DROPSA Sumo Operating instructions

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Sumo Pump
Modular electric pump
User and Maintenance Manual
Original text translation
Manual compiled in accordance with Directive C2116IE WK 44/16
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
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 [email protected]m

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1. INTRODUCTION
This user and maintenance manual relates to the Sumo pump. Using this pump means that oils and greases can be distributed
within lubrication systems even at high pressures of up to 400 bar (5880 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 Sumo 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 pump is controlled by normal electrical apparatus which is able to effect inversion and perform the programmed cycles.
The Sumo electric pump is fully protected against the external environment and can operate without difficulty under the most
severe environmental conditions.
Photo 1
Sumo 100 kg
Sumo 30 kg
Photo 2

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2.1 TROLLEY MOUNTED VERSION
Sumo Pump trolley mounted 30 Kg metal reservoir; the system is complete with electrical control equipment that allows the
pump motor control when the pressure exceed provided or in case of malfunction of the lubrificant system distribution.
Sumo Pump 30 kg trolley mounted

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2.2 TRANSPARENT RESERVOIR VERSION
Sumo Pump 80 Kg with transparent reservoir made of polyethylene for special applications.
E
A
B
C
D
E
F
780
734
630
580
1410
Ø335
A
B
C
D
E
F
PLASTIC GREASE
RESERVOIR
148,5
Ø14
DISTANCE BETWEEN HOLES
WITHOUT PALLET
N° 4 HOLES Ø13 a 90° BETWEEN THEM ON Ø210
100
606,5

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3. PRODUCT IDENTIFICATION
On the front part of the pump tank there is a plate which indicates the product code, the supply voltage and the basic
characteristics.
4. TECHNICAL CHARACTERISTICS
The pump consists of a series of components with the following characteristics:
4.1 HYDRAULIC FUNCTION DIAGRAM
Technical characteristics
Max. pressure
400 bar
Outlet delivery
400 cm3/ min (24 cu. in/min)
(2 x 200 cm3(12 cu. in) pump modules )
Working temperature
da - 5° C a + 50° C (da 23° F a +122° F)
Working humidity
90% max
Mineral oil lubricants
Viscosity at working temperature
Min. 32 cSt
Grease lubricants
Viscosity at working temperature
NGLI 2 Max.
Degree of protection
IP 55
Electric motor
Three phase
Power 0.75kW
Protection IP55 class B
Voltage: 230-400 Volt ± 5% 50 Hz
280-480Volt ± 5% 60 Hz
S1 continuous service.
N.B.: do not supply the machine with voltages and pressures different from those indicated on the plate.
STANDARD GREASE PUMP (DUAL LINE)
Hydraulic diagram SUMO grease pump (30 and 100 Kg) –dual line
POMPA STANDARD OIL PUMP (DUAL LINE)
Hydraulic diagram SUMO oil pump (30 and 100 Kg) –dual line
Max. visual level
indicator
Manifold group
Refilling oil cap with
filter 10 µm
Min./max float
level indicator
Electromagnetic
switch
P/N 0083420
Connection
1/2" BSP
Connection
3/8" BSP
Line 1
Line 2
Min. level indicator
NO or NC
Electromagnetic
switch P/N 0083420
Connection
1/2" BSP
Grease
refilling
Connection
3/8" BSP
Line 1
Line 2
Manifold group
Max. visual
level indicator

