DROPSA PoliPUMP eco Instructions de fonctionnement

PoliPUMP eco

Multi-line electric pump for grease

User Operating and Maintenance Manual

Original Instructions

Manual drawn up in accordance with EC

Directive 06/42

C2291IE- WK 24/19

Dropsa products can be purchased from Dropsa bracnhes and authorized distributors,

visit www.dropsa.com/contact or contact us at [email protected]

Sommario

1. INTRODUCTION ........................................................................................................................... 3

2. GENERAL DESCRIPTION ............................................................................................................... 3

2.1 DIRECT-POINT LUBRICATION...............................................................................................................3

2.2 SPECIFICATIONS .................................................................................................................................3

3. PRODUCT IDENTIFICATION .......................................................................................................... 3

4. TECHNICAL CHARACTERISTICS...................................................................................................... 4

5. COMPONENTS............................................................................................................................. 5

6. UNPACKING AND INSTALLATION ................................................................................................. 6

6.1 UNPACKING .......................................................................................................................................6

6.2 INSTALLATION OF PUMPING ELEMENTS / CAPS...................................................................................6

7. OPERATING INSTRUCTIONS ......................................................................................................... 8

7.1 MEASURES TO BE TAKEN PRIOR TO START-UP.....................................................................................8

7.2 USE ........................................................................................................................................... 9

7.3 FILLING THE RESERVOIR............................................................................................................. 9

8. PROBLEMS AND SOLUTIONS ...................................................................................................... 10

9. MAINTENANCE PROCEDURES .................................................................................................... 11

9.1 SCHEDULED MAINTENANCE..............................................................................................................11

10. DISPOSAL ................................................................................................................................ 11

11. ORDER INFORMATION............................................................................................................. 12

12. DIMENSIONS ........................................................................................................................... 13

13. HANDLING AND TRANSPORT ................................................................................................... 13

14. PRECAUTIONS FOR USE............................................................................................................ 14

14.1 LUBRICANTS ...................................................................................................................................14

15. CONTRAINDICATIONS OF USE ........................................................................................................... 14

1. INTRODUCTION

This operation and maintenance manual refers to "PoliPUMP eco" electric pump and contains important information for

the health and safety protection of the personnel who use this equipment.

The most recent version can be obtained by requesting it from the Sales Technical Office or online at

http://www.dropsa.com.

This manual must be read carefully and kept so that it is always available to the operators who want to consult it.

2. GENERAL DESCRIPTION

2.1 DIRECT-POINT LUBRICATION

The PoliPUMP eco electric pump directly lubricates friction points without needing to use other flow-rate dosing

devices. This allows you to have a product for inexpensive lubrication that is versatile and easy to use.

PoliPUMP eco was developed to supply lubrication systems at a single point in vehicles, in installations and in various

types of machinery, for use with grease. Any use other than the use intended shall be deemed to be in non-compliance

with requirements.

2.2 SPECIFICATIONS

The PoliPUMP eco electric pump is a piston pump driven by an eccentric system, designed to be operated with a

maximum of 35 pumping elements, allowing several independent lines to be supplied.

It is supplied as a standard without pumping elements, which must be ordered separately by choosing the desired flow

between six models that can be identified by pairing different colours. La standard version has a reservoir with a capacity

of 2 litres.

A contoured stirring paddle and reservoir wiper set eliminate the presence of air bubbles in the lubricant contained within

the pump, thereby ensuring proper operation, even at low temperatures.

The pump is driven by a 12 or 24V DC gear motor.

3. PRODUCT IDENTIFICATION

A label is located on the side of the pump that indicates the product part number, the

power supply voltages and the basic features.

