DROPSA SMART3 Operating instructions

SMART3 PUMP
User and
Maintenance Manual
Original instructions
Manual drawn up in accordance with C2194IEWK 37/20
EC Directive 06/42
http://www.dropsa.com
TABLE OF CONTENTS
1. INTRODUCTION
2. GENERAL DESCRIPTION
3. PRODUCT-MACHINE IDENTIFICATION
4. TECHNICAL INFORMATION
5. MACHINE COMPONENTS
6. VERSIONS
7. UNPACKING AND INSTALLATION
8. INSTRUCTIONS FOR USE
9. PROBLEMS AND SOLUTION
10. MAINTENANCE PROCEDURE
11. DISPOSAL
12. ORDERING INFORMATION
13. DIMENSIONS
14. HANDLING AND TRANSPORTATION
15. OPERATING HAZARDS
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Vimodrone, MILANO (IT)
t. [phone]
Dropsa products can be purchased from Dropsa branches and authorized distributors,visit
www.dropsa.com/contactor contact us [email protected]

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1. INTRODUCTION
This User and Maintenance Manualrefer toDropsa’s“SMART3 “ Oil lubrication Pump for oil and fluid grease.
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 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
SMART3 is a compact and versatile electric gear pump package particularly suited for machine tool and work centre lubrication
systems using 33V injector systems.
The versatility of this product is thanks to a wide range of electric motors and the fact it is available with a Dropsa optical switch
that can work with both oil and fluid greases.
The lubrication cycle can be determined either externally by a host PLC or by selecting a model with the built in controller board
that will operate and monitor the system accordingly.
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.

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4. TECHNICAL INFORMATION
Note. The informationrefer to the temperature of use of +20°C (+68°F)
(1)
2800 rpmwith no load
* If a different or special lubricant product is used, please contact Dropsa to ensure its suitability.
4.1 HYDRAULIC SYSTEM
As illustrated, all pumps are
equipped with:
- An integrated by-pass for
pressure-regulating
- Arelief valve for pressure
- An electrical minimum level
- A lubricant charging filter
- A pre-calibrated pressure
switch
- Apressure gauge.
GENERAL INFORMATION
Empty weight
4.5 Kg
ELECTRIC INFORMATION
Motor power supply
110V –2p–50/60 Hz 140/175W- (2800/3500 rpm)
230V –2p–50 Hz 135 W- (2800 rpm)
230V –2p–60 Hz 170 W- (3500 rpm)
24 V DC - 55 W (1) - (2800 rpm)
OTHERS INFORMATION
Degree of Pump protection
IP 55
Pumping system
Gear pump
Pump flow rate (free flow)
180 cc/min @ 2800 rpm
220 cc /min @ 3500 rpm
Maximum working pressure
30 bar
Outlet connection
G1/8” BSP
Reservoir capacity
2L/3L
Minimum level –Float switch option, for oil only
With NC in case of liquid
Minimum level –DropsaOptiLev Optical sensing
system for oil and fluid greases.
NPN or PNP short-circuit protected signal, "off" in case of minimum
level
Filter
1000 µ filtering degree
By-pass
Adjustable 0÷30 bar –precalibrated25 bar
Pressure switch
10÷20 bar - precalibrated to 18 bar
Working Temperature
+ 5 + 60 C
Working Humidity
90 % rel. humidity
Permitted lubricants *
Mineral lubricating oil 32 cSt-320 cSt ;
Grease max NLGI000;
Storage temperature
-20 +80 °C
Sound Pressure Level
< 70 dB(A)
Max working time in continuous operation
1 min
MIN STANDBY time
5 times T-on
Dropsa recommends a 4 AMP overload fuse

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5. PUMP COMPONENTS
Following main components of the pump:
6. VERSIONS
6.1 MANUAL VERSION
This version is not equipped with an integrated control system. All control and
monitoring of the pump is done by an external control system or PLC. This is
typically the configuration used for Machine Tools factory fit.
The Pump is equipped with connection plate located under the pump cover
where all electrical connections are concentrated (motor, minimum level,
pressure switch). On the front face of the pump, there is a button to activate a
lubrication cycle manually. When pressed, the button closes a contact. This
signal is fed back to the external PLC control that will then run a lubrication
cycle.
The level and Pressure switch can be wired either in series or in parallel
depending on the choice of connector used by the host PLC which will
determine alarm or low-level condition that may be present.
PUMP COMPONENTS
1
Motor
2
Connector plate
3
Pump
4
Level indicator
5
Filling filter
6
Reservoir
7
Pressure/Outlet Manifold
8
By-pass adjustment screw
9
Clamping bracket
10
Pressure gauge
11
Plug
12
Control board
(for automatic versions)
1
2
3
4
5
6
7
8
9
11
10
12

