DROPSA 989 Series Operating instructions

PUMP
SERIES 989
User and
Maintenance Manual
Warranty information
TABLE OF CONTENTS
1. INTRODUCTION
2. GENERAL DESCRIPTION
3. PRODUCT-MACHINE IDENTIFICATION
4. TECHNICAL SPECIFICATIONS
5. MACHINE COMPONENTS
6. UNPACKING AND INSTALLING THE MACHINE
7. INSTRUCTIONS FOR USE
8. TROUBLESHOOTING
9. MAINTENANCE PROCEDURE
10. DISPOSAL
11. ORDERING INFORMATION
12. DIMENSIONS
13. HANDLING AND TRANSPORTATION
14. OPERATING HAZARDS
15. PRECAUTIONS
16. WARRANTY INFORMATION
17. DECLARATION OF COMPLIANCE WITH STANDARDS
18. DROPSA LOCATIONS
www.dropsa.com
Manual drawn up in accordance with C2113IE– WK 40/13
EC Directive 06/42

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1. INTRODUCTION
This user’s and maintenance manual refers to a 989 pump series for grease.
It is recommended that this manual is carefully kept in good condition and is always available to persons requiring to
consult it.
To request further copies, updates or clarifications with respect to this manual contact the Engineering Department at
Dropsa SpA.
The use of the pump referred to in this manual must be entrusted to qualified personnel with a knowledge of
hydraulics and electrical systems.
The manufacturer reserves the right to update the product and/or the user’s manual without the obligation to revise
previous versions. It is however, possible to contact the Engineering Department for the latest revision in use.
The pump, and any accessories mounted on it, should be carefully checked immediately on receipt and in the event of
any discrepancy or complaint the Dropsa SpA Sales Department should be contacted without delay.
DROPSA S.p.A. declines to accept any responsibility for injuries to persons or damage to property in the event of the
non-observance of the information presented in this manual.
Any modification to component parts of the system or the different destination of use of this system or its parts
without prior written authorization from DROPSA S.p.A. will absolve the latter from any responsibility for injury or
damage to persons and/or property and will release them from all obligations arising from the guarantee.
2. GENERAL DESCRIPTION
The features which distinguish this pump are:
high performance,
simplicity of construction,
modularity,
The simplicity of construction guarantees long life, reliability and simplified and reduced maintenance. The modularity
of the components allows the system engineer to construct the lubrication unit to meet the specific needs of the
lubrication system it is serving.
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 SPECIFICATIONS
TECHNICAL CHARACTERISTICS
Pressure
300 Bar ( 4410 psi)
Fixed delivery max (pumping Ø6 mm)
10 cm
3
/ min (0.55 cu. in/min)
Fixed delivery max (pumping Ø8 mm) 17 cm
3
/ min (1.03 cu. in/min)
Adjustable delivery max (pumping Ø6 mm)
1,4-10 cm3/ min (0.085 - 0.61 cu. in/min)
Adjustable delivery max (pumping Ø6 mm)
2,5-17 cm3/ min (0.15 - 1.03 cu. in/min)
No. pumpings 1 ÷ 3
Capacity reservoir
5 kg. (11 lb)
Lubricant
Grease
Lubricant Viscosity
000 ÷ 2 NLGI
Working Temperature + 10° C ÷ + 40° C (+50° ÷ +104° F)
Motor Voltage
220/380 V – 50/60 Hz
Power absorption
90 W

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5. MACHINE COMPONENTS
5.1 Minimum level indicator
Electro-mechanical type
Normally closed at minimum level. Maximum commutable power ISA; maximum commutable voltage 220/240 VAC.
5.2 Pressure gauge (Accessory)
Part No. PRESSURE RANGE
3292099 0 ÷400 Bar (0 ÷40 Mpa)
5.3 BY-PASS VALVE (Accessory)
It is possible to adjust working pressure by means of a by pass valve installed on delivery line.
The use of the by pass valve it’s recommended to control the pump operating and to avoid over pressure in the circuit.
5.4 Filling filter
This removable cartridge filter is recommended to ensure the filling of lubricant which is free from foreign bodies and
to avoid the formation of air bubbles. Type of lubricant: Grease NLGI 2
Part No. PRESSURE RANGE
888036 0 ÷250 bar (0 ÷3675 psi).

