DROPSA SMART2 Operating instructions

1
SMART 2
Oil Lubrication Electro-Pump
SW ver. 1.10
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
Manual drafted in compliance with C2084IE– WK 54/04
EC Directive 98/37, Annex I, paragraph 1.7.4
http://www.dropsa.com
Manufacturer DropsA SpA
Product SMART2
Year 2004
Certification
DRAFT

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1. INTRODUCTION
This User and Maintenance Manual refers to SMART2 - Oil Lubrication Electro-Pump.
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.
This manual contains important information on health and safety issues for the personnel. It is recommended
to attentively read this manual and carefully keep it in good condition so that it is always available to personnel
requiring to consult it.
2. GENERAL DESCRIPTION
Oil lubrication pump SMART2 has been designed for industry machine tools.The electric gear-pump was
designed to work with Single Line Injectors and Valves 33.
SMART2 is available in two versions:
- Manual SMART2, manually controlled via the PLC of the machine tool;
- Automatic SMART2, automatically controlled via built-in VIP2004 controller.
2.1 LUBRICATION CONTROL SYSTEM - PRINCIPLES OF OPERATION
AUTOMATIC SMART 2 operates on the principle of intermittent lubrication which involves the following
three steps:
 Prelube
 Lube (lube – wait)
 Standby
2.1.1 PRELUBE
This step is made up of a set of cycles (max 999 cycles) during which the lubrication system runs a series of
lubrication cycles (lubrication will be described in paragraph 2.1.2) necessary to vent air from the pump and
check lubrication functions.
Prelube takes place:
- on POWER-ON;
- on RESET;
- Any time new parameters are set.
When prelube is set to “0”, Intermittent Lubrication will only consist in the lube – standby/standby - lube
phases (see START mode).
2.1.2 LUBE
This step is made up of a set of cycles (max 999 cycles) during which lubrication is carried out. Each cycle
consists of two sub-cycles (lube and wait) and involves the monitoring of timers and/or inputs:
- during lube, system delivers lubricant to the lubrication points;
- during wait, a timer defines the wait time between two or more lube cycles or before the beginning of
the standby phase (in case only 1 lube cycle was set).
There are three types of lube:
 TIMER: Lubricant delivery is simply regulated by a timer;
 PS: Lubricant delivery is carried out only if the system is in pressure;
 SEP: Lubricant delivery is carried out only the system detects three changes in the position of the
mechanical piston.
2.1.3 STANDBY
During this step lubrication system is idle until the next lubrication cycle. There are three ways to regulate
standby:
 TIMER: a timer regulate system idling;
 PULSE: a pulse counter regulate system idling;
 BOTH: both a timer and a pulse counter regulate system idling. The type of standby will depend on
which of these two events will start first.

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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
4.1 General technical specifications
Lubricant Mineral Oil
Lubricant Viscosity 68 ÷ 320 cSt (320 ÷ 1480 SUS)
Working Temperature +5°C ÷ + 60°C (+41°F ÷ +140°F)
Storage Temperature - 20°C ÷ + 60°C (-4°F ÷ +140°F)
Working Humidity 90% max
Mechanical Protection Grade IP-55
Sound Pressure Level <70 dB (A)
4.2 Electric gear pump
Voltage 110V/50Hz 110V/60Hz 220V/50Hz
Power absorption 162W 155 W 150W
Nominal current 1.48A 0.69A
Pump flowrate 180 cm³/min
(10.98 cu.in.)/min
220 cm³/min
(13.42 cu.in.)/min
180 cm³/min
(10.98 cu.in.)/min
Maximum Pressure 30 bar (411psi)
Reservoir Capacity 3 litres (0.66 gals)
By-pass Calibration 25 bar (367.5 psi)
Pressure-Switch calibration 18 bar (264.6 psi)
Insulation Class B
Rotation direction clockwise
Revolutions/min 2900 3500 2900
Max working time in continuous 2 minutes
MIN STANDBY time 5 times MIN setup time
NOTE: pump output is energized.
4.3 Battery backup (DATE and TIME)
CPU real time clock is powered by a lithium battery for Date and Time backup in the event of powerfailure.
Voltage 3.7V
Current consumption 100mA
Capacitance 800 mA/h
Temperature -50°C÷+70°C (-58°F÷+158°F)
Lifetime 5 years
5. MACHINE COMPONENTS
The following main components are assembled to the baseplate:
 A reservoir, made of transparent plastic material;
 An electric gear-pump, with high performance and minimum power consumption;
 A SAMBA level sensor, which indicates lubricant minimum level via a N.O. electric contact
(reservoir empty). To reverse N.O. to N.C., please contact Dropsa Eng. Dept.;
 A manometer;
 A N.O. Pressure-switch , which detects system in pressure;
 A PCB user interface.

