DROPSA 201000 Operating instructions

PNEUMATICALLY
OPERATED PUMP
Type 201000
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. UNPACKING AND INSTALLING
7. PUMP OPERATIONS
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
Manual drafted in compliance with C2013IE – WK 32/03
EC Directive 98/37, Annex I, Paragraph 1.7.4
Manufacturer DropsA SpA
Product 201000
Pneumatically operated pump
Year 1999
Certification
http://www.dropsa.com

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1. INTRODUCTION
This manual refers to a Pneumatically operated pump, series 201000. 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 pneumatic pump is designed to be utilized in mineral oil and grease lubrication systems.
3. MACHINE IDENTIFICATION
The pump identification label is located on the front side of the pump assembly and contains details of the operating
parameters of the pump including input voltage.
4. TECHNICAL CHARACTERISTICS
TECHNICAL CHARACTERISTICS
Lubricant outlet: Rp ¼ BSPT tube seating Ø 8 mm (0.3 in)
Compressed air inlet: G 1/8 BSPT tube seating Ø 6 mm (0.2 in)
Lubricant: NLGI 00 or NLGI 2 grease according to the specific pump
model (see chapter 11).
Working pressure: from 2 to 8 bar (from 29.4 to 117.6 psi)
Working temperature: -5 °C ÷+ 70 °C (23 °F ÷158 °F)
Operating humidity: 90 % rel.
Min and Max with reed type magnetic contact
Max. Voltage 220 V DC
Max. Current 0,8 A
Lubricant level control:
Max. Power 20 W at 26 V AC
Level of continuous sound pressure < 75 dB(A)
Standard compression ratio: 50:1 (see chapter 11)
CAUTION: Operate the pump only with the voltage indicated on the product label and within the
specific operating parameters.

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5. PUMP COMPONENTS
The pump assembly comprises:
A steel body with an hardened and lapped piston.
The pneumatic command assembly consisting of an aluminium cylinder wherein a piston operates with an oil
resistant rubber seal. A 3-way pneumatic control device: line-cylinder-exhaust is required.
A double spring ensuring the returning of the piston to its start position. The impulse time shall be sufficient to
pressurise the system and the pause, between one cycle and the next, shall allow complete release. The expansion
of the flexible tubing used in the system will reduce the potential delivery.
6. UNPACKING AND INSTALLING
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.
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.
No pump assembly operations are envisaged.
1. Check carefully the integrity of the reservoir as any denting could impede pressure disk travelling and
lubricant leakage.
2. Connect the pump to the compressed air system ensuring the maximum working pressure is not exceeded.
3. Fill the reservoir with lubricant avoiding presence of air under the pressure disk (it could impede the clutch of
the pump).
6.3 ADJUSTING THE PUMP
The only parameter which can be modified is that of pressure; to modify the value, increase or decrease the control
air pressure.
7. PUMP OPERATIONS
7.1 COMMISSIONING THE PUMP
♦ The unit must be utilised, opened and repaired ONLY by qualified personnel.
♦ The pump MUST NOT be utilized in particularly aggressive or explosive/inflammable environments if not
prepared for this purpose beforehand by the supplier.
♦ For correct fixing verify the distance between centres shown in the diagram in chapter 12.
♦ Use gloves and safety glasses as required in the lubrication oil safety chart.
♦ DO NOT use lubricants incompatible with NBR gaskets and seals; if in doubt consult our Engineering
Department, who will provide a chart with the details of recommended oils.
♦ DO NOT ignore health and safety regulations and observe all hygienic requirements.
♦ WARNING! All electrical components must be grounded. This refers both to electrical components and control
devices. As regard to this ensure that the ground cable is correctly connected. For reasons of safety the ground
cable must be approx. 100 mm longer than the phase cables. In the event of accidental detachment of the cable,
the ground terminal must be the last to be removed.