4. TECHNICAL CHARACTERISTICS

GENERAL TECHNICAL CHARACTERISTICS

Pumping system

With single acting pumping systems with cam

drive

Drive assembly

DC motor with reducer

Motor power-supply voltage

12V DC

24V DC

Net weight

standard version

3 Kg (6.6 lb)

Max. number of outlets/pumping elements

12 –24 –36

Delivery connection (pumping element outlet)

Push-in Ø4mm (5/32in)

Nominal flow rate for single pumping element *

0.02cc/stroke –RED (1 notch)

0.03 cc/stroke –GREEN (2 notches)

0.04 cc/stroke –YELLOW (3 notches)

0.08 cc/stroke –BLUE (4 notches)

0.10 cc/stroke –GREY (5 notches)

0.13 cc/stroke –BLACK (6 notches)

Rotation speed (cycle)

3 RPM

Maximum reachable pressure

on the outlet of the pumping element

80bar** (1,160psi)

Reservoir capacity

2 litres (0.53 gallons)

Grease consistency

NLGI00 ÷ NLGI2

Protection degree

IP 69

Temperature of use

-10°C ÷ +60°C (14°F ÷ 140°F)

Storage temperature

-20°C ÷ +80°C (-4°F ÷ 176°F)

Max. relative humidity without operating condensation

90%

Sound pressure level

< 70 db (A)

Electrical connection terminal

1.5mm² max.

ATTENTION:Do not power the machine with voltage different than what is indicated on the label.

* NOTE:

The flow rate indicated refers to the following test conditions: grease with NLGI class 00; ambient

temperature 20° C (68° F); ambient pressure 1 bar (14.5 psi); back pressure of 5 bar (72.5 psi).

** NOTE:

The date refers to the maximum operating pressure of the single pumping element. The maximum

pressure supplied by the pump depends on several variables (number of pumping elements used, type

of grease, operating temperature, see Section 7).

5. COMPONENTS

PoliPUMP (standard)

PUMPING ELEMENTS

RED - (1 notch)

0.02cc/cycle

GREEN - (2 notches)

0.03cc/cycle

YELLOW - (3 notches)

0.04cc/cycle

BLUE - (4 notches)

0.08cc/cycle

GREY - (5 notches)

0.10cc/cycle

BLACK - (6 notches)

0.13cc/cycle

Push-in outlet Ø4

Notches

Pump replacement cap

(included within the

scope of supply)

Stirring paddle with

wiper reservoir

Input power cable gland

Pumping element

housing holes/caps

Loading door to the

grease nipple

Cartridge loading

predisposition/eventual

return in pump M22x1.5

Reservoir, 2L

Warranty seal

6. UNPACKING AND INSTALLATION

6.1 UNPACKING

Once you have identified the suitable place for installation, open the package and remove the pump and check that it has

not suffered any damages during transport and storage. The packing material does not require special disposal

precautions as it is in no way dangerous or pollutant. For disposal, refer to local regulations.

6.2 INSTALLATION OF PUMPING ELEMENTS / CAPS

The pumping elements are not included in the pump, they must be purchased separately by selecting the appropriate part

numbers. The caps are included in the packaging; to be inserted into the holes that are not being used by the pumping

elements.

To assemble the pumping elements, proceed as follows:

Locate the correct position by distributing them evenly over the holes on the pumping element holder cylinder.

MOUNTING POSITIONS

1-7

13-19

25-31

1, -5, -9

13, -17, -21

25, -29, -33

1-4-7-10

13-16-19-22

25-28-31-34

1-2-4-7-10

13-14-16-19-22

25-26-28-31-34

1-3-5-7-9-11

13-15-17-19-21-23

25-27-29-31-33-35

1-2-4-5-7-9-11

13-14-16-17-19-21-23

25-26-28-29-31-33-35

1-2-4-5-7-8-10-11

13-14-16-17-19-20-22-23

25-26-28-29-31-32-34-35

1-2-3-5-6-7-9-10-11

13-14-15-17-18-19-21-22-23

25-26-27-29-30-31-33-34-35

1-2-3-4-5-6-7-9-10-11

13-14-15-16-17-18-19-21-22-23

25-26-27-28-29-30-31-33-34-35

1-2-3-4-5-6-7-8-9-10-11

13-14-15-16-17-18-19-20-21-22-23

25-26-27-28-29-30-31-32-33-34-35

1-2-3-4-5-6-7-8-9-10-11-12

13-14-15-16-17-18-19-20-21-22-23-24

25-26-27-28-29-30-31-32-33-34-35-36

Positioning of pumping elements

Screw in the pumping elements and tighten with a torque of 10 Nm using a 12mm socket spanner.