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5.1 MANUAL SMART2
The electronic board, located under the cover of manual SMART2, allows pressure-switch and electric level
contact management both indipendent and serial.
On the front panel there are:
 Push-button for manual control, “MANUAL”;
 LED indicator for “PUMP ON”.
5.1 AUTOMATIC SMART2
VIP2004 Controller, located under the cover of automatic SMART2, allows pump total autonomy both in cycle
times, alarms or checks.
On the front panel there are:
 LCD display 16x2 types;
 Push-buttons: three for control/management and one RESET button.

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6. UNPACKING AND INSTALLING THE PUMP
6.1 UNPACKING
Once a suitable location has been found to install the unit, remove the pump from package. Check the unit has
not been damaged during transportation or storage. No particular disposal procedures are necessary as
package materials are no dangerous for health or environment. However, package should be disposed of in
accordance with regulations that may be in force in your area or state.
6.2 INSTALLING THE PUMP
 In order to facilitate any maintenance intervention, to avoid unnatural posture for personnel during
machine operation or the possibility of sustaining impacts, install the machine in a comfortable and
easy-to-reach location.
 Allow sufficient space for the installation, leaving minimum 100 mm (3.9 in.) around the unit.
 Do not install the unit in aggressive or explosive/inflammable environments or on vibrating surfaces.
 To install the pump, use only the supplied bracket provided with two holes for Ø6 mm (Ø 0.2 in.)
screws (see Dimensions, ch. 12).
6.3 HYDRAULIC CONNECTION
Connect SMART2 to the system via the hydraulic connection located on the baseplate, on the right side of the
pump: standard thread ¼ BSP.
6.4 ELECTRIC WIRING
6.4.1 ELECTRIC DIAGRAM
Here follows the general electric diagram for both automatic and manual SMART2:
NOTICE: Pressure can be monitored by a micro-switch or a NPN/PNP proximity sensor.
6.4.2 USER CONNECTIONS
The following picture shows PCB user interface, where the user has to connect power supply and external
outputs for the correct functioning of both automatic and manual SMART2. For details about connections,
please refer to special paragraphs. (PCB serigraphy only refers to automatic SMART2).
PCB user connections
only refers to automatic
SMART2
M1
M2

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6.4.2.1 CONNECTIONS FOR MANUAL SMART2
Here follows user connections for power supply (terminal M1), pressure-switch and electric level contact
(independent or serial), and the manual push-button (terminal M2). Furthermore, it is also shown how to
change the type of connection (indipendent or serial) for the pressure-switch and electric level contact, by
acting on the jumper located on the electronic board of manual SMART2.
6.4.2.2 CONNECTIONS FOR AUTOMATIC SMART2
Here follows user connections for power supply (terminal M1), external alarm and proximity sensor or micro-
switch (terminal M2).

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6.4.3 POWER-SUPPLY SWITCH, VARIABLE RESISTOR AND BATTERY
6.4.3.1 POWER SUPPLY SWITCH
⇒ For 220V switch rightwards.
⇒ For 110V switch leftwards.
6.4.3.2 VARIABLE RESISTOR
It allows to regulate display brightness.
6.4.3.3 BATTERY ACTIVATION
The controller is provided with a three-pin-jumper to activate battery backup of Date and Time when the
equipment is powered off.
To short-circuit the board and activate the battery, insert the bridge only into two pins (see above
picture).
WARNING:
- Each time the bridge is removed or powerfailure occurs, Date and Time are reset. It is
recommended to setup Date and Time each time the bridge is removed and then put back in
place.
- In order to make a complete reset of the machine, remove the bridge and switch-off the
machine.
6.4.4 PRECAUTIONS TO BE TAKEN DURING CONNECTING PROCEDURE
⇒ Prior to any operation, verify the voltage of the machine on the product label.
⇒ In order to prevent dangers of electric shocks due to direct or indirect contact with the
energized parts, electrical power supply line must be protected by a suitable magneto-
thermal circuit breaker with an intervention threshold of 0.03 Ampere and 1 second
minimum operating time. Circuit breaker power must be ≤10 kA and nominal power In =6
A.
BATTERY
JUMPER
At the end of all connecting operations, make sure that pipes and wires are safe from
impacts and carefully fixed.
VARIABLE
RESISTOR
POWER SUPPLY
SWITCH

