replace it if necessary 8 2 VIPO5 CONTROLLER ALARMS AUTOMATIC SMART2 When an alarm occurs an external signal is ON The display will show one of the following alarms for two seconds ALARM 01 TIMER FAULT Internal process error during ube by timer ALARM 02 PX VENT FAILED At the beginning of lube by PS it was detected that the system has not vented air ALARM 04 PS PRESSURE ALARM During ube by PS it was detected that the system never goes in pressure ALARM 06 PS PRESSURE LOSS During ube by PS even though the pump is operating the system loses pressure ALARM 08 PS GENERAL FAULT Internal process error during lube by PS ALARM 09 SEP CYCLE TIMEOUT During lube by SEP the sensor cannot detect one or all the changes of position of the piston ALARM 10 SEP GENERAL FAULT Internal process error during lube by SEP ALARM 11 LOW LEVEL The Samba Level Sensor detected low level Refill the reservoir 13 8 3 RESTART RESET the system Once one of the above alarm status occurs another display will be shown For example ALARM 11 setup reset There are two ways to restore machine operating By pressing setup left push button the system will enter the setup session to modify at any rate parameters and re start the machine By pressing reset for two seconds right push button or RESET button the system will be reset and the machine will be re initializ
7. the product 16 16 WARRANTY INFORMATION All products manufactured and marketed by Dropsa are warranted to be free of defects in material or workmanship for a period of at least 12 months from date of delivery Extended warranty coverage applies as follows Complete system installation by Dropsa 24 Months All other components 12 months from date of installation if installed 6 months or more after ship date warranty shall be maximum of 18 months from ship date If a fault develops notify us giving a complete description of the alleged malfunction Include the part number s test record number where available format xxxxxx xxxxxx date of delivery and installation and operating conditions of subject product s We will subsequently review this information and at our option supply you with either servicing data or shipping instruction and returned materials authorization RMA which will have instructions on how to prepare the product for return Upon prepaid receipt of subject product to an authorized Dropsa Sales amp Service location we will then either repair or replace such product s at out option and if determined to be a warranted defect we will perform such necessary product repairs or replace such product s at our expense Dropsa reserves to right to charge an administration fee if the product s returned are found to be not defective This limited warranty does not cover any products damages or injuries resultin
8. to prelube cycles set up if prelube cycles 0 no prelube is run and the system will start operating either in standby or lube according to the pre set start mode PRELUBE CYCLES PRELUBE STANDBY 7 4 2 Typical system start up www DROPSA com SMART2 rel 1 10 PRELUBE X3 TIMER PRELUBE will be carried out only when prelube cycles are set PRELUBE 0 LUBE X 2 TIMER STANDBY 01m00s Whether prelube has been completely carried out PRELUBE 0 or no 00m05s STOP setup gt start prelube was set PRELUBE 0 LUBE or STANDBY will start see i start mode STANDBY 99 setup gt start em m m Jan 01 01 2004 0 00 During standby you can also see date and time when the function is setup gt start enabled see setup a i wee wee we we we we we we we w 7 4 3 Setup session BACK TO STANDBY OR ALARM IF ACTIVATED SET UP Press YES to enter SETUP YES NO Press NO to go back to STANDBY or ALARM if activated LUBE Time 00m05s Press SET to enter LUBE Time setup use and to change the value and SET NEXT SAVE to save the new setting Push NEXT to go to the next setup To modify STANDBY Time when this function is controlled by a timer STANDBY SET 01m00s NEXT This parameter can be set onlv if STANDBY tvpe is timer or both To modify STAND
9. BY pulse when this function is controlled by a pulse register This parameter can be set only if STANDBY type is pulse or both STANDBY SET NEXT EXTENDED MENU YES NO STANDBY SET Press YES to enter the EXTENDED MENU Press NO to re initialize the machine Press SET to enter STANDBY Type setup use and to select Timer Pulse Both and SAVE to save the new setting Push NEXT to go to the next setup LUBE Type SET DELAY Time SET LUBE Cycles SET PRELUBE SET To modify WAIT Time between two or more lube cycles Note this parameter is displayed only if Lube or Prelube gt 1 WAIT Time SET START SET IN LUBRIC NEXT To select START mode system START IN LUBRIC START IN STANDBY Norm Open NEST To select the type of alarm electric contact Norm Close Norm Open Date amp Time SET Enabled NEXT To enable disable Date and Time function To set the day DATE To set the month DATE To set the year DATE To set the hour TIME To set the minutes TIME MACHINE RE INITIALIZATION 11 7 4 4 Operative parameters Parameter Operative range Dropsa setting Timer A timer defines lube duration 00 015 4m59s Lube starts when system is in pressure Pressure is monitored by a pressure switch LUBE 00m 05s 10s 99 min A proximity sensor detects the changes of position of the piston after three changes a lube cycle