Screw in the caps into the remaining holes and tighten with a torque of 10 Nm using a 12mm socket spanner or a

6mm Allen wrench.

6.3 INSTALLATION OF THE PUMP

Place the pump and fasten to its support by using the appropriate Ø6.5 mm holes (0.256in), with 4 suitable screws.

Assemble the pump in such a way that the grease nipple for filling the reservoir is easily accessible.

Leave at least 100 mm (3.93 in) as a perimeter distance with respect to other equipment or barriers to prevent access

to the pump (in the case of cartridge filling, provide for adequate distances).

Assemble the pump at “labourer height” in order to prevent abnormal posture or possible impact.

Do not install the pump submerged in liquids and/or in aggressive environments.

Do not install the pump in environments where there are explosive or flammable mixtures.

Do not install the pump near sources of heat or near electrical equipment that can disturb the electronics and prevent

them from functioning properly.

Ensure that the pipes and wires have been properly fastened and protected from any possible impact.

Verify that the grease used is fit for operating temperatures, especially at temperatures below 0° C. If in doubt,

contact our Sales Technical Office for the correct choice of lubricant.

6.4 HYDRAULIC CONNECTIONS

The hydraulic connection between the pump and the system is on the pumping element with a pipe push-in Ø4mm

(5/32in). The return to pump can be carried out through the M22x1 threading that is present.

6.5 ELECTRICAL CONNECTION

The electrical connection is the responsibility of the user and must provide for the unique identification of the power

connection.

Connect the machine to the electrical power line as indicated in the present manual.

The power cable must have suitable thickness with regard to the absorption of the machine and type in accordance with

regulations in force.

6.5.1 Connection diagram

ATTENTION:Verify the correspondence between the electrical power supply of the pump and of the

machine (label affixed to the side of the pump.)

ATTENTION:Introduce the pumping element into the predetermined output pumping element paying

particular attention to correct engagement into the thread.

ATTENTION:The pipeline must reach the point of lubrication along the shortest route possible.

7. OPERATING INSTRUCTIONS

7.1 MEASURES TO BE TAKEN PRIOR TO START-UP

The unit may be put into operation by specialized personnel.

Using the pump submerged in fluids or in a particularly aggressive or explosive/flammable environment is prohibited

unless it has been prepared ahead of time by the supplier for this purpose.

Use gloves and eye protection as required by the lubricant safety data sheet.

DO NOT use lubricants that are aggressive to NBR gaskets. If you are unsure, contact the Dropsa S.p.A technical office

for a detailed list of recommended lubricants.

Never ignore health hazards and always follow sanitary regulations.

Always use suitable piping for the operating pressure.

Check the integrity of the pump;

Check the lubricant level in the reservoir (min/max indication on the reservoir), in case of low level, proceed as

described in Section 7.3 Filling the reservoir;

Ensure that the pump operates at operating temperature and that the pipelines are free of any air bubbles;

Check the correct connection of electrical devices.

To determine the maximum operating pressure, it is necessary to know the pressure drop of the pipeline connected to the

pumping elements.

As an example, the following diagram shows the pressure drop of the delivery pipeline flow by unit length depending on

the operating temperature and for a particular type of lubricant (in this case NLGI 00 grease with 160cSt base oil and

NLGI2 grease with a 180 cSt base oil)

Depending on these variables to achieve a proper supply to the delivery point, it is always necessary to ensure that the

pipeline pressure loss plus the pressure required at the lubrication point does not exceed the maximum pressure supplied

for pump delivery.

