DROPSA SUMO II Series Operating instructions

SUMO II PUMP
User and Maintenance Manual
Original text translation
Manual compiled in accordance with Directive C2248IE WK 03/17
CE 06/42
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 PROCEDURES
10. DISPOSAL
11. ORDERING INFORMATION
12. DIMENSIONS
13. HANDLING AND TRANSPORTATION
14. PRECAUTIONS
15. CONTRAINDICATIONS FOR USE
Dropsa products can be purchased from Dropsa branches and authorized distributors, visit
www.dropsa.com/contact or contact us [e-mail]
http://www.dropsa.com
Via Benedetto Croce, 1
Vimodrone, MILANO (IT)
t. [phone]

2
1. INTRODUCTION
This User and Maintenance Manual refer to Dropsa’s “SUMO II“.
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 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
The SUMO II series of lubrication pumps may be adapted to many uses without making any mechanical changes even after it has
been installed. In fact, by making a selection from a set of components which are fully compatible and easy to assemble, the
pressure, quantity of lubricant delivered, actual type of lubricant or type of distribution can be altered.
This construction technique is essentially based on the following modules:
•Electric motor
•Pump body with integrated reducer
•Two pumping elements
•Reservoir
•Valves and outlet unit (inverter, pressure adjustment valve, etc.).
There is only one bearing structure for all versions, with the dual pumping element constituting the essential module.
The pump unit possesses one single output, because the deliveries from the two pumping elements flow into a manifold unit.
Two types of tank for grease and two for oil with different volumes (of 30 or 100 kg) with stirring paddle and level indicators can
be arranged on the pump body.
The SUMO II electric pump is fully protected against the external environment and can operate without difficulty under the most
severe environmental conditions.
3. PRODUCT IDENTIFICATION
Machine identification label is located on the front side of the reservoir and
contains product serial number, input voltage and details of the operating
parameters.
380 cc/min

4. TECHNICAL CHARACTERISTICS
N.b. The specifications refer to the temperature of use of +20°C (+68°F)
(1) If a different product is used, please contact Dropsa S.p.A. to ensure it is suitable for use.
4.1 HYDRAULIC FUNCTION DIAGRAM
The hydraulic diagrams related to the different configurations that can be obtained using the available accessories are shown
below (see paragraph 11)
N.B.: do not supply the machine with voltages and pressures different from those indicated on the plate.
GENERAL CHARACTERISTICS
Empty weight (30 Kg reservoir)
85 Kg
Empty weight (100 Kg reservoir)
100 Kg
ELECTRICAL CHARACTERISTICS
Motor power supply 230-400V - ±5% 50Hz
280-480V - ±5% 60Hz
Rated motor power
0,75 Kw
Motor degree of protection
IP 55
Minimum level
Laser (grease) - floating (Oil)
Maximum level
floating (Oil and grease)
HYDRAULIC CHARACTERISTICS
Pumping system
Piston
Flow rate (per pumping element)
22.8 cu. in ( 190 cc/min )
Maximum operating pressures 5880 psi (400 bar)
Outlet connection
G3/8” BSP
Tank capacity
30-100 Kg (66-220 lb)
Loading filter
Degree of filtering 400 µ
By-pass
Adjustable 0÷400 bar – precalibrated 300 bar
Temperature of use
14 ÷122 °F (-10 ÷50 °C)
Operating humidity
rel. humidity 90 %
Permitted lubricants (5)
Mineral lubricating oil min 32 cSt; grease max NLGI2
Pumping system
- 40 ÷+ 149 °F (-40 ÷+65 °C)
Flow rate (per pumping element)
< 70 dB(A)

4
5. COMPONENTS
5.1 STANDARD PUMP COMPONENTS
5.1 FIXED DELIVERY PUMPING ELEMENTS
The pump has two fixed delivery standard pumping elements (200 cm^3/ min for each pumping element). The seal between the
piston and pumping element casing is dry, as the insertion of a gasket is not required.
The pumping element retention valve is of the tapered seal type. Questa soluzione consente di garantire un’ottima tenuta del
sistema alle alte pressioni di funzionamento (pressione max di 400 bar).
Pumping elements are mounted on the pump casing without the need to disconnect the line pipes with a threaded connection,
which makes assembly/disassembly easier.
STANDARD PUMP COMPONENTS
1
Minimum laser level
7
Pumping system
2
Maximum level
8
By pass
3
Reservoir
9
Pressure gauge
4
Ratio motor
10
Loading (for grease pump)
5
Delivery line 1
11
Minimum tank level (for oil pump)
6
Delivery line 2
12
Lubricant loading cap (for oil pump)
1
3
4
5
2
6
8
7
10
9
12
11