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STANDARD GREASE PUMP (OPTIONS: DUAL LINE,
ELECTROPNEUMATIC INVERTER)
Hydraulic diagram SUMO grease pump (30 and 100 Kg) –dual line
POMPA STANDARD OIL PUMP (OPTIONS: DUAL LINE,
ELECTROPNEUMATIC INVERTER)
Hydraulic diagram SUMO oil pump (30 and 100 Kg) –dual line
Min. level indicator
NO or NC
Electropneumatic
switch P/N 0083450
Connection
1/2" BSP
Grease
refilling
Connection
3/8" BSP
Line 1
Line 2
Manifold group
Max. visual
level indicator
Max. visual level
indicator
Manifold group
Refilling oil cap with
filter 10 µm
Min./max float
level indicator
Electropneumatic
switch P/N
0083450
Connection
1/2" BSP
Connection
3/8" BSP
Line 1
Line 2
SINGLE OUTLET GREASE PUMP (option)
Hydraulic diagram SUMO grease pump (30 and 100 Kg) –Single line
SIGLE OUTLET OIL PUMP (option)
Hydraulic diagram SUMO oil pump (30 and 100 Kg) –Single line
Min. level indicator
NO or NC
Connection
1/2" BSP
Grease
refilling
Connection
3/8" BSP
Single line
Manifold group
Max. visual
level indicator
Max. visual level
indicator
Manifold group
Refilling oil cap with
filter 10 µm
Min./max float
level indicator
Connection
1/2" BSP
Connection
3/8" BSP
SINGLE LINE
Plug
3/8" BSP

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5. COMPONENTS
5.1 FIXED DELIVERY PUMPING ELEMENTS
The pump has two fixed delivery standard pumping elements (200 cm^3/ min for each pumping element). A piston slides inside
the body of the pumping element coupled to the latter by a lapping process. The seal between the piston and the pumping body
is of a dry type, with no gasket provided between the two. The pumping element retention valve is of the tapered seal type. This
solution is able to guarantee an optimum seal for the system at high operating pressures (max. pressure of 400 bar). The
pumping elements are assembled on the manifold unit with a threaded attachment, which facilitates its assembly/ dismantling.
5.2 ENDLESS SCREW / WORM WHEEL UNIT
The pump has endless screw-worm wheel working kinematics with a transmission ratio of 1/40. The screw is made from special
steel with high mechanical resistance, which gives it optimum flexible rigidity. To guarantee high resistance to wear, the screw
has been subjected to Tenifer wear-resistant treatment. The screw is supported by oblique contact ball bearings, duly
preloaded, to reduce working clearance. The worm wheel is made of bronze alloy for gear systems, particularly suitable for
making the pump run quietly. The worm wheel shaft is made of special high resistance steel which gives the pump better
reliability and durability.
5.3 INVERTORS
CODE
DESCRIPTION
Series 0083420
Interchangeable electromagnetic inverter (mounted as standard on SUMO pump
Series 0083400
Electromagnetic inverter
Series 0083450
Electropneumatic inverter
SPARE PARTS
Code
Description
Current (A)
Power (W)
3150011
Electromagnet 24V DC
7
170
3150012
Electromagnet 110V AC 50/60 Hz
2
206
3150013
Electromagnet 230V AC 50/60 Hz
1
176
3133262
Seal kit
5.3.1 Interchangeable electromagnetic inverter (code 0083420 mounted on standard pump)
The standard pump is prepared for dual line function, with an electromagnetically controlled inverter being assembled as
standard. The inverter can be replaced if it is not working efficiently, without disconnecting the two line pipes (of an
interchangeable type). This is able to reduce maintenance times and the relating installation shutdown.
This version means that the inverter can be replaced without
disconnecting the line pipes. A solution of this type offers the
following advantages:
Ease of assembly and dismantling (only the 4 front Allen
screws need to be loosened and tightened);
Short replacement time;
Minimum installation shutdown time.
GENERAL NOTE FOR ALL INVERTERS: It is advisable to plan a delay in the de-energizing of the
electromagnets from 2 ÷ 5 sec. to allow complete inversion in relation to the closing time of the pressure
gauge at the end of the line.
Photo 3

