...@ product from BEKA Central lubrication pump Article-no. 2076........ FKGGM-EP / EPR voc FKGGM-EP / EPR vac FKGGM-EP with installed MX-F distributor without control unit - with integrated contol unit EP-ronic 2187... + with integrated control unit BEKAtroniXt 2175. + with integrated contol unit EP-ronic 2X 2060. + with integrated contol unit EP-ronic ZX - $1 2060... + with integrated control unit EP-tronic-2X - $2 2060. State of art: 01 (2019 Original operating and assembly instructions...@ product from a B E KA Content Page Declaration of incorporation a5 1. General 1.1" Intended use 6 1.2 Scope of guarantee 6 13 structions. 7 Safely noies 7 Qualification and training of stat. 7 Hazards in case of non-observance of the safety instructions uy Owners / operator's obligations 8 Safety instruction for maintenance, inspection and assembly... 18 Unauthorized modification and production of spare part. 8 Inadmissiole modes of operation 8 Electrostatic discharge 8 General hazard warning - residual sk ° 1.4 Use of hydraulic hose lines 8 13 Transport and storage 9 16 Shutdown. 8 17 Disposal 8 2. Technical data FKGGM-EPR /EPR 210 3. Functional description " 3.1 Function and setup of a ceniral lubrication system . 1 3.1.1 Function and setup of a progressive central lubrication system - 1" 3.12. Function and setup of a single line central lubrication system <0. 0000202000020 3.2 Function ofthe central lubrication pump 13 3.2.1 Central lubrication pump FKGGM - EP OT 3.22 — Central lubrication pump FKGGM - EPR REN 3.23 Central lubrication pump FKGGM - EP / EPR with installed NXCF distributor ©. 22.00 00.20. 745, 33. Pump element (PE) 16417 3.3.1 Pump elements PE-60, PE-120 und PE.170 7 3.32 Pumpelement PE-120V ...... 48 3333 Pump element with solenoid vaive ai central lubrication pumps for sing line sysioms..--- 19-20 4 vee cee vate e te ceeeteeeseeteteteseeeesse2t Installation dimensions of construction variation of motor housing. 020000002. II Bt 4.1. Central lubrication pump FKGGM -EP .. eeeeeeeneenes ‘2 4.11 Contra lubrication pump FKGGM -EP 1.9 liter reservoir 2 412 Central lubrication pump FKGGM - EP PEI 4.121 25 liter reservoir without level monitoring ETI 2a. 4122 25 liter reservoir- with level monitoring 23 4123 25 liter reservoir- with filing cover. PUI 23 413° Central lubrication pump FKGGM - EP 4 liter reservoir 2 4.14 Gentral lubrication pump FKGGM - EP B liter reservoir so... soci tic tcceteceeeee Bd 4:15 Contra lubrication pump FKGGM - EP 12 liter rasorvoir 25 4.16 Central lubrication pump FKGGM - EP 16 liter reservoir 28 4:17 Gentral lubrication pump FKGGM - EP 20 liter reservoir UEDA ar 4.18 Central lubrication pump FKGGM - EP 30 liter reservoir <0 2220020020228 4.2. Central lubrication pump FKGGM - EPR... Seeeeeeneenes 29 42.1. Central lubrication pump FKGGM - EPR 4 iter reservoir. 2002000000002 TI 29 422 Central lubrication pump FKGGM - EPR 8 liler reservoir. 0222002022228 z 423 Central lubrication pump FKGGM - EPR 12liter reservoir 0002000000200 30 i 42 Central lubrication pump FKGGM - EPR 15 liter reservoir 31 i 425 Central lubrication pump FKGGM - EPR 20 liter reservoir =... 0200202000021 32 g& 43. Central lubrication pump FKGGM - EP with installed MX-F distributor 33 ao 52 5. Accessories a4 #2 © 51 Level monitoring 34 He 5.1.1 FKGGM-EP pump - Proximity switch with plug-type connection M12x1 - 10-60 VIDC: 5... 34 fe 5.12 FKGGMEP pump - Proximity switch with plig-lype connection M12xt ~ 90-250 VIAG. 35 z 5.13 FKGGMEP pump - Proximity switch - connection cubic plug acc. to DIN 43650 35 ae 5.1.4 FKGGM-EPR pump - Proximity switch with plug-type connection MI2x1 «2.202.002 00 296 Hi 5.1.5 FKGGM-EPR pump - Ultrasonic sensor with plig-type connection Mi2xi .. 0.0.2... 20 2.237 E252. Micro switch at pressure relief valve 37 de...@ product from a B E KA 53 Control unit 238 53.1 General 138 532 Collective fault signal 138 6 Assombly instruction of central lubrication pump cee cesseeeeeeseecteereesererse88 6.1. Installation position central lubrication pump FKGGM - EP eesbeepeesecenseepeeeneseeneent) 6.2 Inslallation position central lubrication pump FKGGM=EPR oo... 39 63 Assembly of pipes and hydraulic hoses 39 7. Start-up wees 40 7.1 Connection of the ceniral lubrication pump FKGGM ~ EP or EPR without control unit 44 TAA 12/24V OC withing connection.......- ceed 742 12/24V DGwith bayonet plug 7 pol, connection line 2-cores PII laa 743 12/24V 0G with cubic plug. 4a T44 — 100-250.V AG with Hirschmann plug... 2.02... s os ees eeceeeeeeneeeeeeres .4t 745 100-250 VAC with Harting plug a 7.2. Connection of the central lubrication pump FKGGM - EP or EPR with control unit... 202.2 200022..2.42. 72.1 Control unit ype: EP-tronic aoe 142. 72.2 Control unit type: EP-tronic with intermediate housing ...000. 220.0 0.20. TI 43 723 Control unit type: BEKA-tronix1 44 7.24 Control unit type: BEKA-tronix1 - with intermediate housing 45 725 Control unit ype: EP-tronic 2X... eespeeeeeeneneneeneenenane’’ 7.2 Control unit type: EP-tronic ZX - with intermadiate housing a7 127 Control unt ype: EP tronic 2X wih intermediate housing and trmperatre Sensor 438 728 Control unit ype: EP-tronic ZX - St - with intermediate housing Diliag. 72.9 Gontrol unit type: EP-tronic 2X - $2 - with intermediate housing (12/24'V BG) -11.21.22111.1160 72.10 Control unit ype: EP-tronic ZX - S2 - with intermediate housing (100-250 VAG) 20.0012... 151 7.3 Basic filing of central lubrication pump 52 74 Ventilation of central lubrication pump P82 8 Maintenance 53 8.1 Preventive repair (wear part) TS 82 Level of central lubrication pump 54 8.2.1 Central lubrication pump without control unit and without level monitoring 2... 2... 5 82.2 — Central lubrication pump with lavel monitoring 54 82.3 Central lubrication pump with control unit 54 9.1" Central lubrication pump does not operate . ... 55 8.1.1 Central lubrication pump without control unit 155 9.1.2 Central lubrication pump with control unit... + 155: 9.2 Filling of the central lubrication pump cieiieiienoiesirenesesenentercter eye: 6 22.1 Filling procedure 36.57 8.2.2 Further filing variants of central lubrication pump 88 92.3 Filling connection and filing tools. 59 9.3 Exchange distributor ofa central lubrication pump with installed distributor 60 94 Exchange the proximity switch of a distributor. 