DROPSA LOCOPUMP Istruzioni operative

LOCOPUMP

Pneumatic Grease Pump

Manufacturer DropsA SpA

Product LOCOPUMP

Pneumatic Control Pump

Year 2002

Certification

User and

Maintenance Manual

Warranty information

TABLE OF CONTENTS

1. INTRODUCTION

2. GENERAL DESCRIPTION

3. PRODUCT – MACHINE IDENTIFICATION

4. TECHNICAL CHARACTERISTICS

5. PUMP COMPONENTS

6. UNPACKIGING AND INSTALLING THE PUMP

7. PUMP OPERATION

8. TROUBLESHOOTING

9. MAINTENANCE PROCEDURE

10. DISPOSAL

11. ORDERING INFORMATION

12. DIMENSIONS

13. HANDLING AND TRASPORTATION

14. OPERATING HAZARDS

15. PRECAUTIONS

16. WARRANTY INFORMATION

17. DECLARATION OF COMPLIANCE WITH STANDARDS

18. DROPSA LOCATIONS

C2069IE - WK 37/03

Manual drafted in compliance with EC Directive 98/37,

Annex I, paragraph 1.7.4

http://www.dropsa.com

1. INTRODUCTION

This manual refers to the LOCOPUMP, a pneumatic pump solution for progressive lubrication systems. 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.

Please read this manual carefully, as it contains important information on health and safety issues. A copy of this

manual should remain with the user of the product.

2. GENERAL DESCRIPTION

The Locopump pneumatic control pump uses compressed air to adjust the lubricant delivery during its

operations. Therefore, The Locopump is ideally suited for lubrication equipments installed on machines provided

with compressed air systems.

The pump electric control valve will be 3 ways type (line-cylinder-drain).

Pumping lubricant: mineral grease with no abrasive materials.

Air control pressure: min. 3 bar (44.1 psi) – max. 6 bar (88.2 psi).

Reservoir filling: grease gun with valve UNI 7663 – shape “A” – 1/8” NPT.

Lubricant outlet: G 1/4” bsp.

Compressed air inlet: G 1/8” bsp compression cone seating 6 mm. (0.2 in.) tube.

Cartridge shaped filter positioned at the grease gun inlet.

Electromagnetic level control-switch.

Accessories: see table below, page 3.

3. PRODUCT – MACHINE IDENTIFICATION

The pump identification label is located on the front side of the pump reservoir and contains details of the

operating parameters of the pump including input voltage.

4. TECHNICAL CHARACTERISTICS

TECHNICAL CHARACTERISTICS

Fixed delivery (standard) 2 cm³ (0.12 cu.in.) per stroke

Pump delivery (with regulation kit 3132585) 0,8 ÷ 2 cm³ (0.05 ÷ 0.12 cu.in.) per stroke

Air pressure 3 ÷ 6 bar (44.1 ÷ 88.2 Psi)

Compression ratio 50 : 1

Grease grade at working temperature NLGI 000 ÷2

Working temperature + 5 ÷+ 80 °C (41 ÷176 °F)

Permissible working humidity 90 % max.

Max. commutable 100V DC

Max. commutable current 0.25 A

Minimum level contact Max. commutabile power 8W (NO) – 3W (NC)

Storage temperature - 20 ÷+ 50 °C (-4 ÷122 °F)

Noise < 70 dB(A)

CAUTION: Operate the pump only with the voltage indicated on the product label and within the specific

operating parameters.

5. PUMP COMPONENTS

All the main pump components are fixed to the mounting bracket.

Oil Reservoir: constructed in transparent plastic and compatible with commercial lubricants.

Pump Assembly: constructed in steel and containing a non-return valve. At the working pressure of 300

bar (4410 Psi), the pump can deliver up to 2 cm³ (0.12 cu.in.) per stroke.

Electric Level Control-Switch: Provides remote low level sensing. The switch can be set to either

operate normally open (N.O.) or normally close (N.C.). Standard configuration is N.C.

6. UNPACKING AND INSTALLING THE PUMP

WARNING: The unit can only be opened and repaired by authorized Dropsa personnel.

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

as packaging materials are no dangerous for health or environment. However, packaging should be disposed of

in accordance with regulations that may be in force in your area or state.

CODE DESCRIPTION

3044260 Reservoir 2 Kg (4.4 lb.)

3045202 Mounting bracket

3413500 Pump body

1655183 Electric Level Control-Switch

712100 Re-filling filter

6.2 INSTALLING THE PUMP

Allow sufficient space of at least 100 mm around the pump for ease of maintenance. Install at a suitable level for

refilling the oil reservoir. Do not install the pump neither in aggressive environments such as close to explosive

materials, nor on vibrating shelves. Fix the pump using the two fixing holes and 10 mm screws, and apply flat

washers under the screws. In order to fix the pump correctly, verify the inter axles dimensions (see the pictures

in chapter 12).