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5.3.2 Electromagnetic inverter (code 0083400 option)
The main parts of the inverter are:
A body with a central lapping hole which allows the
dry seal to be coupled to the inversion piston;
a ground piston with a dual coupling surface, with
openings which are able to improve lubrication and
seal at high pressures;
the inversion phase is facilitated by the presence of a
balancing system;
by seal gaskets manufactured to sustain high
pressures, via a pressure chamber, optimising the
inverter operations;
two control electromagnets equipped with a thermal
probe with an intervention temperature of 100°C
(protecting the coils from overheating).
5.3.3 Electropneumatic inverter (code 0083450 option)
Photo 5
The main parts of the device are:
See point 5.3.2;
two simple effect pneumatic actuation cylinders,
controlled by a 5/ 2 type electrovalve.
Spare electrovalves
Code
Description
3155154
Solenoid 24V DC
3155155
Solenoid 24V AC 50/60 Hz
3155156
Solenoid 110V AC 50/60 Hz
3155157
Solenoid 230V AC 50/60 Hz
Photo 4

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5.4 PRESSURE CONTROL VALVE MOUNTED ON THE PUMP
Pump group unit
The pump has a pressure control valve, mounted on the
manifold unit on the right side of the pumping
elements. It is calibrated by turning the bypass pressure
adjustment nut:
clockwise (increase of pressure)
anticlockwise (decrease of pressure)
Once the bypass has been calibrated, the position of the
pressure adjustment nut is locked using a lock nut. It is
important to bear in mind that line inversion is
controlled by closing the contacts of the pressure
switch. Adjusting the pressure switch provides an
operating pressure which is lower than the maximum
pressure controlled by this valve.
Photo 6
5.5 MAXIMUM AND MINIMUM GREASE LEVEL INDICATORS
Standard grease pumps have two types of level:
Minimum capacitive level;
Maximum visual level (float).
5.5.1 Minimum laser level
The minimum level is produced by a laser probe. The capacitive probe is normally closed when it reaches the minimum level the
probe indicates a lack of lubricant. The minimum level contact is indicated by a light signal on the control panel. In addition it
controls any command for the pump to automatically refill the tank.
5.5.2. Maximum visual level (floating)
The phase for loading the lubricant into the tank is carried out by the operator, with an appropriate pump. Once the maximum
level of lubricant has been reached, the small rod which indicates that the tank is full intervenes.
5.6 INDICATORS OF MINIMUM AND MAXIMUM OIL LEVE
Standard oil pumps have two types of level:
Minimum and maximum level float;
Maximum visual level (float).
5.6.1 Minimum and maximum level float
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).
The minimum level contact is indicated by a light signal on the control panel. In addition it controls any command for the pump
to automatically refill the tank
5.7 STIRRING PADDLE FOR GREASE AND OIL (STANDARD PERFORMANCE)
Four tanks are provided with a capacity of 30 and 100 kg. (22 –66.1 –220.4 lb) two for oil and two for grease.
The tanks have a stirring paddle and scraper as standard, and they must not be dismantled when they are being assembled and
replaced. Under the stirring paddle a galvanized steel mesh with 0.5 mm holes (0.02 in.) is provided as standard. In this way the
pump is protected from any foreign bodies which might be inadvertently present during the tank refilling process.
5.8 PRESSURE GAUGE
The pressure gauge is of the glycerine filled type, so it is protected from any pressure leaks which might damage its functioning.
It is mounted directly in the manifold group (positioned on the front of the pump).
5.9 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.
Extractible pumping elements
Bypass pressure
adjustment
Photo 6