60 9.5 Exchange the pump element. Set 9.5.1 Exchange pump element of the central lubrication pump FKGGM - EP/EPR | 6 852 __ Exchange pump element ofthe canal brcaton pump with installed istbutor 62 9.6 Level error coe 8.6.1 Central lubrication pump FKGGM- EP. 0000000000068 9.62 — Cantal lubrication pump FKGGM - EPR 64 10. Troubleshooting 85 Sines rer! BERA201 rate earee...@ product from a B E KA Declaration of incorporation BBEKA Einbauerklarung far unvollstandige Maschinen (nach EG-RL 2006/42/EG) Der Hersteller: BAIER + KOPPEL GMBH + Co. KG Beothovenstrasse 14 91257 Pognitz / Germany Tel: +49 9241 729-0 erklart hiermit, dass folgonde unvollstndige Maschine: Produktbezeichnung; ZENTRALSCHMIERPUMPE Typenbezoichnung: FKGGM- EP /FKGGM- EPR Bestalischlusset 2076, Seriennummer: ‘von AB0500000 bis ABO999989, don folgenden grundiegenden Anforderungen der Richtinie Maschinen (2006/42/EG) ontspricht Anhang |, Artkel 1.1.2, 1.1.8, 1.1.5, 1.32, 1.94, und 1.5.1 Folgende harmonisierte Normen wurden angewandt DIN EN 809: 2012-10 DINEN ISO 12100: 2011-03, Folgende sonstige SpezitkationerwNommen wurden angawanct: VDE 0530-1: 2011-02 Die Schutzzicle der Richtlnio Elektrische Betriebsmittel 2014/35/EU wurden gama® Anheng |, Ne. 1.5.1 der Maschinenrichtinie eingehalten Die unvolistandige Maschine dart erst dann in Betrieb genommen werden, wenn fostgostellt wurdo, dass die Maschine, in wolche dio unvollstindige Maschine eingebaut werden soll, den Bastimmungen der Richtlnie Maschinen (2006/42/EG) entspricht. Die zur Maschine gehérenden speziellen tachnischen Unterlagen nach Anhang Vil Teil 8 wurden orstolt Der Hersteller (Abt. Dokumentation, Tel: +49 9241 729-779 E-Mail: [email protected]) verptlichtet sich, ie spezielien Unterlagen zur unvolistandigen Meschine einzelstaatlchen Stellen aut Verlangen elektronisch zu ubermiteln, Sines rer! BERA201 rate eareeDecaation af incorporation fr incamlea machinery ace to €o-arctne 20084210) Siaemaecy ia cna ecwurtny batbe mnwtcgeae my isch ane tert mre er amy Saye a Colepans sn inom serra is Ese eaentey ate sea srr (he Innoumerkiarng brtende it-volonde machines "contr ache 2a) ‘ior foges omked tacsasaee sd sei 4 wzet tree eet in Marat (ee, Sconce eran etesonnenany rE a product from a BE KA Dictation dincorpravon relative aux quesbmachines {eelon EG. DOSED) ‘aor fogus! tema tenansse 0 Scan acbea Severna em Arn eet mcrae sora Desaracon de nstaoién para maqunes ncompletse “swain sont aoaeses) ir grace avis tae Seepage oe sei pins matron Se Sate ee See tenga immstena gaara Shoo ee trot ooo smear nto acer caer eens SS Stes Siete nua siotim poten Sin 9 each SoHo 42,113, 515,082 13405, cy egret Rae eeeeon Sharcnsencsec pecan pany pe wee moony foneSines rer! BERA201 rate earee ...@ product from a B E KA 1. General ‘These operating- and assembly instructions contain all information that are necessary for installation and ‘operation of the central lubrication system. It helps you getting familiar with the central lubrication system and its functions and to operate itina safe, proper and economical way. It shall help you to avoid risks, damages and downtimes. Furthermore it increases the reliability and the service life of the central lubrication system. Apply the operating instructions according to the national regulations concerning working safety, accident prevention and environmental predection. Keep the operating manual always at the place of operation. All people working with the central lubrication ‘system have to be informed of the contents of this manual, especially of the safety instructions. The operator of the central lubrication system is responsible for the staff. 4.4 Intendeduse ‘The central lubrication systems only allowed for industrial use. ‘The central lubrication system may only be operated, ifits integrated or attached to another ‘machine and will be operated together with it. Use only lubricants according to the machine manufacturer specification. The central lubrication system may only be used according to the technical data (see chapter 2_,technical data". Never exceed the indicated values. Never operate the device without lubricant. Attention! Unauthorized structural changes at the central lubrication system are not permitted. We are not liable for consequential damages of the machine or injuries of persons. This also belongs to an intended use: * Payattention to ll notesin the operating manual. * Carry outall maintenance work. Observe all relevant instructions for the work safety and accident prevention during alllife cycles of the central lubrication system. * You have to have the required professional education and authorization of your company, to carry out the necessary works at the central lubrication system. ‘Aten Another use ora use beyond can not be considered to bean intended use. mn! 1.2 Scopeof guarantee ‘The manufacturer guarantees operational safety, reliability and performance, only under the following conditions and in regards to the intended use: ‘© Assembly, installation, connection and maintenance are only carried out by authorized and qualified staff. ‘+The customer has to cover hazardous parts (e.g. heated or moving parts). ‘+ The central lubrication system is installed and operated according to the operating- and assembly instructions. ‘+The mentioned technical data must not be exceeded in any case. Retrofitting and repair works at the central lubrication system may only be done by BEKA. Guarantees and warranty for any damage at the central lubrication system caused by improper lubricant (e.g. wear of piston, piston jamming, blockades, brittled sealings etc.) will 1] expire: Attention! | BEKA wil generally not assume quarany claims for any damage caused by lubricants, although those have been laboratory tested and released by BEKA, as such damage (e.g. by over-stored or incorrectly stored lubricants, batch fluctuations, etc.) cannot be verified or reconstructed later....@ product from = B E KA 1.3. Safety instructions ‘All persons that are in charge with the assembly, start-up, maintenance and operation of the device must Carefully ead these instructions. Furthermore this manual must permanently be available atthe site of operation! Basicnotes for setup, operation and maintenance can be found below. 