PUMP SERIES 989
Contents
1. only for adjustable delivery Warning put some Loctite type sealant on pump unit screw C which is inserted into pump element D Hold the pump element between wooden vice clamps to prevent damage to the lapped surface Lock up very well the element B immediately Delivery valve dirty Dismount the valve A clean it and mount The system doesn t Delivery valve damaged following the showed sequence RACA E Pree Sule Spring broken Replace the pumping unit Fixed delivery pumping uni Adjustable delivery pumping Part No 299642 6 mm unit Part No 299643 8 mm Part No 299041 6 mm Part No 299042 8 mm 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 9 MAINTENANCE PROCEDURE Position the machine in such a way that it can be checked easily Wear the correct individual protection gear in order to avoid contact with the mineral oil It is necessary to periodically check as follows VERIFICATION WORK CYCLE RUNNING TIME The state of lubrication 1000 every 6 months The oil grease level 2000 once a year Cleanliness of the filling and intake filter where fitted 500 every 6 months The machine does not require special equipment for any inspection and or maintenance activity It is however recommended that the equipment used be suitable and in good condition DPR 547 55 so as to avoid damage t2. 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 Germany Tel 49 0211 39 40 11 Fax 49 0211 39 40 13 E mail sales dropsa de propsA L E Dropsa France 23 Av des Morillons Z I 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 lt gt 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 n 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 si 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 13
3. in min Pumping unit 8 mm Adjustable delivery 2 5 17 2990420 m min 0 15 1 03 cu in min 888036 By Pass 0 250 Bar 3292099 Pressure gauge 0 400 Bar 11 3 SPARE PARTS Part No DESCRIPTION 3301504 Motor GR 56 KW 0 09 220 380 V 50 60 Hz 712100 Filter 220 u 3301505 Reduction gear R 1 30 12 DIMENSIONS FOR WALL MOUNTING No 2 HOLES 9 mm No2 HOLES a em BSP Pumping Unit G 1 4 Outlet Refilling POS en mm In 539 5 21 24 334 13 15 71 2 79 220 8 66 120 4 72 moov D gt E c cE ee D No 4 HOLES 6 mm FOR BASE PLATE MOUNTING 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 No particular precautions are required except as noted on the package itself Handling must be effected by at least two persons Lift the unit with taking account of the right way up indicated on the cardboard carton The machine components can withstand temperatures during storage from 20 to 50 C however in order to avoid damage starting of the machine should occur at a minimum temperature of 5 14 OPERATING HAZARDS involved in the use of lubrication machines The operator must know
4. pump and any accessories mounted on it should be carefully checked immediately on receipt and in the event of any discrepancy or complaint the Dropsa SpA Sales Department should be contacted without delay DROPSA S p A declines to accept any responsibility for injuries to persons or damage to property in the event of the non observance of the information presented in this manual Any modification to component parts of the system or the different destination of use of this system or its parts without prior written authorization from DROPSA S p A will absolve the latter from any responsibility for injury or damage to persons and or property and will release them from all obligations arising from the guarantee 2 GENERAL DESCRIPTION The features which distinguish this pump are high performance simplicity of construction modularity The simplicity of construction guarantees long life reliability and simplified and reduced maintenance The modularity of the components allows the system engineer to construct the lubrication unit to meet the specific needs of the lubrication system it is serving 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 TECHNICAL CHARACTERISTICS Pressure 300 Bar 4410 psi Fixed delivery max pumping 96 mm 1
5. 0 cm min 0 55 cu in min Fixed delivery max pumping 98 mm 17 cm min 1 03 cu in min Adjustable delivery max pumping 6 mm 1 4 10 cm min 0 085 0 61 cu in min Adjustable delivery max pumping 96 mm 2 5 17 cm min 0 15 1 03 cu in min No pumpings 1 3 Capacity reservoir 5 kg 11 Ib Lubricant Grease Lubricant Viscosity 000 2 NLGI Working Temperature 10 C 40 C 50 104 F Motor Voltage 220 380 V 50 60 Hz Power absorption 90 W 5 MACHINE COMPONENTS 5 1 Minimum level indicator Electro mechanical type Normally closed at minimum level Maximum commutable power ISA maximum commutable voltage 220 240 VAC 5 2 Pressure gauge Accessory 3292099 O 400 Bar 0 40 Mpa 5 3 BY PASS VALVE Accessory 888036 0 250 bar 0 3675 psi It is possible to adjust working pressure by means of a by pass valve installed on delivery line The use of the by pass valve it s recommended to control the pump operating and to avoid over pressure in the circuit 5 4 Filling filter This removable cartridge filter is recommended to ensure the filling of lubricant which is free from foreign bodies and to avoid the formation of air bubbles Type of lubricant Grease NLGI 2 5 5 Pumping unit Representing the pump operating member it is screwed directly into pump housing and driven by means of an eccentric cam The suction system consists of a free dual line while