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* Contact the sales office Dropsa for other primary and the inverter supply voltages
6. UNPACKING AND INSTALLING
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 GOING INTO OPERATION
Damage to the supply cable and housing may involve contact with live parts at high voltage and consequently fatal danger:
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 power supply
line must be suitably protected by a specific differential magnetothermic switch, according to regulations and with rated
breaking capacity at list equal to prospective fault current at installation point.
The pump must not be used when submerged in fluids or in a particularly aggressive or explosive/inflammable atmosphere
unless prepared in advance for this purpose by the supplier;
to fix the pump correctly check the pitch dimensions shown in the figures in chapter 12;
Use safety gloves and goggles as indicated in the safety sheet for the lubrication 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;
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.
7.2 ACTION TO BE TAKEN BEFORE START-UP
Check the integrity of the pump.
Refill the tank with suitable lubricant.
Check that the pump is at working temperature and that there are no air bubbles in the pipes.
Check that the electric connection has been carried out correctly.
7.3 USE
WARNING: The unit is only to be opened and repaired by specialist personnel.
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
(24V cc standard)
Out NO e NC
(1 threshold )
Electromagnetic
24 VDC
1639211
1639210
1637008
110 VAC
*
*
1637009
220 VAC
*
*
1637010
Electro pneumatic
24 VDC
1639211
1639210
1637011
110 VAC
*
*
1637012
220 VAC
*
*
1637013
LASER PROBE
24V cc Out 4÷20mA/2 NO
(4 thresholds )
Electromagnetic
24 VDC
1639211
1639210
1637001
110 VAC
*
*
1637003
220 VAC
*
*
1637004
Electro pneumatic
24 VDC
1639211
1639210
1637005
110 VAC
*
*
1637006
220 VAC
*
*
1637007

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Check the data sets imposed.
Press the start button on the machine to which the Sumo pump is connected.
Check pump start-up.
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).
check that the direction of rotation of the electric motor is the one indicated by the indicator arrow, positioned on the
protective housing of the motor fan;
Check that the hydraulic connection is correct.
7.4 ADJUSTMENT/ CALIBRATION OF LEVEL PROBES
7.4.1 Pressure
It is possible to adjust working pressure by rotating the bypass screw clockwise to increase pressure or anticlockwise to reduce
pressure. During this operation pay attention to the pressure gauge positioned on the edge of the pump.
7.4.2 LASER PROBE SETTING, 24V CC OUT NO E 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 by the user.
7.4.3 Procedure for calibrating the capacitive probe (optional)
Before being assembled the capacitive probe must be calibrated in accordance with the following sequence:
1. connect the sensor electrically;
2. immerse the sensor in the lubricant, down to half of its length;
3. remove the sensor from the lubricant until it skims the surface of the lubricant;
4. at this point there can be two possible types of operation:
-the sensor status does not change: its sensitivity must be reduced (by acting on the screws for adjusting sensor
sensitivity) until its state of excitation is reached
-if its status changes, the sensor already possesses the correct sensitivity
5. after checking that the sensor has been correctly read, the sensor reading must be repeated at least three times
6. Tighten the capacitive probe on the probe carrier rod, complying with the following assembly height:
-450 mm (from below the cover up to the lower surface of the sensor) for a 30 kg tank
-900 mm (from below the cover up to the lower surface of the sensor) for a 100 kg tank.
ATTENZIONE: è possibile impostare solo una soglia alla volta.

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Operating instructions for the capacitive probe (model Sc30sp-a20 no)
Sensors in version with alternate current (2 wires)
These are amplified sensors AC. In this version, the standard characteristics of the sensors
include protection against permanent load short circuit, and protection against the peaks
produced when the inductive loads are disconnected.
7.4.4 Procedure for calibrating the laser probe
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, for 30 and 100 kg tank.
Image 6
LASER PROBE CALIBRATION
30 kg tank
100 kg tank
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
23
220
90
C
Minimum
level
fsP2
490
5
850
17
B
Maximum
level
OUT 1=
Fno
nsP1
250
21
250
86
D
Minimum
absolute
level
fsP1
520
3
880
14
N.B.: In the 30 kg pump tank at minimum absolute level there is still a reserve of 3 kg.
In the 100 kg pump tank at absolute minimum level there is still a reserve of 22 k.g
20 ÷ 250 V AC
I= 500 mA
YELLOW/GREEN
BLUE
BROWN
SENSITIVITY
ADJUSTMENT
LED
CABLE
SENSOR (BACK VIEW)