6.3 ELECTRICAL WIRING.

Before carrying out any wiring, ensure that the correct power supply is available (see the picture below). Refer to

the identification label on the Pump. In order to avoid dangers of electric shock it is important to remove all

power before installation or maintenance.

Electrical connections must be carried out in accordance with prevailing standards and must guarantee

adequate power and protection to the pump unit.

6.4 HYDRAULIC CONNECTIONS

Hydraulic connectors are placed on the front face of the pump body. The pump outlets are threaded as standard

with 1/4" BSP threads.

6.5 SUPPLY CONNECTION

Use a fitting of 1/8” BSP to connect the pump. Dropsa double cone fitting can be used.

Use an intercepting valve that allows supply interruption.

6.6 SETTING THE PUMP

Pressure setting: Compression ratio should be of 50:1. Adjust the delivery pressure according to the system

operating parameters.

Delivery setting: The pump has a fixed delivery. For particular needs, the pump delivery adjustment kit 3132585

can be provided under specific request. The kit is showed in the picture below.

Install the kit using the gasket (A) provided with it, remove the tap (E) and screw the fitting (B) with a key 27.

Loose the screw nut (C) with a key 13 so as to free the screw (D). Use the appropriate screwdriver cut either to

tighten (decreasing the pump delivery) or loose (increasing the pump delivery). Once completed the adjustment,

block the screw nut (C) and replace the cap (E).

N.B.: After completing the installation, ensure that all cables and tubing is protected against possible

damage from moving parts within the installation environment.

7. PUMP OPERATION

7.1 COMMISSIONING THE PUMP

•The unit can only be opened and repaired by authorized Dropsa personnel.

•Do not use the pump submerged in fluids, in aggressive environments such as close to extremely hot

substances, flammable or explosive material whether the supplier has not specifically prepared the

pump for it.

•Always wear safety glasses and gloves when working with pneumatic and hydraulic systems.

•Do not use abrasive lubricants with gaskets NBR. In the event of doubts, contact the Dropsa technical

centre that will provide all details on indicated lubricants.

•Do not ignore hazards for health and observe hygienic rules.

•Always use tubing suited for the specific working pressure.

Before using the pump, it is necessary to perform some preliminary checks:

•Check the integrity of the pump; ensure there is no physical damage.

•Fill the Oil reservoir with suitable lubricant (see instructions min/max on the reservoir).

•Check the pump working temperature and ensure there is no trapped air within tubing.

•Check electrical connections have been carried out correctly (CEI 64/8, IEC 364).

•Check level control panel connections and their operating status.

7.2 USING THE PUMP

•Check set data on the panel.

•Push the start button of the machine to which the pump is connected.

•Check pump commissioning.

•Ensure the machine is properly lubricated (in the event of doubts, contact the Dropsa technical centre to

request the testing procedure.

8. TROUBLESHOOTING

The following table highlights some of the most common problems encountered when using the

Locopump and how to resolve them.

In the event of doubts or problems not listen, do not dismantle the pump but contact a DropsA technical

centre for assistance.

DIAGNOSTIC TABLE

PROBLEM

The pump starts but does not

deliver lubricant or delivers

different quantities from the

required discharge.

The pump does not deliver

lubricant at the set pressure or

does not keep the working

pressure.

PROBABLE CAUSE

oThe reservoir has insufficient oil.

oThe control valve does not

discharge.

oFittings may have become lose.

oIncorrect adjustment of the

control inlet air pressure.

oThe check valve may be

damaged or clogged.

SOLUTION

oFill the oil reservoir. Do not

exceed the max. level.

oCheck the pump control valve 3

ways is normally discharging

compressed air.

oTighten any loose fittings on the

pump or the lubrication system.

oAdjust properly the air pressure

within the established range of

pressures considering the

compression ratio.

oClean or change the valve

(chapter 6.6 point F) which is

comprised in the kit 3132671

9. MAINTENANCE PROCEDURE

To facilitate maintenance it is suggested that the pump be installed in an easily accessible location.

Provide users with the necessary personal protective clothing to avoid any contact with lubricant.

Once accurately set by Dropsa, the pump does not require any maintenance.

It is recommended the use of pure lubricants and a periodical accurate cleaning of pump components.

Dismantling has to be carried out as following:

1. There is a grease pushing spring. Before dismantling the reservoir, it has to be emptied of its content.

2. Discharge the supply pressure.

3. Disconnect fitting from the pump.

4. Unscrew fixing screws and then dismantle the reservoir keeping a lot of attention to the grease pushing

spring (the spring could be charged. If so, remove the residual lubricant).