6. E Direttiva compatibilit elettromagnetica poich rispetta tutti i requisiti essenziali di sicurezza e sanitari che le concernono ed in riferimento alle seguenti norme armonizzate e EN 12100 1 2 Sicurezza del macchinario concetti fondamentali principi di progettazione EN 1050 Sicurezza del macchinario principi per la valutazione del rischio EN 982 Sicurezza del macchinario Requisiti di sicurezza relativi a sistemi e loro componenti per trasmissioni oleoidrauliche e pneumatiche Oleoidraulica e EN 11200 Rumore emesso dalle macchine e dalle apparecchiature e EN 894 1 2 3 Requisiti ergonomici per la progettazione dei dispositivi di informazione e di comando e EN60204 1 Sicurezza del macchinario Equipaggiamento elettrico delle macchine sa i e e i me Fida di e O OR O if Vimodrone MI 15 01 07 Modello dichiarazione CEE conforme a quanto previsto dalla norma EN 45014 Sede Legale Via Visconti di Modrone 2 20122 Milano Cap Sociale E 1 548 id CIO LA P30 Cod Fiscale e P IVA 003R4T754 5E 12 18 DISTRIBUTORS Dropsa USA Inc 50679 Wing Drive Utica Michigan 48315 USA Tel 1 586 566 1540 Fax 1 586 566 1541 E mail salesusa dropsa com Ete 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 H Dropsa S p A Via B Croce 1 20090 Vimodrone MI Italy Tel 39 02
7. PUMP SERIES 989 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 SERRE e Manufacturer __ DropsA SpA PUMP SERIES 989 Product 2007 Certification Manual drawn up in accordance with C21131E WK 27 07 EC Directive 98 37 Annex I paragraph 1 7 4 1 INTRODUCTION This user s and maintenance manual refers to a 989 pump series for grease It is recommended that this manual is carefully kept in good condition and is always available to persons requiring to consult it To request further copies updates or clarifications with respect to this manual contact the Engineering Department at Dropsa SpA The use of the pump referred to in this manual must be entrusted to qualified personnel with a knowledge of hydraulics and electrical systems The manufacturer reserves the right to update the product and or the user s manual without the obligation to revise previous versions It is however possible to contact the Engineering Department for the latest revision in use The
8. achine but contact the Engineering Department of DROPSA S p A 10 DISPOSAL During maintenance or disposal of the machine care should be taken to properly dispose of environmentally sensitive items such as oils or other lubricants 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 11 ORDERING INFORMATION 11 1 FIXED DELIVERY Part No Description Grease Electro pump 220 380 V ASRR 1 pumping unit 6 mm 50 60 H Z 989002 Grease Electro pump 1 pumping unit 8 mm Grease Electro pump 1 pumping unit 6 mm Grease Electro pump 1 pumping unit 8 mm 989011 24 V DC 989012 For 24V version the motor is supplied with 1 mt 3 28 ft without terminal ADJUSTABLE DELIVERY Part No Description Grease Electro pump 220 380 V 399008 1 pumping unit 6 mm 50 60 H Z 989004 Grease Electro pump 1 pumping unit 8 mm Grease Electro pump 1 pumping unit 6 mm Grease Electro pump 1 pumping unit 8 mm 989013 24 V DC 989014 For 24V version the motor is supplied with 1 mt 3 28 ft without terminal 11 2 ACCESSORIES Part No DESCRIPTION Pumping unit 6 mm Fixed delivery 10 cm min 299642C 0 61 cu in min Pumping unit 8 mm Fixed delivery 17 cm min SHIN 1 03 cu in min Pumping unit 6 mm Adjustable delivery 1 4 10 299041C cm8 min 0 085 0 61 cu
9. be opened and repaired ONLY by qualified personnel e In order to prevent dangers of electric shock due to direct or indirect contact with live parts it is necessary that the electrical power supply line is adequately protected by a suitable differential magneto thermal circuit breaker with an intervention threshold of 0 03 Ampere and a max operating time of 1 second The breaking capacity of the circuit breaker must be lt 10 kA and the nominal current n 4A e The connection of the pressure switch mounted directly on the tank must be 240 VAC DC e The pump MUST NOT be submersed in fluids or utilized in environments which are particularly aggressive or explosive inflammable if not prepared for this purpose beforehand by the