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Operating instructions for the IFM laser probe model O1D100 (code 3289172)
Image 7
Instructions for calibrating the Laser Probe O1D100
Rotate the wording on the Display by 180°.
1. Press the MODE ENTER key 7 times: EF. appears on the Display.
2. Press the SET key.
3. Press the MODE ENTER key 5 times: diS. appears on the Display.
4. Press the SET key. d3. appears on the Display.
5. Keep the SET button pressed down for 5 sec.
6. When the wording on the Display no longer flashes, press SET once.
7. rd1. appears on the Display.
8. Press MODE ENTER once.
9. Check that the Display wording has rotated by 180°.
Calibrate outlet 1 (OUT 1) operating with window nsP1 (B) & fsP1 (D) (see Calibration table for Laser probe)
1. Press the MODE ENTER key once: OU1 appears on the Display.
2. Keep the SET button pressed down for 5 sec.
3. When the wording on the Display no longer flashes, press SET twice until Fno appears on the Display.
4. Press the MODE ENTER key once: nsP1 appears on the Display.
5. Keep the SET button pressed down for 5 sec.
6. When the wording on the Display no longer flashes, press SET once.
7. The value of the height read appears on the Display.
8. Press the SET button until the desired height appears.
9. Press the MODE ENTER button once and the height set is memorised.
10. Press the MODE ENTER key once: fsP1 appears on the Display.
11. Repeat the previous points from N° 5 to N° 9.
Calibrate outlet 2 (OUT 2) operating with window nsP2 (A) & fsP2 (C) (see Calibration table for Laser probe)
1. Press the MODE ENTER key once: OU2 appears on the Display.
2. Keep the SET button pressed down for 5 sec.
3. When the wording on the Display no longer flashes, press SET 4 times until Fno appears on the Display.
4. Press the MODE ENTER key once: nsP2 appears on the Display.
5. Keep the SET button pressed down for 5 sec.
6. When the wording on the Display no longer flashes, press SET once.
7. The value of the height read appears on the Display.
8. Press the SET button until the desired height appears.
9. Press the MODE ENTER button once and the height set is memorised.
10. Press the MODE ENTER key once: fsP2 appears on the Display.
11. Repeat the previous points from N° 5 to N° 9.
Applications
The optical distance sensor
measures distances between 0.2 and 10 m.
•It has a background suppression at > 10..19 m.
•The measured value is shown in a 10-segment display.
•According to the set output functions 2 output signals can be generated.
•O1D100: Certification 21 CFR PART 1040
Operating and display elements
Functions
4.1 Output function hysteresis
The hysteresis keeps the switching state of the output stable if the measured
value varies about the sensing range. Both outputs (OUT1 and OUT2) can be
set as hysteresis function. → 10.2.4 Hysteresis function
4.2 Output function window
The window function enables the monitoring of a defined acceptable range.
Both outputs (OUT1 and OUT2) can be set as window function.
→ 10.2.6 Window function
4.3 Analogue output function
The sensor can also output an analogue signal on output 2 (OUT2) which is
proportional to the distance. → 10.2.11 Scaling of the measuring range
(analogue output).
Electrical connection

14/ 22
7.4.5 Procedure for calibrating the ultrasound probe model ZWS-70/CI/QS (code 3289173)
Before being assembled the probe must be calibrated in accordance with the following sequence:
1. electrically connect the sensor (following the electric diagram shown below);
2. keep the sensor button pressed down until the two LED (green and yellow lights) flash together;
3. position it in front of the minimum absolute level to be read, entering the height by releasing the button (the two LEDs
display a fixed light);
4. press the button for 3 or 4 seconds (the probe has acquired the Minimum absolute level);
5. keep the sensor button pressed down until the two LED (green and yellow lights) flash together;
6. position it in front of the maximum absolute level to be read, entering the height by releasing the button (the two LEDs have
a fixed light);
7. press the button for 3 or 4 seconds (the probe has acquired the Maximum absolute level);
8. In this way the sensor is calibrated.
N.B.: green Led on indicates that the probe is supplied. Yellow Led on indicates operating mode for reading.
We attach a table with the calibration parameters for the ultrasound probe, for 30 and 100 kg tanks.
Image 8
Calibration of ultrasound probe
Pos.
30 kg tank
100 kg tank
Level
Output
signal
height X
[mm]
Quantity of
grease [kg]
height X
[mm]
Quantity of
grease [kg]
A
Maximum
absolute
level
Threshold
1
110
25
110
92
B
Minimum
absolute
level
threshold
2
490
3
930
4
Photo 9
Image 9
N.B.: In the 30 kg pump tank at the minimum absolute level there is still a reserve of 7 kg.
In the 100 kg pump tank at the minimum absolute level there is still a reserve of 15 kg.
Green LED: status indicator.
Signals that the sensor is powered.
Yellow LED: function indicator.
Report the output status (On/Off).