5.1.1 INVERTERS
For technical characteristics and procedures for use of inverters use the product-specific manual attached to the pump.
5.1.2 POMPANTI A PORTATA FISSA
The pump is set with one or two fixed flow rate pumping elements (190 cm^3/ min for each pumping element).
The sealing between piston and pumping body is of dry type, not being provided any gasket in between.
Pumping check valve is tapered seal type. This solution ensures excellent tightness of the system at high operating pressures
(max pressure 400 bar – 5800psi).
Pumping elements are fitted on the pump body without need to disconnect piping of the line with a threaded connection which
gives an easy assembly / disassembly.
5.1.2 MAXIMUM AND MINIMUM LEVEL FOR OIL AND GREASE
5.1.3.1 Minimum laser level for grease
When the lubricant reaches minimum level, the laser probe signals the lack of lubricant. The probe has two outputs, the first NO
and the second NC when lubricant is present.
For connections and calibration see paragraph7.3.1 and 7.3.2.
5.1.3.2 Maximum/ Minimum floating level for oil
A probe rod with dual float mounted on the pump cover provides a reading of the minimum oil level (reserve) and the maximum
level (which allows the automatic refilling of the tank to be halted).
For connections see paragraph 7.3.4.
5.1.3.3 Maximum visual floating level for oil/grease
The phase that the lubricant is loaded in the tank is realised by the operator, who uses a pump.
Once the maximum lubricant level is reached, a rod is activated that indicates that the tank is full.
5.2 ELECTRICAL CONTROL PANEL
“DROPSA” electrical control panel has been designed to provide a system complete with all the controls necessary for automatic
functioning controlled by safety signals from centralized lubrication installations. The primary voltage is 400 VAC and 50 Hz, the
other voltages are on request.
TYPE OF PROBE
TYPE OF
INVERTER*
VOLTAGE
V**
CODE ELECTRICAL
APPARATUS VIP5 PRO
CODE ELECTRICAL APPARATUS
VIP5 PLUS
CODE ELECTRICAL
APPARATUS WITH PLC
LASER PROBE or
FLOATING
(24V cc standard
version)
Out NO e NC
(1 threshold)
4/2
Electromagnetic or
hydraulic valve 24 VDC
1639211 1639210
1637008
4/2 Electro
pneumatic
hydraulic valve
1637011
LASER PROBE or
FLOATING
24V cc Out
4÷20mA/2 NO
(4 thresholds)
4/2
Electromagnetic
hydraulic valve 24 VDC
1637001
4/2 Electro
pneumatic
hydraulic valve
1637005
* For control equipment with 4/3 inverters contact the Dropsa Technical Sales.
** Contact the sales office Dropsa for other primary and the inverter supply voltages