supplier e For correct fixing verify the distance between centers e Use gloves and safety glasses as required in the lubrication oil safety chart e DO NOT use aggressive lubricants with NBR gaskets and seals if in doubt consult the Engineering Department of Dropsa SpA who will provide a chart with the details of recommended oils e DO NOT ignore dangers to health and observe all hygiene standards e WARNING All electrical components must be grounded This refers to both electrical components and control devices In this regard ensure that the ground cable is correctly connected For reasons of safety the ground cable must be approx 100 mm longer than the phase cables In the event of accidental detachment of the ca
10. ble the ground terminal must be the last to be removed Action to be taken prior to start up e Verify the integrity of the pump e Fill the tank with suitable lubricant min max indication on the tank e Verify that the pump is at operating temperature and the tubing free from air bubbles e Check that the electrical connections have been effected correctly UNI 64 8 IEC The minimum level indicator is supplied unless otherwise specified by the customer with the contact closed for minimum level Should the user require to use a normally open contact it will be necessary to invert the operating direction of the microswitch 7 INSTRUCTIONS FOR USE A Verify the settings made 2 Press the start button of the machine to which the 989 series pump is connected 3 Verify the starting of the pump 4 Verify the adequate lubrication of the machine if doubt exists as to the correct functioning consult the Engineering Department of Dropsa SpA to request test procedures 5 Reservoir is refilled through lubricator A 8 TROUBLESHOOTING 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 Power supply failure Verify power supply system and check the fuse Motor does not Rat Ga operate ene Replace the ratiomoto
11. discharge is provided with an adjustable delivery valve Its components are made of high quality alloy steel specially treated to improve wear resistance characteristics Furthermore a special external coating guarantees excellent resistance to corrosion tested through salt fog tests 5 6 Auxiliary pumping unit 989 pump series are supplied with a pumping unit but it is possible to install one or two auxiliary pumpings with fixed or adjustable delivery Combining the three pump elements for higher output or manage up to three lubrication lines 6 UNPACKING AND INSTALLING THE PUMP 6 1 Unpacking Once a suitable location has been found to install the unit remove the pump from the packaging Check the pump has not been damaged during transportation or storage No particular disposal procedures are necessary however packing should be disposed of in accordance with regulations that may be in force in your area or state 6 2 Installing the pump Damage to the power supply cable and housing could result in contact with high voltage 220 380 VAC live parts and hence be a danger to life e Mount the pump in a way that the refill lubricator and timer are always easy to access e Carefully check the integrity of the power supply cable and the unit before use e Inthe event of there being damage to the power supply cable or the unit DO NOT put the system into service e Replace the damaged power supply cable with a new one e The unit can
12. e version of the pump without a release it is possible to encounter squirts of oil for this reason appropriate protective clothing must be worn e contact with oil gt see the requirements for the use of suitable personal protective clothing e use of unsuitable lubricant gt the characteristics of the fluid are shown on the pump and in the manual in case of doubt contact the Eng Dept of Dropsa Spa e protection against direct and indirect contact must be provided by the user e given the purpose of the pump it must always be functioning for this reason it is necessary to pay attention to the electrical connections which in the case of a power failure the customer s machine is restarted only by means of a reset while the lubrication pump is able to restart automatically e incorrect assembly of the regulator valve can result in an over pressure which can prejudice the functioning of the pump itself and create danger for the user This is avoided by stamping the mounting instructions on the table Lubricants with abrasive additives High wear rate of contacted parts Lubricants with silicone based additives Seizure of the pump Petrol solvents inflammable liquids Fire explosion damage to seals Corrosive products Corrosion of the pump injury to persons Oxidation of the pump Food substances Contamination of the substances themselves 10 16 WARRANTY INFORMATION All products manufactured and marketed by Dropsa a