10. E e NOTICE Pressure can be monitored by a micro switch or a NPN PNP proximity sensor 6 4 2 USER CONNECTIONS The following picture shows PCB user interface where the user has to connect power supply and external outputs for the correct functioning of both automatic and manual SMART2 For details about connections please refer to special paragraphs PCB serigraphy only refers to automatic SMART2 M2 M1 6 4 2 1 CONNECTIONS FOR MANUAL SMART2 Here follows user connections for power supply terminal M1 pressure switch and electric level contact independent or serial and the manual push button terminal M2 Furthermore it is also shown how to change the type of connection indipendent or serial for the pressure switch and electric level contact by acting on the jumper located on the electronic board of manual SMART2 Pressure switch and electric level contact serial connections common monitoring signal E T Me manual push button 7 not to be connected Pressure switch and electric level contact indipendent connections common level contact 9 pressure switch M2 manual push button 7 not to be connected s e eco v 220 V M1 f jumper upwards 110 V 1 0 V jumper downwards es 6 4 2 2 CONNECTIONS FOR AUTOMATIC SMART2 Here follows user connections for power supply terminal M1 external alarm and proximity sensor or micro
11. al I R device and Dropsa software to be installed on your PC This innovative system will allow you to remotely manage 171 5 m 39 60 in two important operations Lube status reading reading of the machine data on your PC lube parameters date time and logs Machine programming setup of the machine data from your PC lube parameters date and time The I R communication system Dropsa software included is furnishable by Dropsa on demand 8 TROUBLESHOOTING WARNING This unit can be opened and repaired by Dropsa personnel only The following diagnostic table indicates the main anomalies which may be encountered the probable causes and possible solutions If you cannot solve the problem do not attempt to disassemble the unit but contact the Engineering Department of DROPSA S p A 8 1 PUMP DIAGNOSTICS MANUAL AND AUTOMATIC SMART2 ANOMALY PROBABLE CAUSE SOLUTION Pump does not deliver lubricant e Pump draws off air because the reservoir Pump does not deliver the is empty fixed amount of lubricant Refill the reservoir and vent air from the system Retighten all the fittings Be sure there are no Leakages Loosened inner pre Pump delivers oil at an improper pressure Wear Wearofthe pump the pump Replace the pump Install a pressure gauge to Wrong calibration of the does valve adie by pass at the proper pressure e of the e Vent valve damaged inspect and
12. ed and will operate according to the last saved data setup 9 MAINTENANCE PROCEDURE The machine does not require any special tool for check or maintenance tasks However it is recommended the use only of appropriate and in good conditions tooling protective devices gloves and clothing 626 94 and DPR 547 55 to avoid injury to persons or damage to machine parts WARNING Prior to any maintenance be sure that the power and the hydraulic supplies are off and there is no residual pressure in the main branch pipe SMART2 has been designed and manufactured to require the minimum maintenance Anyway it is recommended To keep the unit clean and periodically to check pipe joints to readily detect possible leaks WARNING It is recommended the use of impurity free lubricant PERIODICAL MAINTENANCE Number of Maintenance Procedure work cycles Lubrication 1000 J 0 00 0 0 00 07 O Cleanliness of refill filter 4 000 Replace the refill filter if necessary Cleanliness of reservoir 6 000 Clean the bottom of the reservoir in case of impurities 10 DISPOSAL During maintenance or disposal of the machine care should be taken to properly dispose of environmentally sensitive items Refer to local regulations in force in your area When disposing of this unit it is important to ensure that the identification label and all the other relative documents are also destroyed 14 11 ORDERING INFORMATION 11 1 MANUAL SMART2 PART
13. er e PS Lubricant delivery is carried out only if the system is in pressure e SEP Lubricant delivery is carried out only the system detects three changes in the position of the mechanical piston 2 1 3 STANDBY During this step lubrication system is idle until the next lubrication cycle There are three ways to regulate standby e TIMER a timer regulate system idling e PULSE a pulse counter regulate system idling e BOTH both a timer and a pulse counter regulate system idling The type of standby will depend on which of these two events will start first 3 PRODUCT MACHINE IDENTIFICATION Machine identification yellow label is located on the front side of the reservoir and contains product serial number input voltage and details of the operating parameters 4 TECHNICAL SPECIFICATIONS 4 1 General technical specifications Mineral Oil Lubricant Viscosity 68 320 cSt 320 1480 SUS Working Temperature 5 C 60 C 41 F 140 F 4 2 Electric gear pump Voltage 110V 50Hz 110V 60Hz 220V 50Hz Power absorption 162W 155 W 150W 1 48A 0 69A Simo flowrate 180 cm min 220 cm min 180 cm min 10 98 cu in min 13 42 cu in min 10 98 cu in min 30 bar 411 fisulationClss O o o o e _ NOTE pump output is energized 4 3 Battery backup DATE and TIME CPU real time clock is powered by a lithium battery for Date and Time backup in the event of powerfailure Voltage 800 mA h 50 70