6
6. UNPACKING AND INSTALLATION
6.1 UNPACKING
Once a suitable installation position has been identified, unpack the product and prepare for installation. It is important to
inspect the product to ensure that there has been no damage during transportation. The packaging material used does not
require any special disposal procedures. You should refer to you regional requirements.
6.2 INSTALLATION
No pump assembly operations are envisaged. The pump is fixed on a metal pallet, which allows safe handling using a
transpallet or forklift truck. This pallet has been designed so that it can be installed in the installation, being
equipped with 4 (four) holes of Ø 14 mm suitable for fixing to the floor. Provide adequate space (as shown on the
installation diagram) to avoid abnormal posture or possible impact. Then, as described previously, the pump must be
connected hydraulically to the machine and then connected to the control panel.
7. OPERATING INSTRUCTIONS
7.1 START-UP OF THE PUMP
Before using the product, a few preliminary checks must be performed:
•Check the integrity of the supply cable and the unit prior to use;
•If the supply cable or the unit is damaged, do not start up the system!
•Replace the damaged supply cable with a new one;
•The unit can be opened and repaired only by specialist personnel;
•In order to prevent the danger of electrocution due to direct or indirect contact with live parts the electric supply line must
be adequately protected by an appropriate magnetothermal differential switch with threshold of intervention of 0.03
ampere and max intervention 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 lubricants which are aggressive towards NBR gaskets, and if in doubt consult the Dropsa SpA technical office
which will supply a detailed list of the recommended oils;
•Do not ignore dangers to health and comply with health and safety regulations;
•Check the integrity of the pump.
•Check that the pump is at working temperature and that there are no air pockets in the pipes.
•Check that the electric connection has been carried out correctly.
•Once the pump has started, check that the direction of rotation of the electric motor is as indicated by the arrow on the
motor's protective casing; if it rotates backward; reconnect it as shown in the wiring diagram provided with the motor.
7.2 INSTRUCTIONS FOR USE
Press the start button on the machine to which the SUMO II pump is connected.
1) Check pump start-up.
2) To change the pressure value, turn the by-pass adjustment screw (see Chap. 5). Turn it clockwise to increase the pressure
or counter clockwise to decrease it;
3) Check that the machine is adequately lubricated (if there are still some doubts about its correct functioning you can contact
the Dropsa S.p.A Technical Office and request a test procedure).
The interruption power of the switch must be ≤10 kA and rated current In =6 A.
Warning! All the electric components must be earthed. This applies to both the electric components, and to the control
devices. To this end make sure that the earth wire is connected correctly. For safety reasons the earth conductor must be
approximately 100 mm longer than the phase conductors. If the cable is accidentally removed, the earth terminal must be the
last one to be removed.

7.3 ADJUSTMENT/ CALIBRATION OF LEVEL PROBES
7.3.1 LASER PROBE SETTING 0295131, 24V cc Out NO and NC (1 threshold)
1. Reference notch
2. Yellow led: lights when the set value is reached, (outlet=ON).
3. Lock ring
4. Setting lock ring (be adjusted manually after unlocking).
5. Green led: indicates the correct power supply (24V cc).
* To obtain a correct setting bring the lock ring to maximum setting value and then down to desire value.
On the pump is placed a label that shows the wiring diagram and setting values. The pump is normally equipped with pre setting
sensor to "L" thresholds (minimum level). Whereas other thresholds: MM (absolute maximum level), M (absolute level), LL
(absolute minimum level), can be set
7.3.3 Procedure for calibrating the laser probe 24V cc Out 4÷20mA/2 NO (4 thresholds)
The laser probe possesses a representative and programming display mounted on board. It is possible to operate in analogue
mode (with signal from 4 to 20 mA) or in digital mode (two outputs and four intervention thresholds).
We attach a table showing the calibration parameters for the laser probe.
7.3.4 Collegamento galleggiante REED 0295150/0295160
Image 6
LASER PROBE CALIBRATION
100 kg reservoir
30 kg reservoir
Pos.
Level
Output
signal
set-up
height X
[mm]
Quantity of
grease [kg]
height X
[mm]
Quantity of
grease [kg]
A
Maximum
absolute level
OUT 2= Fno
nsP2
220
90
220
23
C
Minimum level
fsP2
300
17
490
5
B
Maximum level
OUT 1= Fno
nsP1
250
86
250
21
D
Minimum
absolute level
fsP1
330
14
520
3
NOTE: To change calibration thresholds of laser and ultrasound probes contact DROPSA staff
Attention you can only set one thresholds at a time