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Re-setting to factory settings:
START
Remove power.
END
Release the button.
Press and hold the button while power is applied.
(both LED flashing simultaneously)
Press the button for about 13 sec. while the green LED is constant.

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8. TROUBLESHOOTING
Below is a diagnostic table showing the main faults, the probable causes and the possible solutions.
In the event of doubts and/or problems which cannot be solved, do not proceed to look for the fault by dismantling parts of the
machine, but contact the Dropsa Technical Office.
Fault
Cause
Solution
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
Internal gasket between pumping element and
manifold unit broken.
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.

17/ 22
Lubrication installation accessories
METERING UNIT AG6
Alarm signal indicating
non-delivery of
lubricant. The small rods
visible inside the
metering unit turrets
must move sequentially
up and down and
activate the control
microswitch when the
pump is working. If this
is not the case the two
outlets or the single
outlet of that metering
unit will not deliver
lubricant.
Metering unit small piston jammed.
Piping between metering unit outlet and point
requiring lubrication obstructed.
Pressure on the line too low (the lubricant is not
delivered by any outlet or only by a few outlets).
Metering unit arranged for two outlets by used for
only one outlet.
Replace the metering unit with another one
having the same characteristics. However it is
advisable to make sure that the metering units
have been correctly assembled, particularly
with regard to fixing. Over-locking of the fixing
screws may damage the metering unit and
cause the small piston to jam.
Remove the outlet pipe and check to see if the
metering unit is delivering lubricant.
Change the pressure control valve adjustment
(bypass) or the adjustment of the control
pressure gauge (and of line).
Check that, when one single outlet is used, the
right pad is assembled and that the other
outlet is sealed.
See instruction sheet for AG6 metering units.
END OF LINE PRESSURE
GAUGE
The pressure gauge is
not sending the signal to
the electric command
and control panel.
The pressure gauge
sends the signal before
the end of the
lubrication cycle.
Electrical connection incorrect.
Incorrect adjustment of the control pressure
gauge. The pressure value set is too high and the
pressure adjustment valve (bypass) intervenes
before the pressure gauge can be activated.
Incorrect adjustment of the control pressure
gauge. The pressure value set is too low.
Check the electrical connection.
Reduce the pressure gauge calibration pressure
until an electrical contact is obtained.
Increase the pressure gauge calibration valve.
The optimum calibration value is the one which
allows a pressure of 50-70 bar (735 –1029 psi)
at the end of the lubrication line.
9. MAINTENANCE PROCEDURES
Use the individual protective devices needed to avoid contact with mineral oil or grease.
Regular inspection
The following regular checks must be carried out:
the lubrication status
1000 hours
Cleanliness of the loading and suction filter
4000 hours
The machine does not require any special equipment for any checking and/or maintenance activity, however the
recommendation is to use suitable equipment which is in a good condition in order to avoid causing damage to persons or
machine parts (according to current regulation).
If necessary clean the tank paying due attention (when the machine is off and without it being possible to restart it). Remember
to reseal the tank once the operation has been completed.
Make sure that the electric and hydraulic supply has been disconnected before carrying out any maintenance intervention.
10. DISPOSAL
In the course of machine maintenance, or if the machine is scrapped, do not dispose of polluting parts into the environment.
Refer to local regulations with regard to their correct disposal. When scrapping the machine the identification plate and any
other documents must be destroyed.