1.3.1 Safety notes Do not only observe the safety instructions within this main point but also have a look at the special safety ‘warnings that are implemented in other parts of this documentation, Warning of electrical voltage. Safety instructions which in case of non-observance might cause hazards to persons are ‘marked with the general danger symbol, This symbol wams of hot surfaces. Warning of suspended loads. Warning of material damage due to electrostatic discharge! Marks potential risks which may result in material damage, ifnotavoided. > PPP ‘Attention! | Ts heading is used ifthe improper or general non-observance of the operating manuel, | specified work flow and the like might result in central lubrication system damage. Note! | Thistermis used to point outparticular details Notes directly attached at the unit, must strictly be followed and held in readable condition! 1.3.2 Qualification and training of staff ‘The staff in charge for operation, maintenance, inspection and assembly has to have the according qualification for these tasks. Competence, responsibility and supervision of staff must be clearly defined by the operator. In case the staff does not have the necessary knowledge it has to be instructed and trained accordingly. The operator is obliged to ensure that the stafffully understands the contents of this user information. > 1.3.3 Hazards in case of non-observance of the safety instructions Results of non-observance of the safety instructions can be hazards to persons, the j environment and for the central lubrication system. Non-observance of the safely Sines ater! BEKAIO1 Aas earee instructions may result in the loss of any liabilty claims. In detail the non-observance could entail the following hazards “Failure of important system functions, Failure of prescribed methods for maintenance and repair ‘Danger to persons by electrical, mechanical and chemical effects “=Dangerto the environment by leakage of hazardous substances...@ product from a B E KA 1.3.4 Owner's/ operators’ ol ligations Ifmovable, redating, hot or cold parts of the device bear risks, these partsneed tobe secured against contact by the customer. This predection against contact must not be removed. Any leakages of hazardous substances must be drained in a way that no risks for persons or the environment arise. Please also observe the data sheets and safety data sheets of the according manufacturers. Keep toalllegal provisions. Hazards due to electricity are to be excluded. Examination of pines and hoses regarding safe provision, use, proper assembly and function has to be carried out according to regionally applicable directives. Inspection intervals may not be exceeded. Defective pipes or hoses must be replaced immediately and professionally. Hydraulic hoses and polyamide pipes are subject to a natural aging-process and thus have to be exchanged in regular intervals according to the manufacturer's specifications. A safety data sheet of the currently used lubricant must be provided at the device. Observe the universally valid Ordinance on Hazardous Substances in the latest version. 1.3.5 Safety instruction for maintenance, inspection and assembly All maintenance, inspection and assembly work may only be carried out by qualified personnel whos sufficiently informed by thorough reading of the user information. Generally any work at the central lubrication system may only be carried out at complete standstill and in pressureless as well as disconnected condition. Furthermore appropriate personal predective equipment (goggles among others) is necessary. The shutdown procedure of the central lubrication system as described in the manual must be strictly followed. ‘Secure the device against intentional or unintentional recommissioning during maintenance or repair. All safety and predection arrangements have to be put back in place again immediately after finishing work Environmentally hazardous media must be disposed professionally and in correspondence to relevant legal provisions. Polluted and contaminated surfaces have to be cleaned before maintenance. Please wear predective equipment to that purpose. See the lubricant manufacturers’ safety data sheets hereto, respectively the data sheets provided by the ‘manufacturers of auxiliaries and working materials Open light and fire are strictly prohibited due to fire hazard during all maintenance-, inspection-and repair works. 1.3.6 Unauthorized modifica n and production of spare parts feedback. Original spare parts and authorized accessories from the manufacturer contribute to safety. The use of other parts can result in the loss of any liabilities for the resulting A Modification, repair and altorations of the device are only accepted after manufacturer consequences. BEKA does not assume liability for parts that are retrofitby the operator. Sines ater! BEKAIO1 Aas earee 1.3.7 Inadmissi le modes of operation ‘The operational safety of the central lubrication system is only guaranteed for appropriate application as indicated in the operating manual, Never exceed the limit values of the technical data,...@ product from a B E KA 1.3.8 Electrostatic discharge Avoid electrostatic discharge! There are electronic components integrated into the devices which might be destroyed by electrostatic discharge. Observe the safety precautions against electrostatic discharge according to DIN EN 61340-5-1/-3. Ensure that the environment (persons, workplace and packing)is well grounded when handling these devices 1.3.9 General hazard warning -residual risk All components are designed according to valid regulations of the construction of technical systems in regards to operational safety and accident prevention. Independently from this the use can lead to hazards for the user or third parties as well as for other technical facilities. ‘Therefore the device may only fulfil its intended use in a technically acceptable and faultless condition. This has to happen in adherence of the according safety regulations and under observance of the operating manual. Inspect the device and its attachment parts regularly and check them for possible damage or leakages. Liquids could escape under high pressure from pressurized components which become leaky. 