5. Remove the pump and the filters.

6. Unscrew the pump pneumatic cylinder keeping a lot of attention to the charge of the spring. After this, it

is possible to slip off pumping group components.

In this way it is possible to free every pump component, remove and clean them.

Before mounting, each component has to be washed in oil and lubricate.

The following routine operations should be performed:

Operation Interval (in hours)

Check correct lubrication function of the pump 100

Lubricant level 200

Clean the suction and re-filling filters 400

Clean the bottom of the oil reservoir from any dirt or particle deposits 600

The unit does not require any special tooling to operate or maintain it. It is recommended that suitable protective

clothing (including gloves and safety glasses) are worn when maintaining the unit in order to avoid hazards to

equipment or persons.

Be sure that all electrical and pressurized hydraulic components are disconnected prior to any

maintenance.

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 is also destroyed.

11. ORDERING INFORMATION

Ordering instructions

Code Technical Characteristics

3413050 Pneumatic pump R=50:1 Reservoir 2 Kg (4.4 lb.)

3132671 Gasket replace kit

3132585 Pump delivery adjustment kit

12. DIMENSIONS

To facilitate maintenance allow 100 mm of access on all sides.

13. HANDLING AND TRANSPORTATION

Pumps are accurately packed and dispatched in cardboard containers. During transportation and storage always

maintain the pump the right way up as indicated on the box.

On receipt check that the packaging has not been damaged and store the pump in a dry place.

14. OPERATING HAZARDS

It is necessary to read and understand the possible hazards and risks involved when using a lubrication pump.

The operator must fully understand the hazards explained in this manual.

Electrical Power

No maintenance must be performed on the unit without having detached and isolated the power supply

and ensuring that it cannot be reconnected for the duration of the maintenance task. Always remember

to ensure that equipment is properly earthed.

Flammable substances.

Mineral oils generally used in lubrication systems are not normally flammable. However, it is desirable to

avoid contact with extremely hot substances or naked flames. Ensure that the machine that the

lubrication system is installed onto contains the necessary fire extinguishing devices.

Pneumatic & Hydraulic Pressure

Before any maintenance or connection task, ensure that all pressure has been properly bled from the

system. Residual pneumatic or hydraulic pressure can cause the release of undesired spurts of liquid,

which may hit the operator. Always wear safety glasses and glove when working with pneumatic and

hydraulic systems.

Noise and Vibration

The Locopump pump does not produce excessive vibration or noise (less than 70 dB(A) )

15. PRECAUTIONS

Verification of compliance with essential safety requirements and machine Directive dispositions has been

carried out filling in checking lists provided and contained in the technical file.

Dropsa used two kind of checking lists:

•The list of hazards (according to the EN 1050 as it refers to EN 292).

•Enforcement of the essential safety requests (machine Directive – annex 1, part 1).

Residual but acceptable hazards are described below:

•During maintenance operations, spurts of lubricant at low pressure could occur. (Said operations have to

be carried out using the proper health and safety regulations).

•Contact with lubricant. See dispositions for proper health and safety regulations.

•Pre-loaded springs positioned inside the control cylinder and reservoir.

•Use of incompatible/non-permissible fluids. Compatible lubricant characteristics has been shown in this

manual and can be found on the label stick onto the machine. In the event of doubts, contact the Dropsa

technical centre.

•Electrical and hydraulic protection should be provided by users.

•Monitor electric contacts to ensure the pump is working during machine operations. In case of short-

circuits the machine can be reset and restart by user whilst the lubrication pump restarts automatically.

•Do not use alcohol for machine cleaning.

Examples of incompatible/non-permissible Fluids.

Fluid Danger

Lubricants containing abrasive components. Premature wear of pump

Lubricants containing silicon. Pump failure

Petrol, Solvents, flammable liquids Fire, explosion, seal damage.

Corrosive products Pump damage, danger to persons.

Water Pump oxidization

Food Products Contamination of product

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 & 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 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. DECLARATION OF COMPLIANCE WITH CE STANDARDS

Manufacturer:

DROPSA SpA

Via B. Croce, 1 - 20090 Vimodrone (MI)

Address

02 – 250.791

Telephone

Certifies that:

The Machine: LOCOPUMP PNEUMATIC PUMP 36003XX

oHas been manufacturer in conformance with the European Community Directive relating to the harmonised

standards of the member states relating to machine safety, EMC (89/336/CEE) and BT (73/23/CEE) and

subsequent revisions of the aforementioned standards

TECHNICAL DIRECTOR Walter Divisi

Name

DROPSA SpA - Vimodrone (Mi) - Italy

Company

January 2002

Signature Date

Indice

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