DROPSA Dragon Series Operation instructions

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. [phone]
Dropsa products can be purchased from Dropsa branches and authorized distributors, visit
www.dropsa.com/contact or contact us sal[email protected]om

2
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.

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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

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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

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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
1
Motor
2
Connector
3
Pump
4
Level indicator (optical in
the picture –floating
switch optional)
5
Filter
6
Tank
7
Distributor block
8
Non-return valve
(optional)
9
By-pass adjustment screw
10
Clamping bracket
11
Pressure switch (optional)
12
Pressure gauge
13
Plug
6
12
13
1
10
3
2
5
8
4
11

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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)
1
V+ (8÷28 Vdc)
2
V- (GND)
3
Out N
4
Out P
CONNECTION TABLE
(version with floating switch)
1
COM
2
NC
3
NO
4
-
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.
10
5
4 / NC
Note: Set the NC level in VIP5
parameters
4 / NC
n°2 M3 Screw
Green led

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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.

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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
See the diagnostics table
ATTENTION: The machine may only be opened and repaired by authorised Dropsa personnel.

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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

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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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12. DIMENSIONS
CONTROL UNITS
A
B
C
D
E
F
G
3L pump
330
146
246
195
152
172
80
6L pump
431
250
347
259
148
172
80
3L 24V pump
312
146
246
173
150
151
75
6L 24V pump
413
250
347
253
150
151
75

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13. HANDLING AND TRANSPORTATION
Before shipping, the 39050.. pumps are carefully packed inside cardboard boxes. When transporting and storing the equipment,
pay attention to the direction indicated on the boxes themselves.
Upon receipt, check that the package has not been damaged and store the equipment in a dry location.
Manual handling must be done by at least two people.
14. PRECAUTIONS
The warnings aboutthe 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 pressurized 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.
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.
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 is no residual pressure in every branch of the lubrication circuit 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 pressurized 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.
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.
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.
ATTENTION!
Never try to stop or deviate any leaks with your hands or other body parts.

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(1) The use of the pump with grease with a consistency NLGI000 must be assessed on a case by case basis given the extreme difference in the sliding
properties of the compound, which depends both on the viscosity of the base oil as well as the soaps and additives that are used.
The use of the pump with grease with a consistency NLGI000 must be assessed on a case by case basis given the extreme
difference in the sliding properties of the compound, which depends both on the viscosity of the base oil as well as the soaps
and additives that are used. *
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
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. OPERATING HAZARDS
Compliance with the essential safety requirements and the provisions specified in the machine directive was checked by filling
out prepared check lists that are contained in the technical file.
Two types of lists were used:
Risk assessment (UNI EN ISO 14121-1).
Compliance with the essential safety requirements Machine Directive –EC 06/42).
The risks that were not completely eliminated, but considered acceptable, are specified below:
Electrocution: this can only occur in the case of serious user incompetence.
Use of unsuitable lubricant: the types of fluids that are not compatible with correct pump operation are listed below. *
Contact with harmful fluids.
FLUIDS THAT ARE NOT PERMITTED
FLUIDS
RISKS
Lubricants with abrasive additives
wear of the components inside the pump
Lubricants with silicone additives
Pump seizure
Petrol –solvents –inflammable liquids
Fire –explosion –damage to the gaskets
Corrosive products
Pump corrosion - damage to people
Water
Pump oxidation
Food substances
They would be contaminated
* For more detailed information regarding product compatibility with particular fluids, contact the Dropsa S.p.A. technical
office
NOTE: The pump was designed to operate with lubricants with a maximum rating NLGI 000. (1)
Use lubricants that are compatible with NBR gaskets.
Any internal residual lubricant used for assembly and testing purposes is 32 cSt oil