1.4 Use of hydraulic hoses A If hydraulic hose lines are installed at the pump, the operator has to observe / ensure the following: ‘*Examination of proper assembly and function are to be carried outaccording to regionally applicable directives. ‘*Examination of pipes and hoses regarding safe provision, use, proper assembly and function has to be carried ‘outaccording to regionally applicable directives. ‘Inspection intervals may not be exceeded ‘Defective pipes or hoses must be replaced immediately and professionally ‘*Hydraulic hoses and polyamide pipes are subject to a natural aging-process and thus have to be exchanged in regular intervals according to the manufacturer's specifications, 1.5. Transportand storage Usea suitable lifting device for the transport Donot throw the central lubrication system or impose itto shocks. Usea suitable lifting central lubrication system for transport. Store the system ata temperature between -40°C to +70°C, Observe all valid safety and accident prevention regulations for the transport. Wear suitable predective equipment if necessary. Keep adequate distance to suspended loads. The transport help or the elevating device must have the adequate carrying capacity. When storing the device pay attention that the storage area is cool and dry in order to avoid corrosion of the individual parts of the device. 1.6 Shutdown Relief the central lubrication pump from pressure! Shut down current! ‘Separation of central lubrication pump from current supply must be done by a professional electrican. = Remove all pipes and hoses from the device and loosen all fastenings for the demounting, i a? i 22 1.7 Disposal fs ‘Observe the disposal instructions of the lubricant manufacturer when lubricant is changed! 22 Tote: | Lubsicants or cloths contaminated with lubricant or similar must be collected in specially ge Note! marked receptacles and disposed accordingly. Disposal of the central lubrication system aE must be done properly and professionally and according to the national and international EE laws and regulations. Be 22 properly disposed batteries willbe recycled. They contain important raw materials...@ product from a B E KA 2. Technical data FKGGM-EP/EPR GENERAL: Reservoir capacity Central lubrication pump FKGGM-EP: 4,91/2,51 /41/81/121/161/201/301 Central lubrication pump FKGGM-EPR.... se 41/811 121/151/201 Medium: ‘greasesup to consistency class NLGI-cl.2 Operating temp. range: Transport and storage temperature: ‘Sound pressurele Level monitoring (optional): Installation position: ‘Central lubrication pump FKGGM-EP: vertical ‘Central lubrication pump FKGGM-EPR: rotating system 25°C to +60°C (depends on lubricant, up to 40°C possible on demand) -40°C10+70°C - Lube point eg. SXE2 : lines / ‘Secondary distributor Ce...@ product from a B E KA 3.1.2 Function and setup ofa single line central lubricatio system ‘The single line lubrication system consists of a central lubrication pump and distributors. One of the distributors is equipped with a pressure gauge and pressure switch for monitoring. Itshall be installed at the end of the longest line in the system. ‘The lubrication cycles can be controlled either by means of the contol ofthe central lubrication pump or by an ‘extemal control unit. The reservoir level is monitored (optional). During the pump operation lubricant is delivered into the pressure lines until the switch pressure is reached. The ‘switch pressure can be checked at the pressure gauge. The pressure line has to be relieved by a 2/2 way valve in order to enable the displacement of lubricant in the distributor. The pressure line is automatically relieved when the pumpis switched off. After the pressure line is relieved, the single line distributor supplies lubricant to the lube points. Installation example: Fig. 2: Lines towards the Tube points ‘eg UEN Central lubrication pump Single tine distributor eq. UEN with pressure swith ‘aha ears u i i 12‘aha ears eric ...@ product from a B E KA 3.2 Function central lubrication pump 3.2.4 Centrallubrication pump FKGGM-EP ‘The central lubrication pump FKGGM-EP is an electric driven grease pump and designed to supply lubricant up toNUGlel.2. ‘The installation has to be done with reservoirin vertical position. The positively controlled metering piston of the pump element and the agitator blade ensure a perfect priming. The central lubrication pump has a level monitoring (optional). Functional descri The motor powers the eccentric via a gear. The eccentricity effects a suction and pressure movement of the ‘supply piston. The integrated non-return valve avoids a return pumping of lubricant into the lubrication line. The pump element is compulsory controlled by the eccentric, thus a function at low temperatures is ensured. The delivery rate depends on the installed pump element. The grease reservoirs are equipped with an agitatorin order to ensure smooth priming of the delivery piston. The mediumis by the agitator pushed into the suction chamber; at the same time rising gas bubbles are able to leak ‘The skimmer at the agitator enables a visual control of available grease in the transparent reservoir. ‘Components: Fig. 3 (example 2076 00326) - Reservoir cover _ _ Level monitoring Level sticker BEKA WIND Ventilation Reservoir 8 liter Agitator blase —_ 5 large version i ws-fiting Straight fling connection. fl ~ ™ Prossure root valve Pump housing — wihmoor CT Stee! pipe 6x1 Filling nipple-~ Pump bracket ———-- fo 1 | —Pump element Re PE-170 ! oS —— Pump type platte ow D Connection x Lower motor: y housing‘aha ears eric ...@ product from a B E KA 3.2.2 Centrallubrication pump FKGGM-EPR ‘The central lubrication pump FKGGM-EPR is an electric driven grease pump and designed to supply lubricants uptoNLGI-cl2. ‘The follow-up piston in the reservoir enables an installation in each position, also in rotating parts. The installation in rotating parts implies that the function of the follow-up piston is supported by the centrifugal force. The positively controlled metering piston of the pump element and the agitator blade ensure a perfect priming behaviour. The central lubrication pump has an integrated level monitoring (optional). Functional descriptior Lubricant is pressed through a sieve by a spring loaded follow-up piston into the suction room of the pump. element. Air bubbles are crushed. ‘The motor powers the eccentric via a gear. The eccentricity effects a suction and pressure movement of the supply piston. The integrated non-return valve avoids a return pumping of lubricant into the lubrication line. The pump element is positively controlled by the eccentric, thus a function at low temperatures is ensured. The delivery rate depends on the installed pump element. ‘The grease reservoirs are equipped with an agitator (for the FKGGM-EPR only in the area of the pump housing) in order to ensure smooth priming of the delivery piston. The agitator pushes the medium into the suction chamber, atthe same time rising gas bubbles can escape. ‘Components: Fig. 4 (example 2076 00584): Ventilation: T Reservoir liter Level sticker BEKA WIND Filling nipple ~ with dust cap follow-up piston ° ~ = spring loaded Overfill predection . 