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5.5 Pumping unit
Representing the pump operating-member, it is screwed directly into pump housing
and driven by means of an eccentric cam. The suction system consists of a free-dual-
line, while discharge is provided with an adjustable delivery valve
Its components are made of high-quality alloy steel, specially treated to improve wear-
resistance characteristics. Furthermore, a special external coating guarantees excellent
resistance to corrosion, tested through salt fog tests.
5.6 Auxiliary pumping unit
989 pump series are supplied with a pumping unit but it is possible to install one or two auxiliary pumpings (with fixed
or adjustable delivery). Combining the three pump elements for higher output or manage up to three lubrication lines.
6. UNPACKING AND INSTALLING THE PUMP
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, however
packing should be disposed of in accordance with regulations that may be in force in your area or state.
6.2 Installing the pump
Damage to the power supply cable and housing could result in contact with high voltage (220/380 VAC) live parts and
hence be a danger to life:
•Mount the pump in a way that the refill lubricator and timer are always easy to access;
•Carefully check the integrity of the power supply cable and the unit before use;
•In the event of there being damage to the power supply cable or the unit, DO NOT put the system into service!;
•Replace the damaged power supply cable with a new one;
•The unit can be opened and repaired ONLY by qualified personnel;
•In order to prevent dangers of electric shock due to direct or indirect contact with live parts it is necessary that
the electrical power supply line is adequately protected by a suitable differential magneto-thermal circuit breaker
with an intervention threshold of 0.03 Ampere and a max. operating time of 1 millisecond.
•The connection of the pressure switch mounted directly on the tank must be 240 VAC/DC.
•The pump MUST NOT be submersed in fluids or utilized in environments which are particularly aggressive or
explosive/inflammable if not prepared for this purpose beforehand by the supplier.
•For correct fixing verify the distance between centers.
•Use gloves and safety glasses as required in the lubrication oil safety chart;
•DO NOT use aggressive lubricants with NBR gaskets and seals; if in doubt consult the Engineering Department of
Dropsa SpA, who will provide a chart with the details of recommended oils;
•DO NOT ignore dangers to health and observe all hygiene standards;
•WARNING! All electrical components must be grounded. This refers to both electrical components and control
devices. In this regard 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.
The breaking capacity of the circuit breaker must be = 10 kV and the nominal current
In
=
4 A

5
Action to be taken prior to start up:
•Verify the integrity of the pump;
•Fill the tank with suitable lubricant (min/max indication on the tank);
•Verify that the pump is at operating temperature and the tubing free from air bubbles;
•Check that the electrical connections have been effected correctly (UNI 64/8, IEC …);
7. INSTRUCTIONS FOR USE
1. Verify the settings made;
2. Press the start button of the machine to which the 989 series
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).
5. Reservoir is refilled through lubricator “A”.
The minimum level indicator is supplied, unless otherwise specified by the customer, with the
contact closed for minimum level. Should the user require to use a normally open contact it will be
necessary to invert the operating direction of the microswitch.

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8. TROUBLESHOOTING
The following diagnostic table indicates the main anomalies which may be encountered, the probable causes and
possible solutions. If you cannot solve the problem, do not attempt to disassemble the unit, but contact the
Engineering Department of DROPSA S.p.A.
N
ANOMALY
CAUSE
REMEDY
01 Motor does not
operate
Power supply failure
Verify power supply system, and check the fuse
Ratiomotor does not operate
Replace the ratiomotor
02 Pump does not
deliver lubricant
Reservoir is empty
Refill the tank with clean lubricant,
Air-bubbles in lubricant
Disconnect main piping from pumping element fitting.
Operate the pump in the manual mode until lubricant
free of air-bubbles comes out of the fittings
Obstructed suction pipe-line Disassemble the pumping unit and clear the suction
pipe-line
03
Pump operates but
does not deliver
lubricant to the
bearing- points
Disconnected piping
Inspect piping and replace the wear pipes
Blocked progressive
distributor Clear the distributor. Replace it, if necessary
N
ANOMALY
CAUSE
REMEDY
04
Lubricant reaches the
bearing-points in
incorrect quantities
The distributor is not
correctly connected to the
bearing-points.
Verify that the dosages are those indicated in the
system diagram
Delivery is not correct (only
for adjustable delivery pump
unit).
Adjust delivery by means of regulation screw
05
Pump starts
lubricating but stops
immediately
Faulty motor or high output
consumption.
Allow the pump being cooled for a few minutes and try
again. If the problem still continues, contact the
Customer Service
06 Irregular flow rate
Screw C, which secures the
pump element D and return
spring E, is loose (only for
adjustable delivery pump
unit).
Remove the pump element assembly from the pump
body and completely disassemble it.
To reassemble the pump element assembly see the
sequence in the diagram.
Check and clean all pump unit parts. Verify the
component integrity.
Warning: put some Loctite type sealant on screw C,
which is inserted into pump element D. Hold the pump
element between wooden vice clamps to prevent
damage to the lapped surface. Lock up very well the
element B.
07 The system doesn’t
reach the pressure
Delivery valve dirty.
Delivery valve damaged.
Spring broken
Dismount the valve A, clean it and mount following the
showed sequence.
Replace the pumping unit.

