Pump Series 999 DROPSA SpA - PRO-CONS
Contents
1. A C2021IE Pump 999 23 02 Page 5 of 11 3 0 CORRECT USE 3 1 Putting into service 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 carefully check the integrity of the power supply cable and the unit before use In the event of there being damage to the power supply cable or the unit DO NOT put the system into service Replace the damaged power supply cable with a new one The unit can be opened and repaired ONLY by qualified personnel 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 In 6 A The connection of the pressure switch mounted directly on the tank must be 24 VAC DC The pump MUST NOT be submersed in fluids or utilised in environments which are particularly aggressive or explosive inflammable if not prepared for this purpose beforehand by the supplier For correct fixing verify the distance between centres shown in the diagram in Section 2 Use gloves and safety glasses as required in the lubrication oil safety chart DO NOT use aggressive lubricants with NBR gask2. N outlets Pressure 299482 1 1 EFTE 299484 2 1 0 200 bar 299486 2 2 299443 1 1 5 35 MPa 299444 2 1 50 350 bar 299445 2 2 299481 1 1 eae 299483 2 l 50 700 b 299485 2 2 ii C2021IE Pump 999 23 02 Page 10 of 11 CE Declaration Of Conformity Manufacturer DROPSA SpA Company Via Croce 1 20090 Vimodrone MI Italy Address 39 02 250791 Telephone It is certified that The machine Pump 999 is manufactured in conformity with the DIRECTIVE OF THE COUNCIL OF THE EUROPEAN COMMUNITY concerning the harmonisation of member states legislation relative to machines 98 37 CE 91 368 CEE EMC 89 336 CEE and BT 73 23 CEE and relative amendments is manufactured in accordance with the following standards and harmonised technical specifications EN 292 1 EN 292 2 EN 50081 2 EN 50082 2 CEI EN 60204 1 EN 1050 x Technical Manager Product Manager Ing Walter Divisi Name DROPSA SpA Vimodrone MI Italy C2021IE Pump 999 23 02 Company a January 1999 Signature Date DROPSA SPA DISTRIBUTORS ITALY U S A BRAZIL AUSTRALIA Dropsa SpA Dropsa Corporation Dropsa Dropsa Australia Ltd t 39 02 250791 t 1 586 566 1540 t 55 011 563 10007 t 61 02 9938 6644 f 39 02 25079767 f 1 586 566 1541 f 55 011 563 19408 f 61 02 9938 6611 SPAIN U K GERMANY FRANCE Polydrop S A Dropsa UK Ltd Dropsa Gmbh Dropsa Ame t 34 93 260 22 50 t 44 01784 431177
3. cc stroke Maximum pressure bar 750 MPa 75 Tank capacity 3 5 10 30 Characteristics of the mineral oil min 15 CSt lubricant grease max NLGI2 5C 40 C Temperature of use f Consult Engineering Dept For operations outside of this range Dropsa Variable flow rate model AC Motor 220 380 V 50 60 Hz specify if single or 3 phase at 1500 rpm DC Motor 24V at 2200 rpm Fixed flow rate model AC Motor specify if single or 3 phase DC Motor 220 380 V 50 60 Hz at 1500 rpm 24V at 2200 rpm Insulation Class F Minimum level indicator Electro mechanical type Normally closed at minimum level Maximum commutable power ISA maximum commutable voltage 220 250 VAC a lubricant maximum level and reserve indicator is available on request fitted with floats and two switches minimum and zero 1 2 Pressure gauge Accessory C2021IE Pump 999 Page 2 of 11 Two types of pressure gauge are available PART N PRESSURE RANGE 299196 0 500 bar 0 50 MPa 291395 0 1000 bar 0 100 MPa 13 Pressure regulator Accessory Three types of regulator valves are available to protect the system from overpressures PART N PRESSURE RANGE 299450 0 250 bar 0 25 MPa 299451 0 350 bar 0 35 MPa 299452 50 800 bar 5 80 MPa WARNING Pay strict attention to what is indicated on the valves when assembling Incorre
