DROPSA SMART3 Istruzioni operative

SMART3 PUMP

User and

Maintenance Manual

Original instructions

Manual drawn up in accordance with C2194IEWK 37/20

EC Directive 06/42

http://www.dropsa.com

TABLE OF CONTENTS

1. INTRODUCTION

2. GENERAL DESCRIPTION

3. PRODUCT-MACHINE IDENTIFICATION

4. TECHNICAL INFORMATION

5. MACHINE COMPONENTS

6. VERSIONS

7. UNPACKING AND INSTALLATION

8. INSTRUCTIONS FOR USE

9. PROBLEMS AND SOLUTION

10. MAINTENANCE PROCEDURE

11. DISPOSAL

12. ORDERING INFORMATION

13. DIMENSIONS

14. HANDLING AND TRANSPORTATION

15. OPERATING HAZARDS

http://www.dropsa.com

Via Benedetto Croce, 1

Vimodrone, MILANO (IT)

t. +39 02 250791

Dropsa products can be purchased from Dropsa branches and authorized distributors,visit

www.dropsa.com/contactor contact us [email protected]

1. INTRODUCTION

This User and Maintenance Manualrefer toDropsa’s“SMART3 “ Oil lubrication Pump for oil and fluid grease.

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 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

SMART3 is a compact and versatile electric gear pump package particularly suited for machine tool and work centre lubrication

systems using 33V injector systems.

The versatility of this product is thanks to a wide range of electric motors and the fact it is available with a Dropsa optical switch

that can work with both oil and fluid greases.

The lubrication cycle can be determined either externally by a host PLC or by selecting a model with the built in controller board

that will operate and monitor the system accordingly.

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 INFORMATION

Note. The informationrefer to the temperature of use of +20°C (+68°F)

(1)

2800 rpmwith no load

* If a different or special lubricant product is used, please contact Dropsa to ensure its suitability.

4.1 HYDRAULIC SYSTEM

As illustrated, all pumps are

equipped with:

- An integrated by-pass for

pressure-regulating

- Arelief valve for pressure

- An electrical minimum level

- A lubricant charging filter

- A pre-calibrated pressure

switch

- Apressure gauge.

GENERAL INFORMATION

Empty weight

4.5 Kg

ELECTRIC INFORMATION

Motor power supply

110V –2p–50/60 Hz 140/175W- (2800/3500 rpm)

230V –2p–50 Hz 135 W- (2800 rpm)

230V –2p–60 Hz 170 W- (3500 rpm)

24 V DC - 55 W (1) - (2800 rpm)

OTHERS INFORMATION

Degree of Pump protection

IP 55

Pumping system

Gear pump

Pump flow rate (free flow)

180 cc/min @ 2800 rpm

220 cc /min @ 3500 rpm

Maximum working pressure

30 bar

Outlet connection

G1/8” BSP

Reservoir capacity

2L/3L

Minimum level –Float switch option, for oil only

With NC in case of liquid

Minimum level –DropsaOptiLev Optical sensing

system for oil and fluid greases.

NPN or PNP short-circuit protected signal, "off" in case of minimum

level

Filter

1000 µ filtering degree

By-pass

Adjustable 0÷30 bar –precalibrated25 bar

Pressure switch

10÷20 bar - precalibrated to 18 bar

Working Temperature

+ 5 + 60 C

Working Humidity

90 % rel. humidity

Permitted lubricants *

Mineral lubricating oil 32 cSt-320 cSt ;

Grease max NLGI000;

Storage temperature

-20 +80 °C

Sound Pressure Level

< 70 dB(A)

Max working time in continuous operation

1 min

MIN STANDBY time

5 times T-on

Dropsa recommends a 4 AMP overload fuse

5. PUMP COMPONENTS

Following main components of the pump:

6. VERSIONS

6.1 MANUAL VERSION

This version is not equipped with an integrated control system. All control and

monitoring of the pump is done by an external control system or PLC. This is

typically the configuration used for Machine Tools factory fit.

The Pump is equipped with connection plate located under the pump cover

where all electrical connections are concentrated (motor, minimum level,

pressure switch). On the front face of the pump, there is a button to activate a

lubrication cycle manually. When pressed, the button closes a contact. This

signal is fed back to the external PLC control that will then run a lubrication

cycle.

The level and Pressure switch can be wired either in series or in parallel

depending on the choice of connector used by the host PLC which will

determine alarm or low-level condition that may be present.

