DROPSA PoliPUMP eco Operation instructions

1
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]

2
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

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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.

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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).

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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

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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.
No
.
MOUNTING POSITIONS
No
.
MOUNTING POSITIONS
No
.
MOUNTING POSITIONS
1
1
13
13
25
25
2
1-7
14
13-19
26
25-31
3
1, -5, -9
15
13, -17, -21
27
25, -29, -33
4
1-4-7-10
16
13-16-19-22
28
25-28-31-34
5
1-2-4-7-10
17
13-14-16-19-22
29
25-26-28-31-34
6
1-3-5-7-9-11
18
13-15-17-19-21-23
30
25-27-29-31-33-35
7
1-2-4-5-7-9-11
19
13-14-16-17-19-21-23
31
25-26-28-29-31-33-35
8
1-2-4-5-7-8-10-11
20
13-14-16-17-19-20-22-23
32
25-26-28-29-31-32-34-35
9
1-2-3-5-6-7-9-10-11
21
13-14-15-17-18-19-21-22-23
33
25-26-27-29-30-31-33-34-35
10
1-2-3-4-5-6-7-9-10-11
22
13-14-15-16-17-18-19-21-22-23
34
25-26-27-28-29-30-31-33-34-35
11
1-2-3-4-5-6-7-8-9-10-11
23
13-14-15-16-17-18-19-20-21-22-23
35
25-26-27-28-29-30-31-32-33-34-35
12
1-2-3-4-5-6-7-8-9-10-11-12
24
13-14-15-16-17-18-19-20-21-22-23-24
36
25-26-27-28-29-30-31-32-33-34-35-36
Positioning of pumping elements
36

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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.

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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)

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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

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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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9. MAINTENANCE PROCEDURES
The pump does not require special tools for any check and/or maintenance operations. In any case, it is recommended to
use suitable equipment and personal protective equipment (gloves, protection goggles, etc.) that in good condition in
accordance with applicable regulations to avoid injury or damage to parts of the pump.
The unit has been designed and built in such a way that it requires a minimum level of required maintenance.
Nevertheless, it is recommended to always keep the body of the equipment clean and periodically check the tube joints
in order to be able to readily detect any leaks.
9.1 SCHEDULED MAINTENANCE
The following table lists the periodic inspections, the frequency and the intervention that the maintenance will have to
carry out in order to ensure the efficiency of the system over time.
CHECK
FREQUENCY
INTERVENTION
Attachment of the lines
After the first 500 hours of operation
Every 1500 hours of operation
Check the joint fittings.
Check the fastening to the parts of the machine.
Reservoir level
As required
Restore the lubricant level in the reservoir.
Filling filter
As required
Check and possibly replace.
10. DISPOSAL
Do not dispose of polluting components in the environment during pump maintenance or in case of demolition; refer to
local regulations for correct disposal. Upon demolition of the pump, the identification label and any other document must
be destroyed.
ATTENTION:Before any maintenance or cleaning operation, make sure that hydraulic feed and electric
power are disconnected.

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11. ORDER INFORMATION
PUMPS
PUMPING ELEMENTS
Power
zione
Max. number of PUMPING ELEMENTS
CAPACITY
PART
NUMBER
CAPACITY
PART
NUMBER
12
24
36
0.02cc/cy
cle
0888451
0.08cc/cycle
0888454
12VDC
0888270-ECO
0888271-ECO
0888272-ECO
0.03cc/cy
cle
0888452
0.10cc/cycle
0888455
24VDC
0888273-ECO
0888274-ECO
0888275-ECO
0.04cc/cy
cle
0888453
0.13cc/cycle
0888456
OPTIONAL
SPARE PARTS
PART
NUMBER
DESCRIPTION
PART
NUMBER
DESCRIPTION
5717300
Nylon tube Ø4x3 (low pressure)
0888257
Pump replacement cap
5717218
Nylon tube, Ø4x2, white, 100m
0888116
Reservoir (standard)
5717258
Nylon tube, Ø4x2, black, 25m
3130022
Filling filter
5717259
Nylon tube, Ø4x2, black, 25m, loaded NLGI 00
0888038
Grease filling cartridge kit
3133723
Valved grease filling cartridge kit
3077222
Fitting for loading at 90° M22x1.5

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12. DIMENSIONS
PoliPUMP (standard) Dimensions in mm [in].
13. HANDLING AND TRANSPORT
Before shipment, the pumps are carefully packed inside a cardboard box. During transport and storage of the equipment, pay
attention to the direction indicated on the box. Upon receipt, check that the packaging is not damaged and store the pump in a
dry place.

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14. PRECAUTIONS FOR USE
Electrical power supply
No operations must be carried out on the machine before disconnecting it from the electrical power supply and ascertaining that
no-one can reconnect it during the operation. All installed equipment (electric and electronic) must be connected to the earthing
system.
Flammability
The lubricant generally used in the lubrication circuits is not inflammable fluid. However, it is imperative to take all necessary
steps to prevent it from coming into contact with very hot parts or naked flames.
Valve
Before any operation, check for the absence of any residual pressure in all branches of the lubricant circuit, that could cause
spurts of oil in the event that fittings or components are disassembled.
Noise
The equipment does not emit noise exceeding 70 dB (A).
14.1 LUBRICANTS
A table is shown that compares the NLGI (National Lubricating Grease Institute) and ASTM
(American Society for Testing and Materials) categories for greases, limitedly to the values
that involve the PoliPUMP pump.
For further information on the technical characteristics and the safety measures to adopt,
see the Product Safety Data Sheet (Directive 93/112/EEC) related to the type of lubricant
selected and supplied by the manufacturer.
15. CONTRAINDICATIONS OF USE
Compliance with the essential safety requirements and machine directive provisions has been checked through the completion
of check lists already drafted and contained in the technical file.
Three types of lists were used:
Compliance with essential safety requirements (Machine Directive).
Risk assessment (EN ISO 12100).
Electrical safety requirements (EN 60204-1).
The hazards that have not been entirely eliminated, but that have been deemed acceptable, are listed below:
During the maintenance phase, low pressure spurts of lubricant are possible. (For this reason, maintenance operations
must be carried out using suitable PPE).
Contact with lubricant during maintenance or filling the reservoir. Protection from direct or indirect contact with the
lubricant must be ensured by the user of the machine. (See the regulation on proper use according to applicable
regulations).
Impact and crushing. Moving parts are all enclosed and the designation of such danger has been indicated at the access
point.
Electrocution. This can occur only in the event of serious negligence by the user who, however, is qualified.
Use of unsuitable lubricant. The characteristics of the lubricant are indicated both on the pump and in this Operation
and maintenance manual (in the event of any doubt, contact the Dropsa S.p.A. Technical Office):
PROHIBITED FLUIDS
Fluids
Hazards
Lubricants with abrasive additives
High wear of the contaminated parts
Lubricants with silicon additives
Seizing of the pump
Petrol –solvents –flammable liquids
Fire –explosion –damage to the gaskets
Corrosive products
Corrosion of the pump –damage to personnel
Water
Oxidation of the pump
Food substances
Contamination of the same
GREASES
NLGI
ASTM
00
400 –430
0
355 –385
1
310 –340
2
265 –295
ATTENTION:The warnings on risks using a lubricant pump implies must be carefully read. The user must be
familiar with operation through the Operation and Maintenance Manual.
NOTE: The pump is designed to work with maximum NLGI 2 grade lubricants.
Use NBR gasket compatible lubricants.
Any residual lubricant inside that was used for assembly and testing is NLGI 2 grade.