05 bar > ws. fitting Filling connection for filing press — Steel pipe 6x1 Pump housing Pressure relief valve with motor ‘with return line Ventilation ———— ~Pump element screw PE-170 Lower motor Pump type plate housing...@ product from a B E KA 3.2.3 Centrallubrication pump FKGGM - EP with installed MX-F distributor Description corresponds to FKGGM-EP/EPR.. Additionally a distributor is directly installed at the pump. Distributor MX-F ‘The progressive distributor MX-F consists of an initial-, middie, and end element and is directly attached to the pump. The progressive distributor is designed for an operating pressure up to 300 bar. Due to the progressive piston control ofthe distributor, ahigh operational safety is ensured. Monitoring the distributor: ‘The progressive distributor MX-F can easily be monitored by means of a proximity switch due to ist hydraulic piston control. The pistons are moved by incoming lubricant so that the metered lubricant flows out ofthe outlets. inevitably and at one outlet after the other. The proximity switch monitors the piston movement. The proximity ‘switch sends a signal to the control unit at each piston movement. If the signal is not send within an indicated monitoring time, the connected control unit sends an error message. ‘Components: Fig. 5 (example 2076 00118): _ Veriton Reser soir Disb combination, | tevatasat woe 3 ~ SERA WIND ump element res - Filing ip with useap Gresser with cuss Ss ee ‘Straight filing J onion "ype plate of pnp Motor rosing fepihmetar connecon Motor housing ~ bottom ‘Components FKGGM-EPR: Fig. 6 (example 2076 00599) level tbet Veriaton — SEXA ND Reservoir 4 Lier Disorcombintign 3 MxF a3 x _- Filing nipple with } . 7 oases 2 Overt rotecion. Ba Level switch é Pump element 58 panes __— Pump housing ag Re ‘Straight fling 3 Sreon ‘entiation screw A Motor housing “Type plate of pump Be top with motor RE Motor housing ~~ Gennection 28 bottom 15‘aha ears 3 i i ...@ product from = B E KA 33 Pumpelement (PE) ‘The pump element supplies the lube points with lubricant or forward the output rate to the distributor. Functional description: ‘The actuation of the supply piston is enforced via the piston eccentric ring. During the suction process the supply piston is moved into a final position. The metering chambers filled with lubricant and another turing movement of the eccentric ring effects that the supply piston closes the suction driling whereby lubricant is supplied towards the outlet via the non-return valve. ‘The pressure line shall only be connected if the pump element supplies air free. The non-return valve avoids that lubricantis drawn back. Supplied lubricant always has to be clean to ensure the function of the non-return valve. ‘The pump elements can be ordered with or without pressure limiting valves. The installed pressure limiting valve predects the system from overload. Fig. 7: Pump element draws: Intake bore hole, \ Lubricant ‘Supply piston | Piston eccentric ring Non-return valve Pump element supplies: 16...@ product from a B E KA ‘There are pump elements with different delivery rates that can be installed in the lubrication pumps FKGGM-EP and FKGGM-EPR. The pump elements can be delivered with pressure connection 06, 8 or 010 (optional with pressure limiting valve). The use of a pressure limiting valve Is recommended, optional also a pressure limiting valve with micro switch is available. Fig. 8: Pressure limiting valve with micro switch 3.3.1 Pump elements PE-60, PE-120 and PE-170 (all with fix delivery rate) Fig. 9: (Example PE-120) Pressure limiting valve / set to 280 bar (+15%) M20x1,5, 2.90 Max 5 ar ir] a 5 AF AT a arte FT] 10 OB Reduction fiting Reduction fiting z pipe @ 6-@ 10 pipe 6-08 ‘2 Technical data: 2g Delivery rate PE-60.... ..0,06'/stroke &# Delivery rate PE-120:... 0,12cm'/ stroke 2) Delivery rate PE-170: 0.17 om /stroke E ‘aitypesnotacjustabley EE Operating pressure ‘max. 350 bar 2S Pressure limiting valve: sSetto 280 bar (+15%) § 4 Lubricant: (cl. 00/000toNLGI-cl.2 28 Pressure limiting valve: with or without Seen ee ee eee eee 7...@ product from a B E KA 3.3.2 Pumpelement PE-120V ‘The pump element PE-120 V with controllable output rate is setto full lif by default Fig.10: Ky Pak i Regulation of metering volume: CL + Remove the sealing screw (fig. 10, pos. 1) by means of ahexagon socket wrench AfS ‘Supply rate is adjusted by means of a screw driver at the adjusting disc (Fig. 10, Pos. 2) Tum clockwise to reduce the output rate Turn counterclockwise to increase output rate Maximum stroke of adjusting = 2,4 mm =6notches ‘tum of the adjusting disc= 0,8 mm = 2 notches. Tighten screw plug (Fig. 10, Pos. 1) including sealing ring Technical data: Delivery rate PE-120:. 0,12em’/stroke Regulation: possible min. 0,05 cm? /stroke Snotches per ‘turn reduction 0,013 em*pernotch Operating pressure: . os . max, 350 bar Pressure limiting valve: set to 280 bar Lubricant... rees0 upto NLGI-cl OMOODIONLGL a. 2 Pressure limiting valve: with or without Fig.tt: Delivery rate (cm?) / stroke ong on o.1q 0.09 o.04 0.07 104 2.05 o.o 0.03 0] or] ‘aha ears u 0 05 4 18 20 25 30 Tums i i 18...@ product from a B E KA 3.3.3. Pump element with solenoid valve at central lubrication pumps for single line systems. ‘The solenoid valve which is installed at the central lubrication pump is a 2/2-way valve, consisting of valve part, connection block and pump element (fig. 12). As soon as the switching pressure, as adjusted, is reached, the central lubrication pump is switched off and the solenoid valve releases the way to the reservoir return. The main line is relieved and lubricant is supplied to the lube points by the distributor. Fig.12: Technical data: 30 Way seat valve: VP1-S-A24 14 Type of actuation: 24 DC electric. ‘Switch symbol: Ss Connection: 1a Volume flow: Q.., 151/ min Operating pressure: p,.. 