4. not through the side connection fitted with a filter The piston of the pump element assembly is seized or the piston return spring is broken The pump does not function because the grease being used is of a consistency greater than NLGI 3 max recommenced consistency The pump fails to function because it has been run with the tank empty creating an air lock inside the pump itself Refill the tank with clean lubricant in accordance with the procedure shown in the Maintenance section Warning if the tank has emptied without the minimum level electrical contact having signalled the minimum level check the contact Remove the air vent plug B see fig on page 6 and run the pump allowing the grease to exit until free from air bubbles Replace and partly screw in plug B and continue running the pump until grease exits between the threads and the plug and then fully tighten the vent plug Replace the pump element Remove the tank from the pump remove the unsuitable grease and wash out the tank and filter with petrol Disassemble the pump element and wash out with petrol Reassemble completely refill the tank utilising the side connection fitted with a filter wit suitable grease and run the pump ensuring that grease free from air bubbles exits If necessary remove the air vent plug B see fig on page 6 and proceed as in the previous point Remove the plug which closes the auxiliary pump element outlet or where the p
5. t 49 0211 394 011 t 33 01 3993 0033 f 34 93 260 22 51 f 44 01784 438598 f 49 0211 394 013 f 33 01 3986 2636 Page 11 of 11
6. wooden vice clamps to prevent damage to the lapped surface C2021IE Pump 999 23 02 Page 8 of 11 3 8 Dangers present in use 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 list of dangers as in EN 414 referring to EN 292 application of essential safety requirements Machine Dir att 1 part 1 electrical safety requirements EN 60204 1 The following is a list of dangers which have not been fully eliminated but which are considered acceptable in the version of the pump without a release it is possible to encounter squirts of oil for this reason appropriate protective clothing must be worn contact with oil gt see the requirements for the use of suitable personal protective clothing 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 protection against direct and indirect contact must be provided by the user 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 lubricati
7. 2 1 Fixing and overall dimensions DIMENSIONI IN mm DIMENSIONS IN mm WALL FITTING FISSAGGIO A PARETE FISSAGGIO SU BASAMENTO BASE FITTING 121 2 Dimensions inmm TANKS FOR GREASE TANKS FOR OIL METAL Transparen t Metal Transparent Metal Metal Metal 3 litres 5 litres 10 litres 30 litres C2021IE Pump 999 23 02 Page 4 of 11 2 2 Electrical system Technical Data piston pump AC ELECTRIC MOTOR Electrical power supply Single phase 220 VAC 50 H2 0 12 KW 3 Phase 220 380 VAC 50 H2 0 18 KW 4 pole DC ELECTRIC MOTOR Electrical power supply Single phase 24 VDC 120 W 12 VDC 100 W 2 3 Hydraulic system Technical Data Connection between the pump and the valve block by steel tubing with connectors Only for requested versions SERIES 999000 ELECTRICALLY ELETTROPOMPA SERIE 999000 MOTOR DRIVEN PUMP j amp PAER anal me sessed ESECUZIONE STANDARD ESECUZIONE CON N 2 LAY OUT WITH QTY 2 POMPANTI BY PASS PUMP ELEMENTS BY TANDARD LAY OUT MANOMETRO FILTRO DI 3 Sk CARICAMENTO INVERTITORE PASS PRESSURE GAUGE IDRAULICO E FILTRO IN FILLING FILTER MANDATA HYDRAULIC INVERTER amp DELIVERY FILTER 2 4 Other data Class of protection Grade of mechanical protection IP 55 Operating temperature 5 40 C Operating humidity 90 relative humidity Preservation temperature 20 50 C Level of continuous sound pressure lt 70 dB
8. 6 999604 999646 999666 999676 999656 999686 999696 7 2 51 200 20 999632 999612 999622 999602 999642 999662 999672 999652 999682 999698 Fixed flow rate AC 9 5 750 75 999334 999314 999324 999304 999344 999364 999374 999354 999514 999524 1500 rpm 17 400 40 999336 999316 999326 999306 999346 999366 999376 999356 999516 999526 33 200 20 999332 999312 999322 999302 999342 999362 999372 999352 999512 999522 DC 24V 14 5 750 75 999734 999395 999724 999704 999744 999764 999774 999754 999784 999794 2200 rpm 25 5 400 40 999736 999712 999726 999706 999746 999766 999776 999756 999786 999796 51 200 20 999732 999713 999722 999702 999742 999762 999772 999752 999782 999792 GREASE GREASE MAX NLGI 0 