PUMP COMPONENTS

Motor

Connector plate

Pump

Level indicator

Filling filter

Reservoir

Pressure/Outlet Manifold

By-pass adjustment screw

Clamping bracket

Pressure gauge

Plug

Control board

(for automatic versions)

6.2 AUTOMATIC VERSION

The Automatic version of the pump is equipped with a built in electronic

controller that controls the pump and monitors feedback from the pressure

and level switches.

The control system settings and human interface is via the 16x2 character LCD

display on the front face and the 5 programming buttons. A Reset button is

located on the lower left side.

The Manual cycle button present on the Manual version remains but on the

Automatic version will cause the local built in control system to run a

lubrication cycle.

SMART3 automatic pumps can be programmed to operate withintermittent

lubricationcycle that involves the following three phases:

A) Prelube -> pre- lubrication when system is powered on

B) Lube (lube –wait) ->the lubrication cycle

C) Standby

A)PRELUBE

The pre-lube phaseallows the user to run a set number of lubrication cycles

(250 Max) when the pump is powered on. This typically is used when a

system needs additional quantities of oil on power up.

Prelube takes place:

-on POWER-ON;

-on RESET;

-Any time new parameters are set.

When prelube is set to “0”, the prelube phase is completed skipped and the

pump will work just with the normal lube and standby phases.

B) 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 (lube and

wait) and involves the monitoring of timers

and/or inputs:

-Duringlube, system delivers lubricant to the

lubrication points;

-Duringwait, 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 two types of lube:

TIMER: The pump will simply run for the On time

and then enter standby mode;

PS: The pump will run until the pressure switch is made and pressure is maintained for a check period. Subsequently, the

pump will be switched off and the standby phase will commence.

C) STANDBY

During this step lubrication system is idle until the next lubrication cycle. There are three ways to regulate standby:

TIMER: a timer regulate system idling;

PULSE: a pulse counter regulate system idling;

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.

For conditions of use and programming cycles see chapter 8.

Cycle

Start

Control

Delay

Wait

Lubrication Phase

Lubrication Cycle

Lubrication Cycle can be repeated up to

250 times.

Lubrication Phase can comprise of many Lubrication Cycles

PRELUBE

YES

RUN n

LUBE Cycle

NORMAL

OPERATION

POWER ON

OR RESET

6.3 SIMPLIFIED AUTOMATIC VERSION “Smart & Simple”

This version is designed to allow a very simple ON/OFF operation of the

pump for use in environments where simplicity is the key. The Smart3

“Smart&Simple” version has + / - keys to set the ON and standby timers of

the pump. No cycle monitoring is carried out. The display will indicate the

time setting for both ON and STANDBY timers.

The settable range for Cycle and Standby phases are:

ON TIMER:

1s –5min

OFF TIMER:

5 times ON TIME –99H 00min

6.4 ELECTRICAL CONNECTIONS

6.4.1 Manual version

Following are different type of connectors and available signals:

TYPE 1

-FOR MANUAL VERSIONS WITH NC SERIES PRESSURE SWITCH ALARM*- 3133800

-FOR MANUAL VERSIONS WITH NO SERIES PRESSURE SWITCH ALARM*- 3133800

*APPLICABLE TO PUMP CODES:

4010000/4010100/4010200/4010300/4010400/

4010500/4010600/4010700

A(DIN43650)

B(DIN40050)

DESCRIPTION

AC / DC POWER

INPUT

Voltage Free NC contact alarm

Pressure switch and Level

switch wired in Series

NOT USED

Push Button Contact

(Voltage Free)

Earth

FLOAT LEVEL NC

AND

PRESSURE SWITCH

NC SERIES

REMOTE

BUTTON

CONTACT

Open on

low level

Open on

pressure

Button

push

to made

*APPLICABLE TO PUMP CODES:

4010020/4010120/4010220/4010620/4010320/

4010420/4010520/4010720

A(DIN43650)

B(DIN40050)

DESCRIPTION

AC / DC POWER

INPUT

Voltage Free NC contact alarm

Pressure switch and Level

switch wired in Series

NOT USED

Push Button Contact

(Voltage Free)