400 bar ee als Central plug Nominal power: 20 P,, (W) 0 © © Current: 0.8311, (A) 40 1. Adapter’) ' Manual emergency button Press the button max. actuation pressure 80 N ® this dimensions depends on the manufacturing process and can have up to.40 mm acc. to EN 175 301-803 A c +H a I 25) |_ 299 colt? Cable fiting ° adapter can be installed offset 22,5° or 180°, at adjacent order not all angle a positions are possible 25. switch symbol Solenoid valve Oe LO 7 Connection block t 19...@ product from = B E KA The cable with two sided plug for the connection of the solenoid valve is already installed at the pump housing, Connection solenoid valve via the intermediate housing: Fig. 13: Oil flex tine 110 sax twihPE Contact box for - connection ? 1291.1 at intermediate Plug for a rousing solenaid valve Connection of solenoid valve via flange socket M12 at housing: Fig. 14: Oil fex ine 110 Fange socket m2 2x1 without PE es @es——_}2_ et a@ {- pe 4 or Alb os / ne J Round plug m2 L «1370 ae 7 Plug for solenoid valve ‘aha ears u i i...@ product from a B E KA 4. Inst lation dimensions Installation dimensions of construction variation of motor housing (with or without integrated control) Fig. 15: 474 Variation 12/24 V DC Variation 100-250 V AC without integrated control with intermediate housing for integrated PSU without integrated contro! Variation 12/24 V DC Variante 100-250 V AC with integrated control with intermediate housing for integrated PSU with integrated control Sines rer! BERA201 rate earee 24...@ product from —BBEKA aa ion pump FKGGM- EP 41.1 Centrallubrication pump FKGGM- EP 1,9 Liter reservoir Fig. 16: 306 J Ae 407 44.2 Centrallubrication pump FKGGM -EP 441.21 2,5Liter reservoir -without level monitoring Fig. 17: £9. & Q i 2 = 3 } i i j j j...@ product from —BBEKA 441.22 2,5literreservoir -with level monitoring Fig.18. el AN i! 26 of wr 239 248 130 , (eg 4 ash oan. 342 41.23 2,literreservoir-with filling cover Fig. 19: 363 a Q : 2 = 3 } i i...@ product from —BBEKA 44.3. Centrallubrication pump FKGGM -EP F reservoir Fig. 20: g ESF ll, eh 5 \ J ote 5 — 172 349 444 mp FKGGM -EP Fig.21: g g i zg? + 2 22 g ( aS i i N . . 28 i i a 38 342...@ product from —BBEKA 44.5 Centrallubrication pump FKGGM -EP 12liter reservoir vig22 & >) Ta ocr ° Bh f Foi | ° q 7 230 = \( | 2...@ product from —BBEKA 44.6 — Centrallubrication pump FKGGM-EP 46liter reservoir Fig. 23: 230. ® e *...@ product from —BBEKA 44.7 Centrallubrication pump FKGGM-EP 20liter reservoir Fig. 24: " 58. et 735 142 172 A207 sana uraton pup_O18N Sines avers’ © BERA2019 tats euros...@ product from —BBEKA 44.8 Centrallubrication pump FKGGM -EP 30liter reservoir Fig. 25: 993 970 Oollp ‘40 126 ott 172 Eine avers’ BEKA OTA aa ewres AL227_ sana hr pe...@ product from —BBEKA 42 Centrallubrication pump FKGGM-EPR 424 Fig. 26: 422 — Centrallubrication pump EPR 8liter reservoir a Fig. 27: 230 Q i 2 = 3 } i i j j j...@ product from —BBEKA 42.3 Centrallubrication pump EPR ‘2liter reservoir Fig. 28: odBEKA ...@ product from 424 Centrallubrication pump EPR 1Sliter reservoir Fig. 29: n 731.5 342 A207 sana uraton pup_O18N Sines avers’ © BERA2019 tats euros...@ product from —BBEKA 425 — Centrallubrication pumpEPR 20 liter reservoir Fig. 20: 709 525.3 164.5...@ product from BEKA 43. Contrallubrication pump FKGGM -EP with installed MX-F distributor Fig. 31 1230 & 3 : 3 ey Ly 3 of > 3 \\ | Hy \ dF < , <, a ILA °3 gq we J 250 Sines rer! BERA201 rate earee...@ product from a B E KA 5. Accessories 5.1 Level monitoring The level monitoring is connected withthe integrated control unit by default. Anyway it can be also connected to ‘an extemal control unit. 5.1.1 FKGGM-EPPump Proximity switch with plug-type M12x1 - 10-60 V/DG: Fig. 32: Signal level minimum: Connection’ The level is monitored via a capacitive proximity switch. When the min. level level is reached, the capacitive proximity switch sends a signal (NC or rontoring NO contact depending on electric connection). Switch off the central a lubrication pump to avoid that airis drawn into the system. pees roximaty switch min. level Connect the level monitoring by means of a suitable cable. Put the angled bush onto the level monitoring and tighten the knurled nut. ‘Attention! | Assemble the high pressure hose away from hot parts (max. 50° C) and avoid chafe marks. Insulate the non-used wire. Technical data capacitive proximity switch: Fig. 33: | wow 1.28 (10-50¥) Contact function: PNP NCINO contact ve 2 Operating voltage: 10-60 VIDC. poh ‘Switched current: max. 200 mA on of te ob ‘round View onto plug: brown white blue black |] When connecting the level monitoring with an intelligent control (e.g. on-board computer, Attention! | 16) please observe the following! Closing contact The pump must be switched off after 10 sec, after the capacitive proximity switch stops (Standard) sending the signal. In order to ensure a wire rupture, use the closing contact. ‘The central lubrication pump must be switched off after 10 seconds, after the capacitive Opening contact penn Proximity switch sends a permanent signal. Level | Lovet (ok | empty Cpenog losing —_ Time Hose. 9 ;...@ product from = B E KA 5.1.2 FKGGM-EP Pump Proximity switch -connection cubic plug acc. to DIN 43650 - 10-60 VIDC ‘The NO/NC function mustbe selected when ordering. Connect thelevel monitoring by means of a suitable cable at the contact box. Connecttthis tothe level monitoring of the pump and tighten the fsastening screw. Attention! ‘Assemble the high pressure hose away from hot parts (max. 50° C) and avoid chafe marks. Technical data of capacitive proximity switch: Contact function: PNP NC/NO contact Operating voltage: 10-60 VIDC ‘Switching current: max. 200 mA View onto plug: 11= +Ub, 10-60 2=0V aground 3=NC or NO PE = not assigned level —~ Fig. 35: min, level monitoring Fe ‘monitoring 7 4 +08 mT fF con HH { lack : —_* - t= fee —ov Ee capactive opin proximity white = NC contact switch black = NO contact 54.3. FKGGM-EPPump Proximity switch -connection cubic plug acc. to DIN 43650 -90-250 VAC: 7.90 - 250 V AG oy 1=L./90-250 VAC doa > Blue rom 8 mA to max. 250 mA51.4 FKGGM- ...