14. g from misuse neglect normal expected wear chemically caused corrosion improper installation or operation contrary to factory recommendation Nor does it cover equipment that has been modified tampered with or altered without authorization Consumables and perishable products are excluded from this or any other warranty No other extended liabilities are states or implied and this warranty in no event covers incidental or consequential damages injuries or costs resulting from any such defective product s The use of Dropsa product s implies the acceptance of our warranty conditions Modifications to our standard warranty must be in made in writing and approved by Dropsa 17 17 DECLARATION OF COMPLIANCE WITH CE STANDARDS Manufacturer DROPSA SpA Company Via Croce 1 20090 Vimodrone MI Address 0039 02 250791 Telephone Cn 2c Certifies that The machine SMART 2 PUMP Has been manufactured in conformance with the EUROPEAN COMMUNITY DIRECTIVE relating to machines 98 37 EC 91 368 EEC low voltage BT 73 23 EEC Has been manufactured in conformance with the following technical harmonised standards and specification EN 292 1 EN 292 2 EN 50081 2 EN 50082 2 EIC EN 60204 1 EN 1050 Technical Director ing Walter Divisi Product Manager Name DROPSA SpA Vimodrone Mi Italy Company February 2005 Signature Date 18 18 DROPSA LOCATIONS Dropsa USA Inc 50679 Wing Drive Utica Michi
15. gan 48315 USA Tel 1 586 566 1540 Fax 1 586 566 1541 E mail salesusa dropsa com SS Dropsa UK Ltd Unit 6 Egham Business Village Egham Surrey TW20 8RB Tel 44 01784 431177 Fax 44 01784 438598 E mail salesuk dropsa com il i Dropsa S p A Via B Croce 1 20090 Vimodrone MI Italy Tel 39 02 250 79 1 Fax 39 02 250 79 767 E mail sales dropsa it Export E mail vendite dropsa it National Dropsa Gmbh Volmerswerther Strasse 80 40221 Dusseldorf 1 Deutschland Tel 49 0211 39 4011 Fax 49 0211 39 4013 E mail sales dropsa de a d Dropsa France 23 Av des Morillons 4 1 des Doucettes 91140 Garges Les Gonesse Tel 33 01 39 93 00 33 Fax 33 01 39 86 26 36 E mail sales dropsa com Ed Dropsa do Brazil Rua Sobralia 171 Santo Amaro Sao Paulo Brazil Tel 55 011 5631 0007 Fax 55 011 5631 9408 E mail salesbr dropsa com Polydrop S A Av Fabregada 26 Pje Est 2 08907 L Hospitalet de LLobregat Barcelona Spain Tel 34 93 260 22 50 Fax 34 93 260 22 51 E mail sales dropsa it Dropsa Australia Pty C20 148 Old Pittwater Road Brookvale NSW 2100 Tel 61 299 386 644 Fax 61 299 386 611 E mail sales dropsa com Web site http www dropsa com E mail sales dropsa com 19
16. ge of the machine on the product label In order to prevent dangers of electric shocks due to direct or indirect contact with the energized parts electrical power supply line must be protected by a suitable magneto thermal circuit breaker with an intervention threshold of 0 03 Ampere and 1 second minimum operating time Circuit breaker power must be lt 10 kA and nominal power In 6 A At the end of all connecting operations make sure that pipes and wires are safe from impacts and carefully fixed 7 INSTRUCTIONS FOR USE 7 1 Manual SMART2 When the unit is equipped with the manual system located on the frontal side panel you find the PUMP ON indicator which is on when the pump is operating Remote control is via external timer or PLC Warning Manual control device cannot be used through a direct control but must be operated through a deck or an electronic circuit with a max power absorption of 400mA 7 2 Automatic SMART2 When the unit is equipped with an automatic control all the pump functions and checks are carried out through the built in 5 controller alarms and external signals included Timers are also controlled by the system For details about machine operation please refer to par 7 4 7 3 Machine operations T 3 1 Prior to machine start up Verify the unit is undamaged Check that hydraulic and electric connections have been carefully carried out Refill the reservoir with compatible lubricant Ver