18/ 22
11. ORDERING INFORMATION
11.1 STANDARD VERSION
Data Base
1°
2°
3°
4°
5°
6°
7°
SUMO PUMP PART NUMBER
STANDARD VERSIONS
SUMO Pump - 30 kg GREASE
2477000
A
0
0
0
0
0
SUMO Pump - 100 kg GREASE
2477001
A
0
0
0
0
0
SUMO Pump - 30 kg OIL
2477050
A
0
0
0
0
0
SUMO Pump - 100 kg OIL
2477051
A
0
0
0
0
0
DESCRIPTION
DROPSA P.N.
CODE
From A to Z
From 0 to 9
From A to Z
From 0 to 9
From A to Z
From 0 to 9
Three phase
Electric motor
STANDARD - IE2 230/ 400V 50Hz - 280/480 V 60Hz
3301081
A
Voltage
440 V 60 Hz
3301650
B
440 V 60 Hz with anti-condensation heater 110V AC
3301651
N
460 V 60 Hz
3301652
Q
480 V 60 Hz
3301081
C
575 V 60 Hz
3301653
D
500 V 50 Hz
3301654
E
525 V 50 Hz
3301655
F
550 V 50 Hz
3301656
G
415 V (±10%) 50 Hz(±5%) insulation class.: F
3301657
I
690 V 50 Hz
3301658
W
380 V 60 Hz
3301659
Y
Voltage
UL and CSA standard with IE2 230/ 400V 50 Hz - 280/480V
60Hz
3301528
H
440 V 60 Hz
3301670
J
460 V 60 Hz
3301671
U
575 V 60 Hz
3301672
L
500 V 50 Hz
3301673
M
550 V 50 Hz
3301674
P
UL 480V 60Hz standard with anti-condensation heater 120V
3301556
Z
Pneumatic motor
3301539
V
Mono-phase
electric motor
Voltage
220V 60Hz
3301549
X
220V 50Hz
3301676
XX
Minimum level
STANDARD grease version with LASER level 24V cc Out NO e
NC (1 threshold)
0295131
(for 30/100 kg)
0
STANDARD oil version with floating Reed
0295150 (for 30 kg)
0295160 (for 100 kg)
Variants
Min - max laser level kit 24V cc Out 4÷20mA/2 NO
(4 thresholds)
0295130
2
Ultrasound Kit level - 100 kg
0295140
3
Ultrasound Kit level - 30 kg
laser level Kit - 100 kg –Exd custody
0295135
5
Capacive level kit 100 Kg (250 V AC)
0295121
6
Capacive level kit 30 Kg (250 V AC)
0295122
7
Maximum level
STANDARD GREASE VERSION
0295100
(per 30 kg and 100 kg)
0
STANDARD oil version with floating Reed
0295150 (for 30 kg)
0295160 (for 100 kg)
Variant
Laser sensor 24V cc Out NO e NC (1 threshold)
0295131
(per 10 kg and 30 kg)
A
Pumping elements
TWO FIXED DELIVERY STANDARD PUMPING ELEMENTS
0295040 + 0295040
0
Variant
1 Pumping element with fixed delivery
0295040+0295049+
3190491
3
Electromagnetic
switch with
sub base
24 V DC (IED24) + base
0083420 + 0295046
0
Variants
NOT PRESENT
A
110 V AC + base
0083421 + 0295046
B
230 V AC + base
0083422 + 0295046
C
Electromagnetic
switch
24 V DC + Kit
0083400 + 0295047
D
110 V AC + Kit
0083401 + 0295047
E
230 V AC + Kit
0083402 + 0295047
F
Electro pneumatic
switch
24 V DC + Kit
0083450 + 0295047
G
24 V AC + Kit
0083451 + 0295047
H
110 V AC + Kit
0083452 + 0295047
J
230 V AC + Kit
0083453 + 0295047
K
Hydraulic
change-over
0086450
L
Heater band
STANDARD NOT PRESENT
0
Variants
100 kg
0295065
1
30 kg
0295066
2