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6.2 AUTOMATIC VERSION
The Automatic version of the pump is equipped with a built in electronic
controller that controls the pump and monitors feedback from the pressure
and level switches.
The control system settings and human interface is via the 16x2 character LCD
display on the front face and the 5 programming buttons. A Reset button is
located on the lower left side.
The Manual cycle button present on the Manual version remains but on the
Automatic version will cause the local built in control system to run a
lubrication cycle.
SMART3 automatic pumps can be programmed to operate withintermittent
lubricationcycle that involves the following three phases:
A) Prelube -> pre- lubrication when system is powered on
B) Lube (lube –wait) ->the lubrication cycle
C) Standby
A)PRELUBE
The pre-lube phaseallows the user to run a set number of lubrication cycles
(250 Max) when the pump is powered on. This typically is used when a
system needs additional quantities of oil on power up.
Prelube takes place:
-on POWER-ON;
-on RESET;
-Any time new parameters are set.
When prelube is set to “0”, the prelube phase is completed skipped and the
pump will work just with the normal lube and standby phases.
B) 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:
-Duringlube, system delivers lubricant to the
lubrication points;
-Duringwait, 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 two types of lube:
TIMER: The pump will simply run for the On time
and then enter standby mode;
PS: The pump will run until the pressure switch is made and pressure is maintained for a check period. Subsequently, the
pump will be switched off and the standby phase will commence.
C) 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.
For conditions of use and programming cycles see chapter 8.
Cycle
Start
Control
Delay
Wait
Lubrication Phase
Lubrication Cycle
Lubrication Cycle can be repeated up to
250 times.
Lubrication Phase can comprise of many Lubrication Cycles
PRELUBE
1
YES
RUN n
LUBE Cycle
NO
NORMAL
OPERATION
POWER ON
OR RESET

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6.3 SIMPLIFIED AUTOMATIC VERSION “Smart & Simple”
This version is designed to allow a very simple ON/OFF operation of the
pump for use in environments where simplicity is the key. The Smart3
“Smart&Simple” version has + / - keys to set the ON and standby timers of
the pump. No cycle monitoring is carried out. The display will indicate the
time setting for both ON and STANDBY timers.
The settable range for Cycle and Standby phases are:
ON TIMER:
1s –5min
OFF TIMER:
5 times ON TIME –99H 00min

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6.4 ELECTRICAL CONNECTIONS
6.4.1 Manual version
Following are different type of connectors and available signals:
TYPE 1
-FOR MANUAL VERSIONS WITH NC SERIES PRESSURE SWITCH ALARM*- 3133800
-FOR MANUAL VERSIONS WITH NO SERIES PRESSURE SWITCH ALARM*- 3133800
*APPLICABLE TO PUMP CODES:
4010000/4010100/4010200/4010300/4010400/
4010500/4010600/4010700
A(DIN43650)
B(DIN40050)
PIN
DESCRIPTION
PIN
DESCRIPTION
1
AC / DC POWER
INPUT
1
Voltage Free NC contact alarm
Pressure switch and Level
switch wired in Series
2
2
3
NOT USED
3
Push Button Contact
(Voltage Free)
4
Earth
4
FLOAT LEVEL NC
AND
PRESSURE SWITCH
NC SERIES
REMOTE
BUTTON
CONTACT
Open on
low level
Open on
pressure
Button
push
to made
*APPLICABLE TO PUMP CODES:
4010020/4010120/4010220/4010620/4010320/
4010420/4010520/4010720
A(DIN43650)
B(DIN40050)
PIN
DESCRIPTION
PIN
DESCRIPTION
1
AC / DC POWER
INPUT
1
Voltage Free NC contact alarm
Pressure switch and Level
switch wired in Series
2
2
3
NOT USED
3
Push Button Contact
(Voltage Free)
4
Earth
4
FLOAT LEVEL NC
AND
PRESSURE SWITCH
NO SERIES
REMOTE
BUTTON
CONTACT
Open on
low level
Close on
pressure
Button
push
to made