8
8. PROBLEMS AND SOLUTIONS
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 discovered anomalies, with a detailed description.
PROBLEM
POSSIBLE CAUSE
REMEDIAL ACTION
The electric pump is not
delivering any lubricant.
The electric motor is not functioning.
The tank is empty.
The pump is not triggered. Causes of the pump’s
failure to trigger:
•The motor is turning in an inverted direction
(clockwise);
•The motor is turning in the right direction but the
stirring paddle is not turning;
•Presence of air bubbles in the lubricant.
The pressure adjustment valve (bypass) has been
calibrated at too low a value
Presence of dirt in the non-return valve.
Check the connection between motor and electric supply
line.
Check the motor winding.
Check that the connection plates for the motor terminal
box are positioned in accordance with the supply voltage.
Fill the tank.
N.B.: If the tank was emptied without the electric signal
for reaching the minimum level being given, the minimum
level contact must be checked.
Remove the cover from the tank and check that the
stirring paddle is turning anticlockwise and that the
lubricant is moving; if not invert two of the three motor
phases.
See above.
Remove the pump delivery pipe and drain off the
lubricant until the air bubbles have been eliminated.
The pump will not go
under pressure.
Possible dirt on the cone of the pump stop valve
Clean the cone and the pumping element stop valve
housing, draining off the lubricant.
Replace the gasket (code 3190489).
No signal indicating
minimum level when
there is no lubricant in
the tank.
Incorrect adjustment of minimum level.
Check the correct functioning of the level probe in the
following way:
Dismantle the minimum level unit and recalibrate the
capacitive probe.
Selection of minimum
level, with lubricant
below the minimum and
pump working.
Incorrect adjustment of minimum level.
The light on the control panel is still on: check the electric
connection and, if necessary, replace the capacitive
probe.
9. MAINTENANCE PROCEDURE
The pump was designed and built in order to minimise 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 loading 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 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.
ATTENTION: The unit may only be opened and repaired by authorised Dropsa personnel.
ATTENTION:
Make sure that the electric and hydraulic power supplies are disconnected before carrying out any
maintenance work.

11. ORDERING INFORMATION
11.1 STANDARD VERSION
N.B. The part number of the pump is composed by 7 numbers. Numbers 8, 9 e 10 must be used only for additional options.
Standard
Data base
4°
5°/6°
7°
8°
9°
10°
11°
SUMO II PUMP
245
0
00
0
0
0
0
0
Description
DROPSA P.No.
CODE
Reservoir
-
-
0
30kg
0295080
1
100kg
0295090
2
Triphase electric
motor
MOTOR NOT PRESENT
-
00
STANDARD IE3
2230/400V 50Hz - 280/480V 60Hz
3301081 01
440 V 60 Hz
3301650
02
440 V 60 Hz with anti-condensation heater 110V AC
3301651
03
460 V 60 Hz
3301652
04
575 V 60 Hz
3301653
05
500 V 50 Hz
3301654
06
525 V 50 Hz
3301655
07
550 V 50 Hz
3301656
08
380 V 60 Hz
3301659
09
UL and CSA standard with IE3 230/ 400V 50 Hz -
280/480V 60Hz
3301528 50
440 V 60 Hz
3301670
51
460 V 60 Hz
3301671
52
460V 60Hz standard with anti-condensation heater
3301556
53
575 V 60 Hz
3301672
54
500 V 50 Hz
3301673
55
550 V 50 Hz
3301674
56
UL and NEMA standard 230/460V 60 Hz
On request
80
Pneumatic motor
3301539 95
Inverter NOT PRESENT - 0
4/3 Valve
Electromagnetic
24 V DC 0083550 1
4/2
Electromagnetic
inverter
24 V DC 0083560 2
4/2 electro
pneumatic
inverter
24 V DC 0083580 3
Hydraulic inverter
0086450 4
Optional
Minimum Level
Laser level standard 24V cc Out NO e NC (1 threshold) 0295131 0
Laser with 2 outlets digital configurable and 4÷20mA
0295130
1
*Float Reed for oil 30kg
0295150+3130138
2
*Float Reed for oil 100kg
0295160+3130138
3
Maximum Level
Floating visual level
0295100
0
Laser 24V cc Out NO and NC (1 threshold)
0295131
(for 30kg and 100kg)
1
Heating Band
Heating Band NOT PRESENT
-
0
100 kg Pump Heating Band
0295065
1
30 kg Pump Heating Band
0295066
2
The pump is equipped with 2 pumping elements with
fixed flow rate
0296080
0
Pumping elements
1 pumping element with fixed flow rate
0296080+0295049
+3190489-
3190491
1
* The oil floating level indicate both minimum and maximum level
For special versions (e.g. version with separate outlets) contact our DropsA Technical Sales Department.