17. ify the voltage MAX 220VAC RESERVOIR REFILL Use ONLY compatible lubricant and refill the reservoir by means of the oil refill plug provided with a filter Do not pour lubricant directly into the reservoir without using this oil refill plug 7 3 2 Machine start up In order to avoid damage to the machine the unit must start operating at a minimum working temperature of 5 41 F Switch ON the unit Verify unit start up Verify piping are air bubble free Adjust pressure Set up machine parameters Verify machine correct operation pump must carry out lubrication correctly and according to parameters setup AIR VENTING Pump well functioning is not affected by presence of air in the system However it is advisable to vent air by starting the pump until lubricant comes out air bubbles free It is recommended to avoid pump operation when lubricant is below the minimum level PRESSURE REGULATION Pressure can be verified via pressure gauge It is possible to regulate pressure by acting on the screw located on the frontal side of the baseplate To increase pressure turn the screw clockwise gt To decrease pressure turn the screw anticlockwise In case of doubts as to correct machine functioning it is recommended to contact our Eng Dept to request testing procedures 7 4 SMART2 with built in 5 controller operation 7 4 1 Typical working session Notice prelube is always carried out according
18. is completed Timer timer defines standby duration 01m00s 999h59m59s 01m 00s system idle A pulse register defines standby 1i 9 999 999 duration system idle UM s STANDBY Standby duration system idle is defined by both standby timers timer See Standby 01m 00s 99i Timer and pulse and pulse whichever occurs first Timer Both Timer Lube type It allows to choose the type of stndby PS SEP A timer defines the duration of PUMP POR ON time lag for pump OFF once the 00m 10s system goes in pressure LUBE Cycles Number of lube cycles to be carried 01 999 2 out by the system Number of prelube cycles which will CYCIES be carried out before the lube cycles A timer defines the duration of pause time between each lube process 01s 16m39s 01m 00s ONLY for LUBE type SEP Set 00 005 for continuous service It allows to choose how to start the START IN LUBRIC START IN WAIT Time mm It allows to choose the type of alarm Nomi Open electric contact Date amp Time engpieidtsdo eate me Enabled display and setup Day It allows to set the day 1 1 Year 2000 NOTICE When Date and Time are enabled in order to avoid controller malfunctioning it is recommended to set day month and year in accordance with the calendar U 12 7 5 R communication Controller VIPO5 is provided with an I R port for infra red communication via speci
19. ith Single Line Injectors and Valves 33 SMART2 is available in two versions Manual SMART2 manually controlled via the PLC of the machine tool Automatic SMART2 automatically controlled via built in VIPO5 controller 2 1 LUBRICATION CONTROL SYSTEM PRINCIPLES OF OPERATION AUTOMATIC SMART 2 operates on the principle of intermittent lubrication which involves the following three steps e Prelube e Lube lube wait e Standby 2 1 1 PRELUBE This step is made up of a set of cycles max 999 cycles during which the lubrication system runs a series of lubrication cycles lubrication will be described in paragraph 2 1 2 necessary to vent air from the pump and check lubrication functions Prelube takes place on POWER ON on RESET Any time new parameters are set When prelube is set to 0 Intermittent Lubrication will only consist in the ube standby standby lube phases see START mode 2 1 2 LUBE This step is made up of a set of cycles max 999 cycles during which lubrication is carried out Each cycle consists of two sub cycles ube and wait and involves the monitoring of timers and or inputs during ube system delivers lubricant to the lubrication points during wait a timer defines the wait time between two or more lube cycles or before the beginning of the standby phase in case only 1 lube cycle was set There are three types of lube e TIMER Lubricant delivery is simply regulated by a tim
20. st know the machine functioning through the User and Maintenance Manual Power supply Any type of intervention must not be carried out before unplugging the machine from power supply Make sure that no one can start it up again during the intervention All the installed electric and electronic equipment reservoirs and basic components must be grounded Flammability The lubricant generally used in lubrication systems is not normally flammable However it is advised to avoid contact with extremely hot substances or naked flames Pressure Prior to any intervention check the absence of residual pressure in any branch of the lubricant circuit as it may cause oil sprays when disassembling components or fittings Noise Pump does not produce excessive noise less than 70 dB A 15 PRECAUTIONS No particular operating hazards characterize the machine except for the following precautions Operators contact with the lubricant in case of piping breaking opening or during refill maintenance gt Protection against direct and indirect contact with the fluid must be provided by the user the operator must be provided with suitable individual protective clothing and devices tit VIII 626 Use of incompatible lubricant Main unauthorized fluids Y Fuds Dangers Petrol solvents inflammable liquids Corrosive products Pump damage danger to persons Pump oxidization Food Products Contamination of
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