Mini-SUMO Pump
Mini-SUMO Pump
Original instructions
CONTENTS
1. INTRODUCTION
2. GENERAL DESCRIPTION
3. IDENTIFICATION OF THE MACHINE AND MARKING
4. TECHNICAL CHARACTERISTICS
5. PUMP COMPONENTS AND ELECTRICAL CONNECTIONS
6. UNPACKING AND INSTALLATION
7. INSTRUCTIONS FOR USE
8. PROBLEMS AND SOLUTIONS
9. MAINTENANCE PROCEDURES
10. DISPOSAL
11. ORDERING INFORMATION
12. DIMENSIONS
13. HANDLING AND TRANSPORT
14. PRECAUTIONS
15. CLEANING
16. TRAINING
The manual has been prepared in compliance with Directive C2197IE WK 42/18
CE 06/42
m
http://www.dropsa.com
Via Benedetto Croce, 1
Dropsa products can be purchased from Dropsa branches and authorized distributors, visit
Vimodrone, MILANO (IT) www.dropsa.com/contact or contact us sales@dropsa.com
t. +39 02 250791
1. INTRODUCTION
This user and maintenance manual relates to the Mini-SUMO Atex Pump, version in compliance with ATEX standards, for
potentially hazardous areas, classified zones 1 and 21 with presence of IIC group inflammable gas and combustible dusts. The
maximum surface temperature developed by Mini-SUMO Atex pump in the most extreme conditions is 100°C.
The Mini-SUMO Atex Pump allows grease to be distributed within lubrication systems at high pressures of up to 400 bar (5880
psi).
The latest version may be obtained from Dropsa Sales Office, or by consulting our web site http://www.dropsa.com.
This user and maintenance manual contains important information about protecting the health and safety. You must read and
look after it carefully, making sure that it is available at all times for any operators that may need to consult it.
2. GENERAL DESCRIPTION
The Mini-SUMO Atex lubrication pump series is particularly suited for dual line systems and progressive systems and can be
adapted to many needs without making mechanical changes, even after installation is complete. In fact, by selecting from a set
of components that are perfectly compatible with each other and easily assembled, it is possible to vary the pressure, the
quantity of the delivered lubricant, the type of lubricant and the type of distribution. This Pump consists of the following:
Electric motor;
Pump body manifold with integrated pressure adjustment (bypass) and instrumentation;
Two pumping elements;
Reservoir;
Dual Line Pressure change-over valve.
There is one load bearing structure for all versions, the dual pumping element constitutes the essential module.
The pump unit has only one outlet.
Two types of grease tanks and two for oil, with different volumes (10 or 30 kg) can be positioned on the pump casing, with
spatula and level indicators.
The electric Mini-SUMO Atex pump is fully protected against the external environment and can run without problems in the
most severe ambient conditions.
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3. IDENTIFICATION OF THE MACHINE AND MARKING
On the front part of the pump tank there is a plate which indicates the product code, the supply voltage and basic
characteristics.
On the pallet, a reference plate indicates the ATEX marking and certification (Figure 3.1)
Figure 3.1
2GD equipment for explosive atmosphere due to flammable gas and combustible dust. 2GD Category is
appropriate for zones classified as 1 zone (2 zone included) and 21 zone (22 zone included).
Note: IP65 protection grade is referred to electric parts. Not electric parts are protected from combustible dust by the type of
process that provides for the continued presence of oil and grease on the mechanical ignition sources.
4. TECHNICAL CHARACTERISTICS
GENERAL CHARACTERISTICS
Empty weight (10 Kg tank) 62 Kg
Empty weight (30 Kg tank) 65 Kg
Empty weight pump without reservoir 42 Kg
ELECTRICAL CHARACTERISTICS
3 Ph - 0,25 Kw - 230Δ/400Y 50/60 Hz – Maximum working
Motor power supply
voltage 690V.
Motor degree of protection IP 65
Minimum and maximum level Capacitive-laser-ultrasounds
HYDRAULIC CHARACTERISTICS
Pumping system Piston
Flow rate (per pumping element) 25 cc/min
Maximum operating pressures 380 bar
Outlet connection G3/8” BSP
Tank capacity 10-30 Kg
Loading filter Degree of filtering 300 µ
By-pass Adjustable 0÷380 bar – precalibrated 300 bar
Temperature of use - 5 + 50 C
Operating humidity 90 % rel. humidity
(1)
Permitted lubricants Mineral lubricating oil min 32 cSt; grease max NLGI2
Storage temperature -20 +65 °C
Continuous sound pressure level < 70 dB (A)
WARNING: do not supply the machine with voltages and pressures different from those indicated on the plate.