Earth

FLOAT LEVEL NC

AND

PRESSURE SWITCH

NO SERIES

REMOTE

BUTTON

CONTACT

Open on

low level

Close on

pressure

Button

push

to made

TYPE 2

- FOR MANUAL VERSIONS WITH PRESSURE SWITCH SIGNAL AND OPTICAL LEVEL (N) *- 3133803

- FOR MANUAL VERSIONS WITH PRESSURE SWITCH SIGNAL AND OPTICAL LEVEL (P)* - 3133805

A(DIN43650)

C(M12X1)

D(M12X1)

DESCRIPTION

AC / DC

POWER INPUT

Push Button

Contact (Voltage

Free)

Level Sensor

Power supply +

Level Sensor

Power supply -

NOT USED

Earth

PNP Alarm

Output of level

PNP signal of

pressure switch

A (DIN43650)

C(M12X1)

D(M12X1)

DESCRIPTION

AC / DC

POWER

INPUT

Push Button

Contact (Voltage

Free)

Level Sensor

Power supply +

Level Sensor

Power supply -

NOT USED

NPN Alarm

Output of level

Earth

NPN signal of

pressure switch

NOT USED

*APPLICABLE TO PUMP CODES:

4010013/4010113/4010213/4010313/4010413/

4010513/4010613/4010713

Optilev

level

sensor

REMOTE

BUTTON

CONTACT

Button

push

to made

Open on

pressure

LEVEL

PNP

PRESSURE

SWITCH

PNP

REMOTE

BUTTON

CONTACT

Optilev

level

sensor

Button

push

to made

Open on

pressure

* APPLICABLE TO PUMP CODES:

4010015/4010115/4010215/4010315/4010415/

4010515/4010615/4010715

For4010225-4010525 pumps the PS is close on

pressure

PRESSURE

SWITCH

NPN

LEVEL

NPN

12V

24V

TYPE 3

- FOR MANUAL VERSIONS WITH NC SERIES ALARM*- 3133801

- FOR MANUAL VERSIONS WITH NO SERIES ALARM*- 3133801

A(DIN43650)

D(M12X1)

DESCRIPTION

AC / DC POWER INPUT

Common

Level alarm

NOT USED

Pressure Switch Contact

Earth

Push Button Contact

(Voltage Free)

*APPLICABLE TO PUMP CODES:

4010001/4010101/4010201/4010301/4010401/

4010501/4010601/4010701

Button

push

to made

Open on

low level

Open on

pressure

REMOTE

BUTTON

CONTACT

Button

push

to made

Open on

low level

Close on

pressure

A(DIN43650)

D(M12X1)

DESCRIPTION

AC / DC POWER INPUT

Common

Level alarm

NOT USED

Pressure Switch Contact

Earth

Push Button Contact

(Voltage Free)

*APPLICABLE TO PUMP CODES:

4010621/4010721/4010021/4010121/4010221/

4010321/4010421/4010521

REMOTE

BUTTON

CONTACT

COMMON

LEVEL

ALARM

PRESSURE

SWITCH

CONTACT

COMMON

LEVEL

ALARM

PRESSURE

SWITCH

CONTACT

- FOR MANUAL VERSIONS WITH OPTICAL LEVEL (N) AND PRESSURE SWITCH IN SERIES*- 3133802

- FOR MANUAL VERSIONS WITH OPTICAL LEVEL (P) AND PRESSURE SWITCH IN SERIES*- 3133804

A(DIN43650)

D(M12X1)

DESCRIPTION

AC / DC POWER

INPUT

Level Sensor Power supply +

Level Sensor Power supply -

NOT USED

NPN Alarm Output.

Level and Pressure switch

in series

Earth

Push Button Contact

(Voltage Free)

REMOTE

BUTTON

CONTACT

Button

push

to made

Open on

pressure

A(DIN43650)

D(M12X1)

DESCRIPTION

AC / DC POWER

INPUT

Level Sensor Power supply +

Level Sensor Power supply -

NOT USED

PNP Alarm Output

Level and pressure switch

in series

Earth

Push Button Contact

(Voltage Free)

*APPLICABLE TO PUMP CODES:

4010012/4010112/4010212/4010612/4010312/

4010412/4010512/4010712

*APPLICABLE TO PUMP CODES:

4010014/4010114/4010214/4010314/4010414/

4010514/4010614/4010714

Button

push

to made

Open on

pressure

Optilev

level

sensor

REMOTE

BUTTON

CONTACT

OPTIC LEVEL N

AND

PRESSURE

SWITCH

NC SERIE

Optilev

level

sensor

OPTIC LEVEL

AND

PRESSURE

SWITCH

NC SERIE

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