OIL VISCOSITY MIN 15 cSt MAX NLGI 0 DC 12V 14 5 350 30 999380 999390 999385 2200 rpm Rpm and flow rates shown in the table refer to AC motors with 50 Hz frequency With 60 Hz the speed of the motor and the flow rate will increase by 20 Always specify at time of ordering voltage current 3 Phase or Single C2021IE Pump 999 23 02 Page 9 of 11 phase Frequency 4 1 Mounting Kit 999 series pumps can be supplied complete with a kit comprising of Filling filter Pressure gauge Pressure regulating valve and mounting Base To order the Kit it is necessary to indicate the pressure of the pump the number of pump elements and the number of outlets Kit Part N N Pump elements
9. INSTRUCTIONS FOR USE Pump Series 999 DROPSA SpA In accordance with point 1 7 4 to I Dir 98 37 CE Sections 0 0 INTRODUCTION 1 0 DESCRIPTION OF THE PUMP 2 0 TECHNICAL SPECIFICATIONS 3 0 CORRECT USE 4 0 INSTRUCTIONS FOR ORDERING AND LIST OF DISTRIBUTORS DECLARATION OF CONFORMITY Catalogue P N C2021IE Wk 23 02 Registered name DROPSA SpA Address via Croce 1 20090 Vimodrone MI Italy Model Pump 999 Year of manufacture 1999 Marking CE 0 0 INTRODUCTION This user s and maintenance manual refers to a series 999 modular motor driven gear pump for oil and grease This modular pump is particularly suitable for the distribution of oil and grease in lubrication systems 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 pump and any accessories mounted on it should be carefully checked immediately on receipt and in the ev
10. ct assembly of the regulator valve can result in an overpressure which could prejudice the correct functioning of the pump itself and be dangerous for the user 1 4 Filling filter only for the grease version Accessory 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 1 5 Hydraulic inverter Accessory PART N DESCRIPTION 86240 Complete with base mounting plate 86199 Inverter only Pressure up to 300 bar Type of lubricant oil minimum viscosity 15 cSt grease maximum consistency NLGI2 1 6 Auxiliary pump element The pumps are supplied with one pump element only but a second one can be mounted this would permit the feeding of two lines independently or the combining of the outlets of the two pump elements to obtain a doubling of the flow rate To obtain the part number of the auxiliary pump element consult the table by utilising the last number off the 999 base pump or its flow rate specification at 1500 rpm and its maximum working pressure 1 7 Maximum level electrical contact The metal tanks except those of 3 and 5 litres can be fitted with electrical maximum level indicators for automatic replenishing of the tank Tanks for grease Electrical contact Part N 299197 Tanks for oil Electrical contact Part N 291155 2 0 TECHNICAL SPECIFICATIONS C2021IE Pump 999 23 02 Page 3 of 11
11. ent 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 authorisation 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 Instructions for the correct ordering of the required model and a list of importers is shown in Section 4 1 0 DESCRIPTION OF THE PUMP 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 The pump is made up of a series of components 1 1 CHARACTERISTICS PUMP 999 Electric piston pump Fixed flow rate pump element Piston diam 6 mm Piston diam 8 mm Variable flow rate pump element Piston diam 6 mm Piston diam 8 mm 0 20 cc stroke 0 35 cc stroke from 0 028 to 0 20 cc stroke from 0 05 to 0 35
12. ets and seals if in doubt consult the Engineering Department of Dropsa SpA who will provide a chart with the details of recommended oils DO NOT ignore dangers to health and observe all hygiene standards 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 cable the ground terminal must be the last to be removed fe o Action to be taken prior to start up Verify the integrity of the pump Fill the tank with suitable lubricant min max indication on the tank Verify that the pump is at operating temperature and the tubing free from air bubbles Check that the electrical connections have been effected correctly UNI 64 8 IEC o a 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 3 2 Use 1 Verify the settings made 2 Press the start button of the machine to which the 999 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 Engineeri