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4.1 HYDRAULIC FUNCTION DIAGRAM
The hydraulic diagrams related to the different configurations that can be obtained using the available accessories are shown
below (see paragraph 11)
Line 1 0.18 kw – 4p
Line 2
0.18 kw – 4p
G3/8”
BSP 0.67 cc/stroke
Line 1 0-600 BAR Pmax 380 BAR
Line 2
G3/8”
BSP 0-600 BAR 0.67 cc/stroke
Pmax 380 BAR
Hydraulic diagram for standard pump Hydraulic diagram for grease pump with
with single grease outlet Electropneumatic switch – Dual line
0-380 BAR
0.18 kw – 4p
Linea 1
Linea 2
G3/8”
BSP 0-600 BAR 0.67 cc/giro
Pmax 380 BAR
The pump has two fixed delivery standard pumping elements (25 cm^3/ min for each pumping element).
The seal between the piston and the pumping body is of a dry type, with no gasket provided between the two.
The pumping element retention valve is of the tapered seal type. This solution is able to guarantee an optimum seal for the
system at high operating pressures (max. pressure of 380 bar).
The pumping elements are assembled onto the pump body without disconnecting the hydraulic line thanks to a threaded
cartridge design, facilitating assembly/disassembling.
Figure a – Version with reservoir
1 2
10
8
13 5 6 9
12
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Figure b – Version without reservoir
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5.2 MINIMUM AND MAXIMUM GREASE LEVEL INDICATORS
The minimum level is realised by a capacitive probe that is positioned at the end of a tube mounted on the tank cover. When the
minimum level is reached, the probe signals that the lubricant is low. If the capacitive probe is replaced, the capacitive probe
must be recalibrated (see calibration procedure – CHAP. 7.2. User instructions).
The phase that the lubricant is loaded in the tank is realised by the operator, who uses a pump.
Once the maximum lubricant level is reached, a rod is activated that indicates that the tank is full.
Inside the Ex d kit case there is a laser range sensor with connector.
It has a 4-digit alphanumeric display and a reading distance up to 10 Mt.
The device includes the programming buttons.
The level is made with two floats at the ends of metal shaft. Lower float acts as a minimum level by closing a contact when the
low position is reached. The Upper floats acts as a maximum level by closing another contact at high position.
5.5 BY-PASS
Pressure gauge is pre-calibrated to 300 bar but it can be adjustable from 0 to 380 bar.
On the structure of the base is possible to mount a safety terminal box that contains a terminal board to connect the electrical
components of the Mini-SUMO Atex assembly (Motor, valves, level indicators, etc).
Choosing this option the pump will be supplied with wirings already connected to the terminal strip.
In figure below you can see the electrical connections on terminal board of the standard model. ( See Cap.11 Information about
ordering)
MAXIMUM
SOLENOID VALVE
MINIMUM
LEVEL LEVEL
FREE TERMINAL
In figure below you can see the electrical connections of the alternative model. ( See Cap.11 Information about ordering)
SOLENOID VALVE
In figure below is underline the positioning of the bar of grounding. For a complete vision refer to assembly design.
Mini-SUMO Atex pump must be connected to a good earth safety system.
WARNING: the distance of path in air trough terminal insulating surfaces at 15 and 16 Intrinsic Security
(capacitance sensor at Intrinsic Security) must be greater than 50mm from other terminals/circuits.
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5.7 ELECTROPNEUMATIC CHANGE-OVER (optional)
The pump can be equipped with a pneumatic change-over valve piloted by a hazardous area certified solenoid.
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. The pump is fixed on a metal pallet that permits safe handling with a transpallet or
fork lift truck. The pallet was designed to be installed in the plant. It has four Ø 14 mm holes suitable for fixing to the floor.
Suitable space must be provided (as shown in the installation diagram) to prevent abnormal positions or the possibility of
impacts. Then, as described above, the pump must be connected hydraulically to the machine and then the connection to the
control panel must be made.
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.
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7.3 CONNECTION / SETTING OF THE LEVEL PROBES
Figure 6 30 kg reservoir
Pos. Level Output signal set-up Height X Grease
[mm] quantity
[kg]
A Absolute nsP2 200 22
maximum level
OUT 2= Fno
C Minimum level fsP2 390 11
WARNERING: The level probes do not have to be in some way tampered with from the user. They are not
therefore possible repairs or variations of calibration of the same probes. For any information, to contact the
technical office/trades them of the Dropsa SpA.
8. PROBLEMS AND SOLUTIONS
ATTENTION: The machine may only be opened and repaired by authorized Dropsa personnel.
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.
The pump does not prime. Cause for the pump not Remove the tank cover and check that the
priming: spatula rotates clockwise and moves the
The motor is rotating in the inverse direction lubricant; otherwise, invert two of the three
(clockwise); motor phases.