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N.B. Action to be taken prior to start up
• Verify the integrity of the pump;
• Insert the pump ensuring there are no air bubbles in the grease.
• Ensure the pump is at working temperature and the tubing is free of air bubbles;
• Check the integrity of the supply line.
• Ensure that any electrical connections have been effected correctly (CEI 64/8, IEC 364);
• Check the connections of any level and solenoid valve to the control panel;
7.2 USE
1. verify the settings made on the control panel (where fitted);
2. press the start button of the machine to which the pump is connected;
3. verify the starting of the pump;
4. verify the adequate lubrication of the machine (if doubt exists as to the correct functioning
consult the Engineering Department of Dropsa SpA to request test procedures).
7.2.1 METHODS OF COMMANDING THE PUMP
It is possible to command the pump manually, by means of a simple valve, or
automatically by means of a 3-way solenoid valve.

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8. TROUBLESHOOTING
The following table highlights some of the most common problems encountered when using the Pneumatically
operated pump 201000 series 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
ANOMALY
The pump does not
deliver lubricant.
PROBABLE CAUSE
• Tank empty.
• The tank has been filled
with too hard grease.
• delivery valve dirty or
damaged.
• Suction valve.
• Piston seized.
• The presence of air under
the pressure disk due to
pump operating without
lubricant.
• Failure of the 3-way
solenoid valve.
• Operating air pressure too
low.
REMEDY
• Fill the tank.
• Empty the tank, clean with kerosene
and refill with suitable grease.
• Unscrew the valve and clean with
kerosene or, if necessary, replace with
a new one.
• In sequence, unscrew the cover and
the upper part of the hexagonal nut.
Clean or replace the cap and
reassemble.
• Replace the pump.
• Refill the tank up to the max. line,
remove the cover and push down the
pressure disk until the air under the
disk is eliminated.
• Check the electrical connections.
Check the coil and replace if
necessary.
• Check the pressure and adjust to the
required value. If necessary, replace
the regulator.

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9. MAINTENANCE PROCEDURE
Locate the machine in conditions which facilitate easy access.
Utilize individual protection to avoid contact with the lubricant.
After having been subjected to stringent inspection by ourselves, the pump requires a minimum of maintenance.
Prior to any cleaning or maintenance operations, close off the power supply and exhaust the pressure from the
pump and the tubing to which it is connected.
Do not subject the pump, the connections, the tubing or the parts under pressure to violent knocks; damaged tubing
and connections are dangerous and should be replaced immediately.
After long periods out of service check the tightness of all the parts subjected to pressure.
It is recommended the use of pure lubricants and a periodical accurate cleaning of pump components.
The pump has been designed to require the minimum of maintenance.
1. Disconnect the air supply and the lubricant delivery tubing;
2. Empty the tank of lubricant;
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
Instructions for ordering
AVILABLE VERSIONS
Command air
pressare - bar
Overall
dimensions
pump
part N°
reser
voir
Kg/Lt
system
max
del.
per
stroke
cm³min max
Comp
ratio height
mm mm
NOTE
201610 2 26 Grease NLGI 00 8 2 8 50:1 565 115 with min & max elect. level
201618 2 26 Grease NLGI 2 8 2 8 50:1 565 115 with min & max elect. level
201670 2 26 Grease NLGI 00 8 2 8 50:1 383 160 without min & max elect. level
201671 4 26 Grease NLGI 00 8 2 8 50:1 560 160 with min & max elect. level
201672 4 26 Oil 15/1000 cst 8 2 8 50:1 560 160 with min & max elect. level
201686 1.5 26 Grease NLGI 00 8 2 8 50:1 420 160 with min & max elect. level
201620 2 26 Oil 15/1000 cst 8 2 8 50:1 565 115 with min & max elect. level
201253 1 03/04/06/33 Grease NLGI 00 35 2 10 10:1 395 110 without min & max elect. level
201259 1 03/04/06/33 Grease NLGI 00 35 2 10 10:1 495 163 in sealed housing
201600 4 04/06/26/33 Grease NLGI 00 35 2 10 10:1 540 163 with min & max elect. level
201615 4 04/06/26/33 Oil 15/1000 cst 35 2 10 10:1 540 163 with min & max elect. level
201605 2 04/06/26/33 Oil 15/1000 cst 35 2 10 10:1 555 115 with min & max elect. level
201625 2 04/06/26/33 Grease NLGI 00 35 2 10 10:1 555 115 with min & max elect. level
201690 2 33 Grease NLGI 0 35 2 10 10:1 590 115 with min level