@ product from a B E KA EPRPump: Proximity switch with plug-type connection M12x1: ‘Signal minimum level ‘The level of the reservoir in the pump is electronically monitored by the control unit of the wind power plant. The level switch opens when the reservoir is empty. Switch aff the pump to avoid that air is pumped into the system. Connect the level monitoring by means of a suitable cable. Put the straight bush into the level monitoring connection and tight Attention! Fig. 97: Technical data ind Contact function: Operating voltage: ‘Switching current: View onto plug: ten the knurled nut. ‘Mount the cable away from hot parts (max. 50°C) and avoid chafe marks. Connection | level monitoring luctive proximity switch: PNP NC contact 10-60 VDC max. 200 mA brown white blue Fig. 39: Fig. 38: ‘a Hexagon nut 5Nm “Grains bush M12x1 for connection at level monitoring...@ product from a B E KA 5.4.5 FKGGM-EPRPump: Ultrasound sensor with plug-type connection M12x1 ignal minimum level /maximum level / reserve: Connect the level switch at the pump by means of a suitable cable aco. to the circuit diagram. Put the straight bush onto the ultrasound sensor on top of the pump and tighten the knurled nut. =] Theplugcan notbe puton wrong. Attention! | Mountthe cable away from hot parts (max. 50°C) and avoid chafe marks. Fig. 40: Technical data ultrasound sensor: (oot bet ot..2U8 (10-60y) Contact function: 3x PNP NO contact aie Operating voltage: 9-30 DC o Let 62 nny max. 200 mA ae ' amp. 5 [om g3 6 bg ase brown white blue Bush M12x1 Bleck for connection grey at level monitoring 52 Microswitchat pressure relief valve ‘The maximum operating pressure in the lubrication pump can be monitored by means of a pressure relief valve installed at the micro switch. If there is a malfunction in the system, the micro switch is actuated. The signal of the ‘switch can be processed by an already existing signal transmitter, e.g. on-board computer or an external or integrated control unit. Lubricant comes out of he pressure relief valve under high pressure (250 bar)! ‘Attention! | Wear safety goggles and do not remain in the danger area if there is a problem with the central lubrication system! Never work at the central lubrication pump if the voltage is, switched on! Relief the pump from pressure befor start working! ‘Terminal diagram of micro switch for external control unit: Fig. 41 burden black. NO contact blue NC contact brown ___| ‘aha ears 5B ue — u sto en 5 Technical data of micro switch: 1 Supply voltage: 100 60 VDC 2 Current load max.: I= 17 EE Contact type 1 change over contact ‘Temperature range "25° C to 485°C Predection type P67 Connection: cable 0.5 m , welded 37...@ product from = B E KA 53 Controlunit description in chapter 7, depending on the control unit. 534 ‘The following actuation types can be selected by means ofa diagnosis device: A) Time control B) Pulse control ©) Speed control D) Pulse cycle contro! Automatic startof lubrication intervals ‘The central lubrication pump starts automatically a cycle time if adjustable intervals are selected. Each cycle time consists of a lubrication time and a puls off time (fig. 38). The lubrication time is the time when the lubrication is active; this means a set time, or set strokes at the distributor or the tums of the pump are to be processed. The green LED in the control unit window glows as long as the lubricationis active (fig. 39). Fig. 43: Lubrication time _|_ Pulse off time. . (lubrication active) - Cycle time. . Fig. 44: Lubrication button ~ to activate an intermediate lubrication / ‘The green LED glows The red LED giows until the reservoir during lubrication or is refilled or the display shows a malfunction function display 5.3.2 Collective faultsignal ‘The central lubrication pump with integrated control unit is equipped with the collective fault signal function. Ifthereis a system error, the external lamp glows permanent. The signal of the collective fault is active if there is aproblem eric The malfunction signal is automatically reset if the error is solved or the cycie time is restarted via the intermediate lubrication,...@ product from a B E KA 6 Assembly of the central lubrication pump ‘Check the pump for transport damages and for integrity before the assembly. Remove possible transport locks. The following conditions must be satisfied to assemble the pump with others parts proper and without impair safety and heatth of persons. ‘There are no special actions to arrange regarding the oscillation reduction and noise prevention when installing the pump. Assemble the pump by means of the suitable fastening material to ensure a safe operation, ‘Also observe the indicated data in the dimensional drawing regarding the fastening drilings. When choosing the ‘assembly position take care that the pump is predected against environmental and mechanic effects. Ensure a full access, for example for lubrication filing 6.1 Installation position central lubrication pump FKGGM -EP: 5 Assemble the pump: Attention! | invertical position. Fig. 45: { pp 62 Installation position central lubrication pump FKGGM - EPR: ‘Attention! | _!7stallthe pump with follow-up piston in direction of the centrifugal force. Pressure Fig. 46 serng | / Centrifugal force Saeator 63 Pipe line and hydraulic hose assembly ‘+ Assemble the lines professional and nondistorted! + Observe pressure tightness of fittings. + Observe permitted pressure range for the lines. 39...@ product from a B E KA 7. Start-up Observe the following items before the pump start-up in order to guarante a perfect function ofthe pump. ‘Attention! | Theelectric connection may only be done at switched off supply voltage. ‘Assemble the electric lines away from hot parts (max. 50°C) and avoid chafe marks. Alonger operation with the wrong sense of rotation can damage motor and pump. The electric connection of the pump must only be done by professionals. The electric components have to be wired professional. Compare the voltage details with the available mains voltage. Central lubrication pump FKGGM -EP: ‘Compare the sense of rotation of the agitator blade with the direction arrow on thelevel label. Ifthe sense of rotation is wrong, check the connection of the terminal box. Central lubrication pump FKGGM-EPR: ‘Compare the sense of rotation of the central lubrication pump by a visual control with the direction arrow on the level label! Remove the ventilation screw (fig. 47) from the pump housing. Check the sense of rotation of the pump by means of the vent screw opening, use a lamp ifnecessary. Fig 47 Ventilation screw Lamp Opening of ventilation screw Check the sense of rotation and the connection in the terminal and change ifnecessary....