10
11.2. OPTIONAL
Equipment
Description
Variant
P. No.
Oil conversion
Min/max oil level float kit 30 Kg (66lb)
Min/max oil level float kit 100 Kg (220lb)
Filling plug with filter
0295150
0295160
3130138
Terminal Box bracket
Bracket for installing a terminal wiring box onto the base pallet
3044455
Terminal
Terminal box
0291655
Electrical control box Bracket
Bracket for installing a control box onto the base pallet
3044456
Metal pallet
Metal Pallet used as the base of the packaging and also for
installation of the pump.
0297150
11.3. SPARE PARTS
Spare part description Variant P.No.
Motors
3Ph - 0,75 Kw IE3- 230Δ/400Y 50Hz
280Δ/480Y 60Hz
3301081
3Ph UL and CSA - 0,75 Kw IE3- 230
Δ
/400Y 50Hz
- 280Δ/480Y 60Hz
3301528
Reducer i=40
3301608
Maximum mechanical level kit meccanico 30 e 100 Kg (grasso)
0295100
Laser probe assembly 30÷100 Kg - 24V cc Out NO e NC (1 threshold)
0295131
Laser level kit 24V cc Out 4÷20mA/2 NO (4 thresholds) – 30 Kg
VAR2
0295130
Laser level kit 24V cc Out 4÷20mA/2 NO (4 thresholds) – 100 Kg
VAR3
Minimum level kit (250V AC) 30 kg (grease)
0295121
Minimum level kit (250V AC) 100 kg (grease)
0295122
Grease loading filter
0295009
By-pass
0234815
Pressure gauge 0 - 600 Bar
3292171
Pumping
0296080C
Metal pallet
0297150
0295130
0295131
0295100
0295009
0296080C
3292171
0234815
3190485
0297155

12. DIMENSIONS
30 Kg
100 Kg
mm
in
mm
in
A
533.5
21
983
38.7
B
1084
42.67
1534
60.39
C
984
38.74
1434
56.45
D
313
12.32
413
16.25

12
13. HANDLING AND TRANSPORT
A metal pallet is used for transport and storage with packing at the side and a wooden cover.
The pump is fixed on a metal pallet, which allows safe handling using a transpallet or forklift truck. The metal pallet has been
designed so that it can be installed in the installation, being equipped with 4 (four) holes of Ø 14 mm suitable for fixing to the
floor.
14. PRECAUTION
The warnings about the 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 pressurised 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 equipment, 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.
Power supply
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.
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
Before each operation, make sure there in every branch of the lubrication circuit that there is no residual pressure 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 pressurised 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.
GREASES
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.
NOTE: The pump was designed to operate with lubricants with a maximum rating NLGI 2.
Use lubricants that are compatible with NBR gaskets.
Any internal residual lubricant used for assembly and testing purposes is NLGI 2 grease.
Lift the equipment according to the direction shown on the cardboard package.
The machine components can support storage temperatures between -40 a + 65 °C (-40÷149F); however in order to avoid
damages, the machine must only be started up after the machine has reached a temperature of -10 °C (+14F).

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.
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. CONTRAINDICATIONS FOR USE
The check on compliance with the essential safety requirements and with the stipulations indicated in the machine directives
are to be carried out by means of compiling the checklists already made available and contained in the technical file.
Three types of lists were used:
•list of dangers (section from EN 414 relating to EN 292)
•Application of the essential safety requirements (Machine Dir. – 06/42)
•electrical safety stipulations (EN 60204-1)
See below a list of dangers which have not been completely eliminated, but are considered acceptable:
•During assembly/maintenance it is possible that there may be an oil splash (consequently this operation must be carried out
using appropriate individual protective devices);
•contact with oil -> see instructions for using appropriate individual protective devices DPI;
•Use of an inappropriate lubricant -> fluid characteristics indicated both on the pump and in the manual (if in doubt consult
our Technical Office);
•protection against direct and indirect contact must be provided by the user;
•whenever the cover is opened for an intervention resealing the catch is essential;
•The pump’s working logic requires it to operate at all times, so it is necessary to pay attention to the electric connection. If
there is no current the customer’s machine can only be restarted following a reset while the lubrication pump can restart
automatically.
FLUIDS EXPLICITY NOT ALLOWED
Fluid
Fluid
Lubricants with abrasive additives
Lubricants with abrasive additives
Lubricants with silicone based additives
Lubricants with silicone based additives
Petrol – solvents – inflammable liquids
Petrol – solvents – inflammable liquids
Corrosive products
Corrosive products
Water
Water
Food substances
Food substances
* For more detailed information regarding product compatibility with particular fluids, contact the Dropsa S.p.A. technical office
NLGI
ASTM
000
445 – 475
00
400 – 430
0
355 – 385
1
310 – 340
2
265 – 295