19/ 22
Part Number SUMO PUMP - 30 kg
GREASE
Example of coding SUMO PUMP - 30 kg GREASE
P.N.
2477000
B
2
0
3
D
0
Electric motor
IE2 440V 60Hz standard
3301081
B
Minimum level
Kit laser level - 30 kg
0295130
2
Maximum level
Not present
0295100
0
Pumping elements
1 Pumping element with fixed delivery
0295040 + 0295049 +
3190491
3
Electromagnetic
inverter
24 V DC + Kit
0083400 + 029547
D
Heater band
Not present
0
Part Number SUMO PUMP - 100 kg OIL
Example of coding SUMO PUMP - 100 kg OIL
P.N.
2477051
A
0
A
3
J
1
Electric motor
IE2 230/400V 50Hz - 280/480 V 60Hz standard
3301081
A
Minimum level
STANDARD OIL VERSION with floating Reed
0295160
0
Maximum level
Laser sensor 24V cc Out NO e NC (1 threshold)
0295131
A
Pumping elements
1 Pumping element with fixed delivery
0295040+0295049+
3190491
3
Electromagnetic
inverter
110 V AC + Kit
0083452 + 0295047
J
Heater band
100 kg
295065
1
*The following alphabet letters have been deleted:
O per non fare confusione con il numero 0
I per non fare confusione con il numero 1.
1.2 SPECIAL VERSIONS
Equipment
Description
Code
400 cm3/min grease pump 80Kg (176 lb) transparent tank with inverter code 0083420 at 24 V DC
2477100
SUMO ATEX Pump 316
2477201
Pump trolley
mounted
400 cm3/min grease pump 30 Kg (66 lb) trolley mounted 30 Kg metal reservoir cod. 1140204
1525212
11.3 OPTIONAL
Equipment
Description
Code
Transparent
reservoir
Reservoir, including the tank (PN# 0295056) and all accessories required for use (flanges,
screws, nuts, seals)
0295210
Pumping
element modules
Reserve pumping module 200cm3/min (24 cu. in)
Closure cap for fixed delivery pumping element
0295040C*
0295024
Oil conversion
Min/max oil level float kit 30 Kg (66lb)
Min/max oil level float kit 100 Kg (220lb)
Filling cap 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.
0043446
* Interchangeable with pumping 0296080C

20/ 22
11.4 SPARES
SPARES DESCRIPTION
VARIANT
PART NUMBER
Maximum mechanical level kit 30-100 kg (grease)
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
VAR 2
0295130
Laser level kit 24V cc Out 4÷20mA/2 NO (4 thresholds) –100 Kg
VAR 3
Minimum level kit (250V AC) 30 kg (grease)
0295121
Minimum level kit (250V AC) 100 kg (grease)
0295122
Ultrasound level Kit - 30 kg
VAR 5
0295140
Ultrasound level Kit - 100 kg
VAR 6
Maximum and minimum float level kit 30 kg (oil)
0295150
Maximum and minimum float level kit 100 kg (oil)
0295160
Grease loading filter
0295009
By-pass
0234815
Tank flange gasket
3190487
Manifold gasket (pump body)
0018863
Manifold gasket (pumping)
3190489
295009 Filter gasket
3190487
Filter cover gasket
0061135
Wormskrew assembly cover gasket
3190488
Body-pump reservoir gasket
3190485
Helicoidal gear assembly
0295020
Wormskrew assembly
0295010
Pumping element 200 cm3/min (24 cu.in)
0295040C*
* Interchangeable with pumping 0296080C
Pump body secondary unit code 0295000
Image 10