13. ng Department of Dropsa SpA to request test procedures 3 3 Transport and storage Transport and storage is effected in a cardboard package 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 C C2021IE Pump 999 23 02 Page 6 of 11 3 4 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 3 5 Regulation Flow rate f
14. on pump is able to restart automatically 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 Fluid Danger 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 Water Oxidation of the pump Food substances Contamination of the substances themselves 4 0 INSTRUCTIONS FOR ORDERING AND LIST OF DISTRIBUTORS VERSIONS Adjustable Pressure SERIES 999 ELECTRIC MOTOR DRIVEN PUMP PART NUMBERS Type of flow rate max motor and cm min TRANSPARENT rpm TANK IN METAL TANKS GREASE MAX NLGI 3 OLIO VISCOSITY MIN 15 cSt GREASE NLGI 0 min max bar MPa 3 Kg 5Kg 10 Kg 30 Kg 3 litres 5 litres 10 litres 30 litres 3 Kg 5 Kg AC 1 4 9 5 750 75 999234 999214 999224 999204 999244 999264 999274 999254 999414 999424 1500 rpm 2 5 17 400 40 999236 999216 999226 999206 999246 999266 999276 999256 999416 999426 5 33 200 20 999232 999212 999222 999202 999242 999262 999272 999252 999412 999428 DC 24V 2 14 5 750 75 999634 999614 999624 999604 999644 999664 999674 999654 999684 999694 2200 rpm 3 6 25 5 400 40 999636 999616 99962
15. or 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 3 6 Maintenance Locate the machine in conditions which facilitate easy access Utilise individual protection to avoid contact with mineral oil Periodic inspections Periodically it is necessary to check VERIFICATION WORK CYCLE RUNNING TIME The state of lubrication 1000 every 6 months The oil grease level 2000 once a year il of the filling and intake filter where 500 every 6 months The machine does not require any special tools to carry out checks or maintenance tasks However it is recommended that only tools suitable for the tasks and in good condition should be utilised DPR 547 55 to avoid injury to persons or damage to machine parts 3 7 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 machine but contact the Engineering Department of DROPSA S p A C2021IE Pump 999 23 02 Page 7 of 11 DIAGNOSTIC TABLE ANOMALY CAUSE REMEDY The pump does not deliver lubricant The tank is empty The tank has been filled from above and
16. ump has two elements fitted remove one of the two pump elements and run the pump until homogeneous grease exits Replace the plug or the pump element and continue running the pump until grease exits free from air bubbles If necessary remove the air vent plug B see fig on page 6 and proceed as indicated above Irregular pressure Pump element return valve and seating dirty Pressure regulating valve by pass dirty Disassemble the parts shown in diagram A see fig on page 6 and wash them in petrol Also clean the valve seating Check the condition of the components and replace if necessary Disassemble the parts of the valve shown in the diagram and wash them in petrol Also clean the valve seating Check the condition of the components and replace if necessary Valve Part N Spring part N Pressure reg 299450 299456 0 250 Bar 299451 299457 0 350 Bar 299452 299458 0 800 Bar Before reassembling the valve check that the ring seal 18818 has not been damaged Irregular flow rate Screw C which secures the pump element D and return spring E is loose Remove the pump element assembly from the pump body and completely disassemble it To reassemble the pump element assembly see the sequence in the diagram Check all the parts and reassemble after having washed them all in petrol Warning put some Loctite type sealant on screw C which is inserted into pump element D Hold the pump element between
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