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TYPE 2
- FOR MANUAL VERSIONS WITH PRESSURE SWITCH SIGNAL AND OPTICAL LEVEL (N) *- 3133803
- FOR MANUAL VERSIONS WITH PRESSURE SWITCH SIGNAL AND OPTICAL LEVEL (P)* - 3133805
A(DIN43650)
C(M12X1)
D(M12X1)
PIN
DESCRIPTION
PIN
DESCRIPTION
PIN
DESCRIPTION
1
AC / DC
POWER INPUT
1
Push Button
Contact (Voltage
Free)
1
Level Sensor
Power supply +
2
2
2
Level Sensor
Power supply -
3
NOT USED
3
NOT USED
3
NOT USED
4
Earth
4
4
PNP Alarm
Output of level
5
PNP signal of
pressure switch
A (DIN43650)
C(M12X1)
D(M12X1)
PIN
DESCRIPTION
PIN
DESCRIPTION
PIN
DESCRIPTION
1
AC / DC
POWER
INPUT
1
Push Button
Contact (Voltage
Free)
1
Level Sensor
Power supply +
2
2
2
Level Sensor
Power supply -
3
NOT USED
3
NOT USED
3
NPN Alarm
Output of level
4
Earth
4
4
NPN signal of
pressure switch
5
NOT USED
*APPLICABLE TO PUMP CODES:
4010013/4010113/4010213/4010313/4010413/
4010513/4010613/4010713
Optilev
level
sensor
REMOTE
BUTTON
CONTACT
Button
push
to made
Open on
pressure
LEVEL
PNP
PRESSURE
SWITCH
PNP
REMOTE
BUTTON
CONTACT
Optilev
level
sensor
Button
push
to made
Open on
pressure
* APPLICABLE TO PUMP CODES:
4010015/4010115/4010215/4010315/4010415/
4010515/4010615/4010715
For4010225-4010525 pumps the PS is close on
pressure
PRESSURE
SWITCH
NPN
LEVEL
NPN
12V
24V
4
5
4
5

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TYPE 3
- FOR MANUAL VERSIONS WITH NC SERIES ALARM*- 3133801
- FOR MANUAL VERSIONS WITH NO SERIES ALARM*- 3133801
A(DIN43650)
D(M12X1)
PIN
DESCRIPTION
PIN
DESCRIPTION
1
AC / DC POWER INPUT
1
Common
2
2
Level alarm
3
NOT USED
3
Pressure Switch Contact
4
Earth
4
Push Button Contact
(Voltage Free)
5
*APPLICABLE TO PUMP CODES:
4010001/4010101/4010201/4010301/4010401/
4010501/4010601/4010701
Button
push
to made
Open on
low level
Open on
pressure
REMOTE
BUTTON
CONTACT
Button
push
to made
Open on
low level
Close on
pressure
A(DIN43650)
D(M12X1)
PIN
DESCRIPTION
PIN
DESCRIPTION
1
AC / DC POWER INPUT
1
Common
2
2
Level alarm
3
NOT USED
3
Pressure Switch Contact
4
Earth
4
Push Button Contact
(Voltage Free)
5
*APPLICABLE TO PUMP CODES:
4010621/4010721/4010021/4010121/4010221/
4010321/4010421/4010521
REMOTE
BUTTON
CONTACT
COMMON
LEVEL
ALARM
PRESSURE
SWITCH
CONTACT
COMMON
LEVEL
ALARM
PRESSURE
SWITCH
CONTACT

10
- FOR MANUAL VERSIONS WITH OPTICAL LEVEL (N) AND PRESSURE SWITCH IN SERIES*- 3133802
- FOR MANUAL VERSIONS WITH OPTICAL LEVEL (P) AND PRESSURE SWITCH IN SERIES*- 3133804
A(DIN43650)
D(M12X1)
PIN
DESCRIPTION
PIN
DESCRIPTION
1
AC / DC POWER
INPUT
1
Level Sensor Power supply +
2
2
Level Sensor Power supply -
3
NOT USED
3
NPN Alarm Output.
Level and Pressure switch
in series
4
Earth
4
Push Button Contact
(Voltage Free)
5
REMOTE
BUTTON
CONTACT
Button
push
to made
Open on
pressure
A(DIN43650)
D(M12X1)
PIN
DESCRIPTION
PIN
DESCRIPTION
1
AC / DC POWER
INPUT
1
Level Sensor Power supply +
2
2
Level Sensor Power supply -
3
NOT USED
3
PNP Alarm Output
Level and pressure switch
in series
4
Earth
4
Push Button Contact
(Voltage Free)
5
*APPLICABLE TO PUMP CODES:
4010012/4010112/4010212/4010612/4010312/
4010412/4010512/4010712
*APPLICABLE TO PUMP CODES:
4010014/4010114/4010214/4010314/4010414/
4010514/4010614/4010714
Button
push
to made
Open on
pressure
Optilev
level
sensor
REMOTE
BUTTON
CONTACT
OPTIC LEVEL N
AND
PRESSURE
SWITCH
NC SERIE
Optilev
level
sensor
OPTIC LEVEL
AND
PRESSURE
SWITCH
NC SERIE