DROPSA Dragon Series Instrucciones de operación

DRAGON XPUMP

User Operating and

Maintenance Manual

Original instructions

The manual has been prepared in compliance with Directive C2150IE WK 20/20

CE 06/42

TABLE OF CONTENTS

1. INTRODUCTION

2. GENERAL DESCRIPTION

3. PRODUCT IDENTIFICATION

4. TECHNICAL CHARACTERISTICS

5. COMPONENTS

6. UNPACKING AND INSTALLING

7. OPERATING INSTRUCTIONS

8. TROUBLESHOOTING

9. MAINTENANCE PROCEDURE

10. DISPOSAL

11. ORDERING INFORMATION

12. DIMENSIONS

13. HANDLING AND TRANSPORTATION

14. PRECAUTIONS

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/contact or contact us sal[email protected]om

1. INTRODUCTION

This user and maintenance manual relates to the Dragon X. Using this pump means that oils and greases can be distributed

within lubrication systems even at high pressures of up to 70 bar (1015 psi).

The latest version may be obtained from the Technical-Commercial Office, or by consulting our web site

http://www.dropsa.com.

The pump subject of this manual must be used by qualified personnel with basic hydraulic and electrical knowledge.

This user and maintenance manual contains important information about protecting the health and safety of the personnel who

intend to use this apparatus. You must read and look after it carefully, making sure that it is available at all times for the

operators who intend to consult it.

2. GENERAL DESCRIPTION

The DRAGON X pump is particularly suggested due to its compact form and versatility when used with press lubrication systems,

machine tools, reducers, guides, chains, etc.

The DRAGON X pump has a built-in release valve* and can be used in the following types of systems:

Lubrication systems with injectors and circulation systems with operating pressures <20 bar (290 psi) –system 01



Lubrication systems that have "direct response" measuring devices with operating pressures < 50 bar (735 psi) -

system 33V.

Progressive lubrication systems and circulation systems controlled by progressive measuring devices with operating

pressures < 70 bar (1015 psi) –system 26. A non-return valve is available for this version.

* The release valve aims to discharge the line pressure when the pump is not in activity. This valve ensures 0.5÷1 bar (7.2÷14.5 PSI) seal on the

supply line, in order to avoid the emptying pipes during the pause time of the pump, that is between a lubrication and the next one.

3. PRODUCT IDENTIFICATION

There is a yellow label on the front of the pump tank that displays the product

code and its basic characteristics.

4. TECHNICAL CHARACTERISTICS

N.b. The specifications refer to the temperature of use of +20°C (+68°F)

(1)

revolutions with load less motor

* If a different product is used, please contact Dropsa S.p.A. to ensure it is suitable for use (see page 12)

GENERAL CHARACTERISTICS

Empty weight

6.2 Kg

ELECTRICAL CHARACTERISTICS

Motor power supply

230-400 V - 50 Hz

265-460 V - 60 Hz

110 V 50 Hz single phase 4p

230 V 50 Hz single phase 4p

24 V CC 2800 rpm (1)

Rated motor power

0.09 Kw –0.11 Kw

Degree of motor protection

IP 55

Minimum level

Optical (oil and fluid grease versions ) / With floating switch (only oil

version)

Optical power supply level

8÷28 V DC inversion protected

Optical level output signal

Type NPN/PNP short-circuit protected, off in the case of minimum

level. Max 1.7A

Optical LED signal

Active when tank is not empty

Level connector (optical- floating switch)

DIN 43650

Float Level output signal

Clean contact 50V max voltage, 40 W max power. SPDT Contact.

Pressure switch

Contact closed in the case of max calibration pressure alarm

(3-18-30 bar)

Pressure switch output signal

Voltage free contact max voltage 42V, max. power 100 W

HYDRAULIC CHARACTERISTICS

Pumping system

Gear pump

Flow rates (1500 rpm)

350 cc/min - 500 cc/min (three-phase/single-phase versions)

600 cc/min - 850 cc/min (24V DC version)

Maximum operating pressures

- 70 bar -three-phase motor (with intermittent service max 5 min

with pause ratio 1:1)

- 40 bar (single-phase motor)

- max 30 bar with continuous service

Outlet connection

G1/8” BSP

Tank capacity

3L/6L

Filter

Degree of filtering 1000 µ

By-pass

Adjustable 0 ÷70 bar –precalibrated 40bar (35bar for single-phase

motors)

Temperature of use

+ 5 + 70 C

Operating humidity

90 % rel. humidity

Permitted lubricants *

Mineral lubricating oil 32 cSt; grease max NLGI000

Storage temperature

-20 +65 °C

Continuous sound pressure level

< 70 dB(A)

three-phase

4.1 HYDRAULIC SYSTEM

The only connection to make is to connect the pump to the point to lubricate or to the metering valves.

Fig.2 Hydraulic diagram with check valve

Fig. 1 Hydraulic diagram

5. COMPONENTS

6. UNPACKING AND INSTALLATION

6.1 UNPACKING

Once the suitable location for installation has been identified, open the package and remove the pump. Check that it was not

damaged during transport or storage. The packaging material does not require special disposal precautions as it is not in any

way dangerous or polluting. Refer to the local regulations for disposal.