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WARNING: Prior to any maintenance, be sure that the power and the hydraulic supplies are off
and there is no residual pressure in the main/branch pipe.
Adjustable delivery pumping
unit:
Part No. 299041 Ø 6 mm.
Part No. 299042 Ø 8 mm
Fixed delivery pumping unit:
Part No. 299642 Ø 6 mm.
Part No. 299643 Ø 8 mm

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9. MAINTENANCE PROCEDURE
Position the machine in such a way that it can be checked easily.
Wear the correct individual protection gear in order to avoid contact with the mineral oil.
It is necessary to periodically check as follows:
VERIFICATION
WORK CYCLE/RUNNING TIME
The state of lubrication
1000/every 6 months
The oil/grease level
2000/once a year
Cleanliness of the filling and intake filter (where fitted)
500/every 6 months
The machine does not require special equipment for any inspection and/or maintenance activity. It is however
recommended that the equipment used be suitable and in good condition so as to avoid damage to people or parts of
the machine.
9.1 Assembly/Disassembly
No pump assembly operations are envisaged.
For wall mounting ensure adequate space is available (as shown in the installation diagram) to avoid abnormal
postures and possible impacts; four fixing holes are provided for wall mounting and three for base fitting.
Subsequently it will be necessary, as previously described, to connect the pump to the machine hydraulically and then
to connect the control panel.
During the disassembly phase ensure the tank is empty.
Disconnect the electrical and hydraulic parts.
Where the machine is to be scrapped, do not dispose of potentially polluting parts in the environment, following local
regulations for their correct disposal.
At the time of the machine being scrapped it is necessary to remove and destroy the identification plate and all other
relative documents.
9.2 Regulation
Flow rate (for versions with adjustable flow rates)
It is possible to regulate the flow rate by rotating the regulating screw (8 mm hexagonal key) clockwise to decrease
and anticlockwise to increase (remove the cap B).
9.3 Repairs
The following diagnostic table indicates the main anomalies which may be encountered, the probable causes and
possible solutions.
The anomalies shown are:
•the pump fails to deliver lubricant
•irregular pressure
•irregular flow rate
In case of doubts and/or problems which cannot be resolved do not attempt to disassemble parts of the machine but
contact the Engineering Department of DROPSA S.p.A.