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12. DIMENSIONS
13. HANDLING AND TRASPORTING
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.
Handling can be effected by one person.
! The machine components can withstand temperatures, during storage, from -20°C to +50°C (-4°F to +50°F) ;
however, in order to avoid damage, starting of the machine should occur at a minimum temperature
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.
You can see overall
height and diameter in
the chapter 11

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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).
The following is a list of dangers which have not been fully eliminated but which are considered acceptable:
♦ it is possible to encounter squirts of oil during maintenance operations (for this reason appropriate
protective clothing must be worn);
♦ contact with oil -> see the requirements for the use of suitable personal protective clothing;
♦ use of unsuitable lubricant -> the characteristics of the fluid are shown on the pump and in the manual
(in case of doubt contact the Eng. Dept of Dropsa Spa);
♦ protection against direct and indirect contact must be provided by the user;
♦ given the purpose of the pump it must always be functioning; for this reason it is necessary to pay
attention to the electrical connections which, in the case of a power failure, the customer’s machine is
restarted only by means of a reset, while the lubrication pump is able to restart automatically.
♦ During the disassembly of the pneumatic motor there exists the danger from the preloaded
spring; take particular precautions against this risk.
INADMISSIBLE 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
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 the 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.

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17. DECLARATION OF COMPLIANCE WITH STANDARDS
Manufacturer:
DROPSA SpA
Via B. Croce, 1 - 20090 Vimodrone (MI)
Address
02 – 250.791
Telephone
Certifies that:
The Machine: PNEUMATICALLY OPERATED PUMP Type 201000
o Has 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
December 2002
Signature Date

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18. DROPSA LOCATIONS
Dropsa USA Inc.
50679 Wing Drive
Utica, Michigan 48315, USA
Tel: [phone]
Fax: [phone]
E-mail: [email protected]
Dropsa France
23, Av.des.Morillons
Z.I. des Doucettes
95140 - Garges Les Gonesse
Tel: [phone]
Fax: [phone]
E-mail: [email protected]
Dropsa (UK) Ltd
Unit 6, Egham Business Village,
Egham,Surrey,TW20 8RB
Tel: [phone] - 431177
Fax: [phone] - 438598
E-mail: [email protected]
Dropsa do Brazil
Rua Sobralia 175/866
Sao Paulo
Tel: [phone]
Fax: [phone]
E-mail: [email protected]
Dropsa S.p.A.
Via B. Croce,1
20090 Vimodrone (MI) Italy.
Tel: (+39) 02 - 250.79.1
Fax: (+39) 02 - 250.79.767
E-mail: [email protected] (Export)
E-mail: [email protected] (National)
Poly Dropsa S.A.
Av. Fabregada 26 - Pje Est.2
08907 L'Hospitalet de LLobregat
Barcelona, Spain
Tel: [phone]
Fax: [phone]
E-mail: [email protected]
Dropsa Gmbh
Volmerswerther Strasse 80
40221 Dusseldorf 1, Germany
Tel: [phone]
Fax:[phone]
E-mail: [email protected]
Dropsa Australia Pty.
C20/148 Old Pittwater Road
Brookvale NSW 2100
Tel: [phone]
Fax: [phone]
E-mail: [email protected]
Web site: http://www.dropsa.com - E-mail: [email protected]