6.2 INSTALLATION

Pump assembly operations are not required.

Allow a sufficient amount of space for installation, leaving a minimum perimetric space of 100 mm (3,93 in.).

For wall-mounting, suitable space must be provided (see the installation diagram) to prevent abnormal positions or the

possibility of impacts; fixing holes are provided on the plate (see Para. 12).

Then, the pump must be connected hydraulically to the machine. Make the connection to the control panel and fill the tank

(making sure not to exceed the maximum visual level).

Empty the tank during the disassembly phase.

Disconnect the electric part from the hydraulic part.

PUMP COMPONENTS

Motor

Connector

Pump

Level indicator (optical in

the picture –floating

switch optional)

Filter

Tank

Distributor block

Non-return valve

(optional)

By-pass adjustment screw

Clamping bracket

Pressure switch (optional)

Pressure gauge

Plug

6.3 MINIMUM LEVEL CONNECTION

The connection at the minimum level is done using connector 2 based on the following table:

6.4 OPTICAL LEVEL CALIBRATION

The level is tested and calibrated with oil by Dropsa, however is recommended before starting the pump to following the

procedure below:

1) Fill the reservoir;

2) Open the front regulating hole;

3) Turn the level adjustment screw using a screwdriver, until the green led on the level is off (see the image below);

4) Turn the screw in opposite way until the green led is on.

At the end of this procedure the level is correctly set. It is possible to re-do the calibration following the same procedure above.

CONNECTION TABLE

(version with optical level)

V+ (8÷28 Vdc)

V- (GND)

Out N

Out P

CONNECTION TABLE

(version with floating switch)

COM

VIP5 Dropsa (Optional)

Connection pin when it is used Dropsa

VIP5 Control Device

Terminal streap M2

n° PIN

Note: Set PIN 4 –M2 connection

exclusively on Out N or on Out P.

4 / NC

Note: Set the NC level in VIP5

parameters

4 / NC

n°2 M3 Screw

Green led

7. OPERATING INSTRUCTIONS

7.1 STARTING THE PUMP

Before using the pump, a few preliminary checks must be performed:

Check the integrity of the power supply cable and the unit prior to use.

If there is damage to the power supply cable or the unit, do not start operations!

Replace the damaged power supply cable with a new one.

The unit may only be opened and repaired by specialized personnel.

In order to prevent the danger of electrocution due to direct or indirect contact with live parts, the electric power supply line

must be suitably protected by a specific differential magnetothermic switch with a triggering threshold of 0.03 Ampere and

max triggering time of 1 second.

It is prohibited to use the pump if submersed in fluids or in a particularly aggressive or explosive/inflammable environment if

not previously prepared for that purpose by the supplier.

Use safety gloves or glasses as specified in the safety sheet for the lubricating oil

DO NOT use aggressive lubricants with NBR gaskets. In the case of doubt, contact the Dropsa SpA technical office to receive a

detailed card about the recommended oils.

Do not ignore the hazards to health and comply with the health regulations.

Check the integrity of the pump

Check that the pump is at the operating temperature and that there are no air bubbles in the pipes.

Check that the electric connection was carried out correctly.

Check the connection of the level and the pressure switch, if necessary, to the control panel.

Once the pump has started, check the direction of rotation of the electric motor: if it rotates backward, reconnect it as

shown in the wiring diagram provided with the motor.

7.2 INSTRUCTIONS FOR USE

1) Press the start button on the machine to which the pump is connected or start it;

2) Check that the pump starts;

3) To change the pressure value, turn the adjustment screw (see Chap. 5). Turn it clockwise to increase the pressure or

counterclockwise to decrease it;

4) Check that the machine lubrication is suitable (if there are doubts about correct operation, the Dropsa SpA technical office

can be contacted to request the inspection procedure).

The cut-off power of the switch must be = 10 kV and the rated current= 4 A

ATTENTION:All components must be ground connected. This applies both to electric components as well as to control

devices. For this purpose, make sure that the ground wire is directly connected. For safety reasons, the ground conductor

must be approx. 100 mm longer than the phase conductors. If the cable is accidentally disconnected, the ground terminal

must be the last to be disconnected.

8. TROUBLESHOOTING

A diagnostics table is provided below that indicates the main anomalies, the probable causes and the possible solutions.

If you were not able to solve the problem after consulting the diagnostics table, do not try to find the fault by disassembling

machine parts but contact the Dropsa technical office and report the anomalies that have been discovered, with a detailed

description.

DIAGNOSTICS TABLE

PROBLEMS

PROBABLE CAUSES

ACTIONS

The pump does not deliver oil

It intakes air because the tank is empty

The intake filter is dirty or clogged

The internal fittings are loose or broken

The motor rotates backward

Restore the level in the tank and bleed the air

from the system

Wash the filter with petroleum and blow with

compressed air

Carefully close all the

fittings, making sure there are no leaks and

replace the broken pipes.