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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 and all the other relative documents
are also destroyed.
11. ORDERING INFORMATION
11.1 FIXED DELIVERY
(*) For 24V version the motor is supplied with 1 mt (3.28 ft) without terminal
ADJUSTABLE DELIVERY
(*) For 24V version the motor is supplied with 1 mt (3.28 ft) without terminal
11.2 ACCESSORIES
11.3 SPARE PARTS
Part No. Description
220/380 V
50/60 Hz
989001 Grease Electro-pump
1 pumping unit Ø 6 mm
989002 Grease Electro-pump
1 pumping unit Ø 8 mm
24 V DC*
989011 Grease Electro-pump
1 pumping unit Ø 6 mm
989012 Grease Electro-pump
1 pumping unit Ø 8 mm
Part No. Description
220/380 V
50/60 Hz
989003
Grease Electro-pump
1 pumping unit Ø 6 mm
989004 Grease Electro-pump
1 pumping unit Ø 8 mm
24 V DC*
989013 Grease Electro-pump
1 pumping unit Ø 6 mm
989014 Grease Electro-pump
1 pumping unit Ø 8 mm
Part No.
DESCRIPTION
299642C
Pumping unit Ø 6 mm - Fixed delivery 10 cm3/min (0.61 cu. in/min)
299643C
Pumping unit Ø 8 mm - Fixed delivery 17 cm3/min (1.03 cu. in/min)
299041C Pumping unit Ø 6 mm - Adjustable delivery 1,4-10 cm
3
/min (0.085 - 0.61 cu. in/min)
299042C
Pumping unit Ø 8 mm - Adjustable delivery 2,5-17 cm3/min (0.15 - 1.03 cu. in/min)
888036
By Pass 0-250 Bar
3292099 Pressure gauge 0-400 Bar
Part No.
DESCRIPTION
3301504
Motor GR 56 KW 0,09 220/380 V 50/60 Hz
3301521 Motor GR 56 KW 0.1 24V DC
712100 Filter 220 µ
3301505
Reduction gear R 1:30

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12. DIMENSIONS
13. HANDLING AND TRANSPORTATION
Prior to shipping, the equipment is carefully packed in cardboard package. During transportation and storage, always
maintain the pump the right way up as indicated on the box. On receipt check that package has not been damaged.
Then, storage the machine in a dry location.
No particular precautions are required except as noted on the package itself.
Handling must be effected by at least two persons.
POS.
DIMENSIONS
mm (in.)
A
539,5 (21.24)
B
~ 334 (13.15)
C
71 (2.79)
D ~ 220 (8.66)
E
120 (4.72)
FOR WALL
MOUNTING
E
D
C
No 4 HOLES Ø 6 mm
FOR BASE PLATE
MOUNTING
Lift the unit with taking account of the right way up indicated on the cardboard carton
The machine components can withstand temperatures, during storage, from -20 to +50°C; however, in
order to avoid damage, starting of the machine should occur at a minimum temperature of -5°C.

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14. OPERATING HAZARDS
Power supply
Any type of intervention must not be carried out before unplugging the machine from power supply. Make sure that
no one can start it up again during the intervention.
All the installed electric and electronic equipment, reservoirs and basic components must be grounded.
Flammability
The lubricant generally used in lubrication systems is not normally flammable. However, it is advised to avoid contact
with extremely hot substances or naked flames.
Pressure
Prior to any intervention, check the absence of residual pressure in any branch of the lubricant circuit as it may cause
oil sprays when disassembling components or fittings.
Noise
Pump does not produce excessive noise, less than 70 dB(A) .
15. PRECAUTIONS
The verification of conformity with the essential safety requirements and regulations of the Machine Directive is
effected by means of the compilation of a check list which has been pre-prepared and is contained in the technical file.
The lists which are utilised are of three types:
•list of dangers (as in EN 414 referring to EN 292)
•application of essential safety requirements (Machine Dir.)
•electrical safety requirements (EN 60204-1).
The following is a list of dangers which have not been fully eliminated but which are considered acceptable:
•in the version of the pump without a release it is possible to encounter squirts of oil (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.
•incorrect assembly of the regulator (valve) can result in an over pressure which can prejudice the functioning
of the pump itself and create danger for the user. This is avoided by stamping the mounting instructions on
the table.
Fluid
Danger
Lubricants with abrasive additives
High wear rate of contacted parts
Lubricants with silicone based additives
Seizure of the pump
Petrol – solvents – inflammable liquids
Fire – explosion – damage to seals
Corrosive products
Corrosion of the pump– injury to persons
Water
Oxidation of the pump
Food substances
Contamination of the substances themselves
WARNING: It is necessary to carefully read about the instructions and the risks involved in the use
of lubrication machines. The operator must know the machine functioning through the User and
Maintenance Manual.