13. o people or parts of the machine 9 1 Assembly Disassembly No pump assembly operations are envisaged For wall mounting ensure adequate space is available as shown in the installation diagram to avoid abnormal postures and possible impacts four fixing holes are provided for wall mounting and three for base fitting Subsequently it will be necessary as previously described to connect the pump to the machine hydraulically and then to connect the control panel During the disassembly phase ensure the tank is empty Disconnect the electrical and hydraulic parts Where the machine is to be scrapped do not dispose of potentially polluting parts in the environment following local regulations for their correct disposal At the time of the machine being scrapped it is necessary to remove and destroy the identification plate and all other relative documents 9 2 Regulation Flow rate for versions with adjustable flow rates It is possible to regulate the flow rate by rotating the regulating screw 8 mm hexagonal key clockwise to decrease and anticlockwise to increase remove the cap B 9 3 Repairs The following diagnostic table indicates the main anomalies which may be encountered the probable causes and possible solutions The anomalies shown are e the pump fails to deliver lubricant e irregular pressure e irregular flow rate In case of doubts and or problems which cannot be resolved do not attempt to disassemble parts of the m
14. r operate Reservoir is empty Refill the tank with clean lubricant 02 Disconnect main piping from pumping element fitting Operate the pump in the manual mode until lubricant free of air bubbles comes out of the fittings Pump does not Air bubbles in lubricant deliver lubricant Obstructed suction pipe Disassemble the pumping unit and clear the line suction pipe line Pump operates but Disconnected piping Inspect piping and replace the wear pipes does not deliver lubricant to the bearing points Blocked progressive disnvuici Clear the distributor Replace it if necessary ANOMALY CAUSE REMEDY The distributor is not Lubricant reaches __ correctly connected to the the bearing points bearing points in incorrect Delivery is not correct only quantities for adjustable delivery Adjust delivery by means of regulation screw pump unit Verify that the dosages are those indicated in the system diagram Allow the pump being cooled for a few minutes Pump starts Faulty motor or high output l l 05 lubricating but stops and try again If the problem still continues consumption contact the Customer Service Remove the pump element assembly from the pump body and completely disassemble it To reassemble the pump element assembly Screw C which secures see the sequence in the diagram the pump element D and Check and clean all pump unit parts Verify the Irregular flow rate return spring E is loose component integrity
15. re 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 resulting from misuse neglect normal expected wear chemically caused corrosion improper installation or opera
16. the machine functioning through the User and Maintenance Manual WARNING It is necessary to carefully read about the instructions and the risks 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 The verification of conformity with the essential safety requirements and regulations of the Machine Directive is effected by means of the compilation of a check list which has been pre prepared and is contained in the technical file The lists which are utilised are of three types e list of dangers as in EN 414 referring to EN 292 e application of essential safety requirements Machine Dir att 1 part 1 e electrical safety requirements EN 60204 1 The following is a list of dangers which have not been fully eliminated but which are considered acceptable e inth
17. tion 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 11 17 DECLARATION OF COMPLIANCE WITH CE STANDARDS va o Dropsa Spa Tel 39 032 250 79 DropsA Via B Croce Fax Sales 39 02 250 79 767 20090 VIMODRONE MI Fax Purch 39 02 250 79 320 ITALY E mail cale lt ioad ropsa it Centralized Lubrication Engineers and Component Manufacturers x eee Gli Specialisti Della Lubrificazione Dal 1946 APPROVED COMPANY DICHIARAZIONE CE DI CONFORMITA Allegato Il A della Direttiva 98 37 CE La Sottoscritta Milena Gavazzi in qualit di legale rappresentante del fabbricante della Societ Dropsa S p A con sede legale in Milano Via Visconti di Modrone 2 DICHIARA sotto la propria esclusiva responsabilit e che le macchine denominate 989001 989002 989003 989004 sono conformi alle condizioni previste dalle Direttive e 98 37 CE Direttiva Macchine e 73 23 CEE Direttiva bassa tensione e 89 336 CE
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