Correctly connect the motor, inverting the

direction of rotation

The pump does not deliver oil at

the required pressure

Pump deteriorated

Pressure control valve decalibrated

(therefore the oil returns immediately to

the tank).

Release valve damaged

Adjustment valve incorrectly calibrated

Presence of dirt in the by-pass valve

Replace the pump

Tighten the adjustment screw until oil comes out

of the delivery pipe

Replace the by-pass valve

Connect a pipe that is approx. 30 cm long to the

pump outlet with a pressure gauge applied to the

free end. Adjust the valve by turning the screw

and reading the corresponding pressure value on

the pressure gauge

Remove the components and wash them with

petroleum. Before reassembling the components,

check the wear status of the O-ring. Replace the

entire assembly if necessary

Line pressure not released

Control valve with irregular operation

Disassemble and clean the by-pass valve, replace

the valve if necessary

Emptying of the main system line

during the pause time

Pump or system outlet fittings loosened

Non-return or release valve dirty

Tighten the fittings

Disassemble and clean the by-pass valve, replace

the valve if necessary

Lubrication cycle not performed

Cycle control pressure switch calibration

pressure not reached due to:

Line pipe broken or loose fittings

Pressure switch calibrated higher than

the pump

The pump does not deliver oil at the

required pressure

The pump does not deliver oil

Replace the pipe - fully tighten the fittings

Correctly calibrate the pressure switch

See the diagnostics table

ATTENTION: The machine may only be opened and repaired by authorised Dropsa personnel.

9. MAINTENANCE PROCEDURE

The pump was designed and built in order to minimize maintenance requirements.

To simplify maintenance, it is recommended to install it in an easy to reach position.

Periodically check the pipe joints to detect any leaks. Furthermore, always keep the pump clean to be able to quickly detect

any leaks or defects.

Check if the filter is clean after every 2000 hours of operation.

The machine does not require any special equipment for any control and/or maintenance activity. It is recommended to use

tools and personal protective devices suitable for use (gloves) and that are in good condition according to current regulations to

prevent damage to people or machine parts.

In the case of doubts and/or problems that cannot be solved, do not try to discover the reason by disassembling machine parts,

but contact the DROPSA S.p.A technical office.

10. DISPOSAL

During machine maintenance, or if it is demolished, do not dispose of the polluting parts in an improper manner. Refer to the

local regulations for their correct disposal. When demolishing the machine, the identification plate and all other documents

must be destroyed.

11. ORDER INFORMATION

11.1 STANDARD VERSIONS

N.B. The following specifications apply for all models:

Bypass calibration pressure 40 bar (35bar for single-phase motors); Pressure gauge 0 –100 bar.

ATTENTION: Make sure that the electric and hydraulic power supplies are disconnected before carrying out any

maintenance work.

ELECTRIC MOTOR

FLOW RATE

TANK CAPACITY

PART NUMBER

(with optical level

to use oil and fluid

grease)

PART NUMBER

(with float level to

use only oil)

230-400 V 50 Hz three-phase- 0.09 KW 4P

265-460 V 60 Hz three-phase- 0.11 KW 4P

350 CC

3 L

3905000

3905040

6 L

3905001

3905041

500 CC

3 L

3905004

3905044

6 L

3905009

3905049

110 V 50 Hz single phase –0,.9 KW 4P

350 CC

3 L

3905007

3905047

6 L

3905012

3905052

500 CC

3 L

3905008

3905048

6 L

3905013

3905053

230 V 50 Hz single phase –0.09 KW 4P

350 CC

3 L

3905005

3905045

6 L

3905010

3905050

500 CC

3 L

3905006

3905046

6 L

3905011

3905051

24V CC

600 CC

3 L

3905002

3905042

6 L

3905003

3905043

850 CC

3 L

3905014

3905054

6 L

3905015

3905055

11.2 SPARE PARTS

ITEM

DESCRIPTION

PART NUMBER

PUMP

Flow rate *350 CC

3099186

Flow rate *500 CC

3099187

MOTOR

230-400 V 50 Hz three-phase- 0.09 KW 4P

265-460 V 60 Hz three-phase- 0.11 KW 4P

3301544

230 V 50 Hz single phase –0.09 KW 4P

3301545

110 V 50 Hz single phase –0.09 KW 4P

3301546

24V CC rpm

3301283

OPTICAL SENSOR LEVEL

For the 3L tank

1639201

For the 6L tank

1639202

FLOATING LEVEL INDICATOR

For the 3L tank

3133627

For the 6L tank

3133628

DISTRIBUTOR BLOCK

1525370

TANK

3 L

6770033

6 L

6770006

PRESSURE GAUGE

0 -100 bar

0020564

* Flowrate is referred to 1500 rpm

11.3 ACCESSORIES

ITEM

DESCRIPTION

PART NUMBER

PRESSURE SWITCH

Calibration pressure 3 Bar

3291028

Calibration pressure 18 Bar

3291048

Calibration pressure 30 Bar

3291022

PRESSURE SWITCH CAP

3042098

PRESSURE GAUGE

0 -16 bar

0020566

NON-RETURN VALVE

0092335

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