The maximum pressures corresponding to the delivery point of the pumping element, taking into consideration the most

severe operating conditions are as follows, taking the toughest operating conditions into consideration:

1÷12 pumping elements = 80 bar (1160 psi)

13÷24 pumping elements = 50 bar (725 psi)

25÷36 pumping elements = 35 bar (507 psi)

7.2 USE

Check the setting data indicated on the control panel (if present);

Press the start button on the machine where the pump is connected;

Ensure that the pump starts;

Ensure the adequate lubrication of the machine (if there are doubts on correct operation, you can contact the Dropsa

S.p.A. Technical Office and ask for the testing procedure).

7.3 FILLING THE RESERVOIR

Check that all the pump housing holes/caps are occupied.

Filling the reservoir is carried out by means of the fully dedicated filter devices. Proceed with filling, ensuring not to exceed

the maximum level line. If this happens, you will note a spill of lubricant from the underside of the lid, which acts as an air

vent.

7.4 HOW TO USE

If there are no regulations foreseen, the pump is electrically powered by a system that controls the drive and that handles

the minimum level contact. For the operation of the lubrication system, refer to the machine’s management and control

instructions where the pump is installed.

ATTENTION:To avoid any malfunctions and to prevent the warranty from becoming void, we recommend

filling the lubricant without impurities, exclusively from dedicated loading system.

Please refer to Section 14.2 Lubricants for the lubricant specifications to be used.

Loading with cartridge

(Part Number 888038)

Loading grease

nipple

8. PROBLEMS AND SOLUTIONS

Below is a troubleshooting table where the main faults, probable causes and possible solutions to be carried out

immediately are indicated (contact Dropsa).

In the event of doubts and/or irresolvable problems, do not search for the fault disassembling parts of the pump, but

rather contact the Dropsa Technical Office.

TROUBLESHOOTING TABLE

FAULT

CAUSE

REMEDIAL ACTION TO BE TAKEN

The pump motor does not

work.

No current present.

Check the power supply.

The gear motor does not work.

Replace the gear motor .

Operating temperatures are too low

for the type of grease used.

Preheat lubricant with a heating element on the

reservoir.

Replace the liquid with one fit for pumpability at low

temperatures.

The pump works but

lubrication does not arrive

at the lubrication points.

Lines disconnected.

Check the condition of the lines and the relative

connections to the fittings. Replace worn lines.

The lubricant is distributed

to the lubrication points in

irregular doses.

Incorrectly set cycle time.

Reprogram the cycle time.

The pump begins the

greasing phase but ends it

immediately

Defective motor or high output

absorption.

Allow to cool for a few minutes and try again. If the

problem persists, replace the gear motor .

Operating temperatures are too low

for the type of grease used.

Preheat lubricant with a heating element on the

reservoir.

Replace the liquid with one fit for pumpability at low

temperatures.

FAULT

CAUSE

REMEDIAL ACTION TO BE TAKEN

The pump does not

dispense lubricant.

The reservoir is empty.

Fill the reservoir with clean lubricant;

Air bubbles in the lubricant.

Disconnect the pipeline from the connection for the

pumping element. Activate the pump by pressing

the reset button for carrying out an extra cycle until

lubricant comes out of the connection without any

air bubbles.

Use of unsuitable lubricant.

Empty the reservoir and refill it with a suitable

lubricant again.

Suction of blocked pumping

element

Dissemble the pumping element and re-clean the

suction pipes.

The piston of the pumping element

is worn out.

Replace the pumping element.

The delivery valve of the blocked

pumping element.

Replace the pumping element.

: Operation may only be carried out by Dropsa specialised personnel (send the product to Dropsa headquarters).

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