The motor is rotating in the correct direction, See above.
but the spatula is not rotating;
Air bubbles in the lubricant.
The pressure control valve (bypass) was calibrated Disconnect the pump delivery pipe and bleed
at a value that is too low the lubricant until the air bubbles have been
Presence of dirt in the non-return valve eliminated.
The pump does not There may be dirt on the pumping element check Clean the pumping element check valve cone
pressurise. valve cone. and seat, bleeding the lubricant.
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9. MAINTENANCE PROCEDURES
The pump was designed and built in order to minimise 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 loading filter is clean after every 2000 hours of operation.
Check Cables and wiring integrity (where it is present) every 4000 hours worked.
Check Secure connection to ground every 4000 hours worked.
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.
ATTENTION: Make sure that the electric and hydraulic power supplies are disconnected before
carrying out any maintenance work.
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.
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12. DIMENSIONS
10 Kg 30 Kg
A 344,5 533,5
B 699 888
C 565 754
12.2. VERSION WITHOUT RESERVOIR
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13. HANDLING AND TRANSPORT
Transport and storage are carried out using a metal pallet with packaging on the side and a wood cover.
The pump is fixed on a metal pallet that permits safe handling with a transpallet or fork lift truck. The metal pallet was designed
to be installed in the plant. It has four Ø 14 mm holes suitable for fixing to the floor.
Lift the equipment according to the direction shown on the cardboard package.
The machine components can support storage temperatures between
-20 to + 65 °C; however, to prevent damage, the machine must only be started up after the machine has
reached a temperature of +5 °C.
14. PRECAUTIONS
The warnings about the risks involved in using a pump for lubricants must be read.
The operator must understand its operation and clearly understand the hazards connected to pumping pressurised grease.
Therefore we recommend the following:
Check the chemical compatibility of the material with which the pump is built with the fluid to be pumped (see chap. 4). An
incorrect selection could cause, in addition to damaging the pumps and pipes, serious risks for people (spillage of irritating
products that are harmful to health) and for the environment.
Never exceed the maximum operating pressure permitted for the pump and the components connected to it. In the case of
doubt, refer to the data specified on the machine plate.
Only use original spare parts.
If components must be replaced with others, make sure they are suitable for operating at the pump's maximum operating
pressure.
ATTENTION!
Never try to stop or deviate any leaks with your hands or other body parts.
Note: Personnel must use protective devices, garments and tools in compliance with current standards with regard to the location
and the use of the pump both during work as well as during maintenance operations.
ATTENTION: The warnings about the risks involved in using a pump for lubricants must be read. The user must understand
its operation using the user and maintenance manual.
Electric current
Do not carry out any work on the machine before disconnecting it from the electrical power supply and making sure that no one
can reconnect it during the operation. All the installed equipment (electric and electronic), tanks and basic structures must be
connected to the ground line.
Inflammability
The lubricant used in the lubrication circuits is normally not an inflammable liquid. It is however necessary to adopt all the
possible measures to prevent that it comes into contact with very hot parts or open flames.
Pressure
Before each operation, make sure there in every branch of the lubrication circuit that there is no residual pressure that could
cause oil to spray when disassembling fittings or components. After long periods of inactivity, check the seal of all the parts
subject to pressure. Do not subject the fittings, pipes and pressurised parts to violent impacts. Damaged flexible pipes or fittings
are DANGEROUS and must be replaced.
Only original spare parts should be used.
Noise
Under normal operating conditions, noise emission does not exceed 70 dB “A” at a distance of 1 metre (39.3 inches) from the
pump.
NOTE:
The pump was designed to operate with lubricants with a maximum rating NLGI 2. Use lubricants that are compatible with
NBR gaskets. Any internal residual lubricant used for assembly and testing purposes is NLGI 2 oil
A comparison table is provided between the classification of NLGI lubricants (National Lubricating Grease Institute) and the
ASTM classification (American Society for Testing and Materials) for greases for the values that concern the pump.
GREASES
NLGI ASTM
000 445 – 475
00 400 – 430
0 355 – 385
1 310 – 340
2 265 – 295
For further information about the technical specifications and the safety measures to adopt, refer to the product safety sheet
(Directive 93/112/EEC) relative to the type of lubricant selected and supplied by the manufacturer.
15. CLEANING
It is necessary to remove periodically dust from pump avoiding the spread in the air. For this operation refers to Safety Officer.
16. TRAINING
Personnel assigned to installation, electrical connections and ordinary and special maintenance of the pump, must have at least
8 hours of specific training by an appropriate organism on equipment for explosive atmospheres caused by the inflammable
gases and combustible dusts.
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