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16. WARRANTY INFORMATION
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 to 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 CE STANDARDS
Technical Director:
Maurizio Greco
.....................................
Legal representative
Milena Gavazzi
.....................................
Vimodrone (MI), Gennaio 2012
La persona autorizzata a costituire il Fascicolo Tecnico c/presso Dropsa S.P.A.
The person authorized to compile the Technical File care of Dropsa S.P.A.
Dropsa Spa
Via Benedetto Croce, 1
20090 Vimodrone (MI)
Italy
Tel.:
Fax Sales:
E-mail:
Web site:
(+39) 02. 250.79.1
(+39) 02. 250.79.767
[e-mail]
http://www.dropsa.com
DICHIARAZIONE DI CONFORMITÁ/DECLARATION OF COMPLIANCE WITH STANDARDS/
DECLARATION DE CONFORMITE/ KONFORMITÄTSERKLÄRUNG DES STANDARDS /DECLARACIÓN DE
CONFORMIDAD/ DECLARAÇÃO DE CONFORMIDADE
La società Dropsa S.p.A., con sede legale in Milano, Via Besana,5/ Dropsa S.p.A., registered office in Milan, Via
Besana,5 / Dropsa S.p.A. au Siège Social à Milan, Via Besana,5/ Dropsa S.p.A., Sitz in Milano, Via Besana 5/ La
sociedad Dropsa S.p.a., con sede legal en Milán, Via Besana,5/ A Dropsa S.p.A, com sede em Milão, via Besana, nº 5
DICHIARA /CERTIFIES / CERTIFIE/ ZERTIFIZIERT, DASS/ DECLARA/ CERTIFICA:
che il prodotto denominato/that the product called/ le produit appelè/ das Produkt mit dem Namen/ el producto que se
llama/ o produto chamado:
Descrizione/ Description/ Description/ Beschreibung/
Descripción/ Descrição:
Pompa a pistoni
Piston pump
Nome Commerciale/ Product Name/ Dénomination/
Handelsname/ Denominación/ Denominação:
989 Series
Versioni/ Versions/ Versions/ Versionen/ Versiones/
Versões:
All versions
Codici/ Codes/ Códigos/:
989001÷989004; 989011÷989014
è conforme alle condizioni previste dalle Direttive CEE /has been constructed in conformity with the Directives Of
The Council Of The European Community on the standardization of the legislations of member states/ a été
construite en conformité avec les Directives Du Conseil Des Communautes Europeennes/ Entsprechend den
Richtlinien des Rates Der Europäischen Union, für die Standarisierung der Legislative der Mitgliederstaaten,
konstruiert wurde/ cumple con las condiciones establecidas por las directivas comunitarias/ foi construído em
conformidade com as diretivas do Conselho das Comunidades Europeias:
•2006/42 CE Direttiva macchine /Machinery Directive/ Directive machines/ Maschinenrichtlinien/Maquinaria / Directiva
Máquinas;
•2006/95 CE Bassa tensione / Low Voltage Directive / Directive Basse Tension/ Niedrigspannungsrichtlinien/ Directiva de
baja tensión/ Directiva de Baixa Tensão;

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18. DISTRIBUTORS
Web site: http://www.dropsa.com - 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: s[email protected] (Export)
E-mail: [e-mail] (National)
Dropsa Ame
23, Av.des.Morillons
Z.I. des Doucettes 91140
Garges Les Gonesse, France
Tel: [phone]
Fax: [phone]
E-mail: [e-mail]
Dropsa (UK) Ltd
Unit 6, Egham Business Village,
Egham,Surrey,TW20 8RB
Tel: [phone] - 431177
Fax: [phone] - 438598
E-mail: [e-mail]
Dropsa do Brazil Ind. E Com. Ltda
Rua Sobralia 175,
Sao Paulo, Brazil
Tel: [phone]
Fax: [phone]
E-mail: [e-mail]
Dropsa USA Inc.
6645 Burroughs Ave
48314-2132 Srerling Hts,Mi Us -USA
Tel: [phone]
Fax: [phone]
E-mail: salesus[email protected]
Dropsa Lubrication Systems
Nr 8 Dongxing Road,
Songjiang Industrial Zone
(Shanghai) Co., Ltd
Tel: [phone]
Fax: [phone]
E-mail: [e-mail]
Dropsa Gmbh
Volmerswerther Strasse 80
40221 Dusseldorf 1, Deutschland
Tel: [phone]
Fax:[phone]
E-mail: [e-mail]
Dropsa Australia Pty.
C20/148 Old Pittwater Road
Brookvale, NSW 2100
Tel: [phone]
Fax: [phone]
E-mail: [e-mail]