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7. INSTRUCTIONS FOR USE
7.1 Manual SMART2
When the unit is equipped with the manual system, located on the frontal side panel you find the PUMP-ON
indicator which is on when the pump is operating. Remote control is via external timer or PLC.
Warning: Manual control device cannot be used through a direct control but must be operated through
a deck or an electronic circuit with a max power absorption of 400mA.
7.2 Automatic SMART2
When the unit is equipped with an automatic control, all the pump functions and checks are carried out
through the built-in VIP2004 controller, alarms and external signals included. Timers are also controlled by the
system. For details about machine operation, please refer to par. 7.4.
7.3 Machine operations
7.3.1 Prior to machine start-up
 Verify the unit is undamaged.
 Check that hydraulic and electric connections have been carefully carried out.
 Refill the reservoir with compatible lubricant.
 Verify the voltage: MAX 220VAC.
RESERVOIR REFILL
Use ONLY compatible lubricant and refill the reservoir by means of the oil refill plug provided with a filter. Do
not pour lubricant directly into the reservoir without using this oil refill plug.
7.3.2 Machine start-up
In order to avoid damage to the machine, the unit must start operating at a minimum working temperature of
+5°C (+41°F).
 Switch ON the unit.
 Verify unit start-up.
 Verify piping are air-bubble-free.
 Adjust pressure.
 Set-up machine parameters.
 Verify machine correct operation: pump must carry out lubrication correctly and according
to parameters setup.
AIR VENTING
Pump well-functioning is not affected by presence of air in the system. However, it is advisable to vent air by
starting the pump until lubricant comes out air-bubbles-free. (It is recommended to avoid pump operation
when lubricant is below the minimum level).
PRESSURE REGULATION
Pressure can be verified via manometer. It is possible to regulate pressure by acting on the screw located on
the frontal side of the baseplate.
⇒ To increase pressure: turn the screw clockwise.
⇒ To decrease pressure: turn the screw anticlockwise.
In case of doubts as to correct machine functionin
g
, it is recommended to contac
t
our Eng. Dept. to request testing procedures.

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7.4 SMART2 with built-in VIP2004 controller operation
7.4.1 Typical working session
Notice: prelube is always carried out according to prelube cycles set-up: if prelube cycles = ‘0’, no
prelube is run and the system will start operating either in standby or lube according to the pre-set
start mode.
7.4.2 Typical system start-up
LUBE X 2 TIMER
00m05s STOP
STANDBY 01m00s
setu
p
-> start
PRELUBE X 3 TIMER
00m05s STOP
PRELUBE will be carried out only when prelube cycles are set
(PRELUBE ≠0).
Whether prelube has been completely carried out (PRELUBE ≠0) or no
prelube was set (PRELUBE = 0), LUBE or STANDBY will start (see
start mode
)
.
www.DROPSA.com
SMART2 rel. 1.10
Jan 01-01-2004 0:00
setu
p
-> start
During standby, you can also see date and time when the function is
enabled (see setup).
STANDBY 99 I
setu
p
-> start
PRELUBE
CYCLES?
YES
PRELUBE
NO
LUBE
YES
STANDBY
LUBE
CYCLES
?
WAIT
NO

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7.4.3 Setup session
Press YES to enter SETUP.
Press NO to
g
o back to STANDBY or
A
LARM
(
if activated
)
.
Press SET to enter LUBE Time setup; use “-“ and “+” to change the value and
SAVE to save the new setting. Push NEXT to go to the next setup.
To modify STANDBY Time,when this function is controlled by a timer.
This parameter can be set only if
STANDBY type
is
timer
or
both
.
To modify STANDBY pulse when this function is controlled by a pulse register.
This parameter can be set only if STANDBY type is pulse or both.
Press YES to enter the EXTENDED MENU.
Press NO to re-initialize the machine.
Press SET to enter STANDBY Type setup;use “-“ and “+” to select Timer
–
Pulse - Both and SAVE to save the new setting. Push NEXT to go to the next
setu
p
.
To select LUBE Type: Timer – PS - SEP.
ONLY for PS: To modify DELAY Time for pump-OFF.
To modify LUBE Cycle.
To modify WAIT Time between two or more lube cycles.
Note: this parameter is displayed only if Lube or Prelube > 1
To select START mode system: START IN LUBRIC. / START IN STANDBY.
To modify PRELUBE Cycle.
To select the type of alarm electric contact: Norm. Close/ Norm.Open.
To set the day (DATE).
To set the month (DATE).
To set the year (DATE).
To set the hour (TIME).
To set the minutes
(
TIME
)
.
SET UP?
YES NO
LUBE Time 00m05s
SET NEXT
STANDBY 01m00s
SET NEXT
STANDBY 99i
SET NEXT
EXTENDED MENU?
YES NO
STANDBY TIMER
SET NEXT
LUBE Type TIMER
SET NEXT
DELAY Time 00m10s
SET NEXT
LUBE Cycles 2
SET NEXT
WAIT Time 00m10s
SET NEXT
START IN LUBRIC.
SET NEXT
PRELUBE 0
SET NEXT
A
LARM Norm.Open
SET NEXT
Day 1
SET NEXT
Month 1
SET NEXT
Year 2004
SET NEXT
Hour 0
SET NEXT
Minute 0
SET NEXT
BACK TO STANDBY OR
A
LARM
(
IF ACTIVATED
)
MACHINE
RE-INITIALIZATION
Date & Time Enabled
SET NEXT To enable/disable Date and Time function