@ product from a B E KA 7.1 Connection central lubrication pump FKGGM -EP or EPR without control unit: Fig. 48: TAA 12/24VDCwithlineconnection: x 90° 1. Number cable: 4Ub = wire 1 Ground = wire 2 X | xy | { \ Fy 7.4.2 12/24 DC with bayonet plug 7pol., connection line 2-cores 2. Color cable (2-cores) +Ub = blue: Ground = brown 4. Number cable: 4Ub = wire 1 = PIN 5 bayonet plug GND = wire 2 = PIN 7 bayonet plug 2. Color cable (2-cores) 4Ub = blue = Pin 5 bayonet plug GND = brown PIN 7 bayonet plug TAS 12/24VDC | Diagram x1 | View onto plug | PINT =+UB; +24V IN 2 = ground; OV Connection X1 71.4 100-250 VAC with Hirschmann plug xf ~ - ~ Nu f z fot tn E ia ns tees | onan assy NePne soo2sovac} » 4 mL Pn? (PE) 2, Fe onto gw | K1296 - _ 4 O [Temes door Ig | e rF ! My a \ ' £1 u E 8g ry 33 te a...@ product from —BBEKA 7.2 Connection central lubrication pump FKGGM -EP or EPR with control unit: 7.24 Controlunittype: EP-troni Voltage: Ub 10-60 V DC (nominal 12/24 VDC) Fig. 49: Pumpe | Steverung EP- tronic ue EPS tronic control xt aie drehungs=| sub Si} fentekt ! Pein pe oy 6| 12/24 DC TL X2: aus ie ent S2) Feat contact 1° statussignal Fiilistond x3: a oe er wa mf oe al a, 7 @ fos | ay Pwr |) pee [3 Pe j= ¢ ove gt el at i Bom HB Xb: pt) Waa rangssenr er wa | of oe wlod | Sal | etaneat« ve | XS: 4 m2] od grin oteen | YP Sines rer! BERA201 rate earee See also description EP-tronic 42...@ product from —BBEKA 7.2.2 Control unit type: EP-tronic - intermediate housing: Fig. 50: ~ - - J Inischengehiuse ns intermediate housing eras, | zs peer supply 120 fe ‘00-250¥ XO vist, _ _ [a He. Se Siotsignel EP- tronic ‘ Feltstns fa) ¢ old Bae Nihorongeschel ar vate x5: 1 | agi xO1 Pot Pe Steverungshalbschale i” EP- tronic! Lf @ contro! shell ee seante Sines rer! BERA201 rate earee Steckergarni tr See also description EP-tronic 43...@ product from | a B E KA 7.2.3 Control unit type: BEKA-troniX1 Voltage: Ub 10-60 V DC (nominal 12/24 V DC) Fig. 51: Pumpe ] Steverung BEKA- troniXi vne BENS roniXt control x1 eet orm Ast | 1543 ov $| 12/24V DC " 52) Faltstond x3: oe al, 1 © al 2 a mo i) eae ot et maT Me Ficzehnann wh XS: ee aed ~ vm | Foe ws oe der Elektreonsch ives ertelst gh der dose sabi tt ‘gum Bajonet stocker a Steckargarnitur XI tm eter 130 ase Ba Sines rer! BERA201 rate earee ie pts Fea amor reo ——Z See also description BEKA-tronix1Control unit type: BEKA-tronixt - (100-250 VAC) ...@ product from —BBEKA with intermediate housing Sines rer! BERA201 rate earee Meno ~ ~ ~~] Zwischengehiiuse Ewes rena intermediate housing or ‘sue tere | Tf ts) PE oye + = — Nise H BEKA- troniXt I Euutstond tt x3 wed wd wr Jd q old ne [Mafel Tp gta epee J et ent Deh inputs 1 Lines rors | tee Stoverungshalbschaye BEKA- troniX] | control shel! BER trent See also description BEKA-EP-tronic_2X...@ product from | a B E KA 7.25 Control unit type: EP-tronic ZX Voltage: Ub 10-60 V DC (nominal 12/24 V DC) Fig. 53: Pumpe pone Steverung EP- tronic ZX €P-"tronic 2X control tate Me 12/24 DC " Undrohungs- ont Me sa Um toe [e8 a oT : suns 2 ytd oy a we 3 1 aH 9 On, 1 red ® PNP ® ‘PNP ol od et en Bint = Xu >" Zu Néherungsschal ier 2 | apd sect) gle | Sea ES | soa pa ‘ve ita xs: NN Ri urate IRI we we | i silver BH Prox 2 gly al Sines rer! BERA201 rate earee Noerungsscholter Dhl iver Steckergornitur Xt See also description BEKA-EP-tronic_2X ‘green 46Sines rer! BERA201 rate earee 7.26 Control unit type: EP-tronic ZX - with intermediate housing (100-250v Ac) ...@ product from Fig. 54 , - sau st fs rr 10-250") Wi diame om] ae. 00 ev —BBEKA Zwischengehduse intermediate housing Statessigne! Futstond tol a5 [9 re pup | ate) pe + et at ne | mae ne on iy pes te ncn een EP- tronic 2X SNES ww Ors . , a ra Steverungshalbschale Br 4 stake EP- tronic 2X! control. shalt Ee Tronic 2 See also description BEKA-EP-tronic_2X...@ product from —BBEKA 7.2.7 Control unit type: EP-tronic ZX - with intermediate housing and temperature sensor (100-250 VAC) Fig. 55: re x 1 aren 05 a) ol us a ea , 1m 0 wm ‘plus gesprrt (2.8. Tewerotursenser wn ee msl, pele eles (1g. lmperaure senser] yc genes a | - N demons vin 03 . ON ee C 2wi schengehiuse {= _ intermediate housing : x22) de me | ca | sing ! EP- tronic 2X x3: 1 a Grier 1 ‘Srna ingame Jf . L ele g i 1 | veh ipas at P| ed cause Niherungsscho|ter X01? @ Ls cere at on Steverungshalbschole 1 EP tronic ZX! antral she ee ironie x + lsgleoanschluse arto ettthee nit Sines rer! BERA201 rate earee See also description BEKA-EP-tronic_ ZX 48...@ product from —BBEKA 7.28 Control unit type: EP-tronic ZX-S1 - with intermediate housing (100-250 Ac) Fig. 86: > - ~——— wi schengehituse 8:6! | intermediate housing wl ero cries a 10-2504} weed red, ners | TTT Fe i | ole) % EP- tronic 2X-St agit mint wig —_ 3 Ol oe o ole ine Pte ne a! Sled eZ a ety: Saco XS. faim “ge X01 |, UT Steverungs- site 0,75 halbschale EP- tronic 2x-S1 | contra! she ep Monte B31 viet a, Sines rer! BERA201 rate earee j j j See also description BEKA-EP-tronic_ 2X 497.2.9 Control unit type: EP-tronic ZX-S2 - wi ...@ product from a B E KA intermediate housing Voltage: Ub 10-60 V DC (nominal 12/24 V DC) Fig. 57: Steverung EP- tronic 2X-S2| Pumpe EP) fp “tronte control 2x32 Sines rar! BERA201 A rate earee pump EP 6 Unde ehungs= Kontakt Fotatton contact w Undr shongs- Kontakt Totottan contact Supe stipan |e cota ‘collecting mal fonction fts"contact clese. *20V eae ov Flaemane ie Tp —] Noherungsschat ter 2 om Verte ler ye | ob dl See also description BEKA-EP-troni fr Elacioensesiues arty! star schnsbichoe...@ product from —BBEKA 7.240 Control unit type: EP-tronic ZX-S2 - with intermediate housing (100250 VAG) Fig. 58: xh too-250v} a E és L - - |e ne | * iu pd tf te a} $130), 9 9) a2 ea} GSE Ge et St ey FeO ee a ne us TT saan hse sry) ams «a HE) Ble [| Steverungs- | st arene * halbschale EP- tronic ! 1X-S2 stasosgrn ie TS Sines rer! BERA201 rate earee See also description BEKA-EP-tronic_ 2X st‘aha ears 3 i i ...@ product from = B E KA 7.3. Basic filling of the central lubrication pump You receive the pump without grease filling. In orderto operate it you have to equipp itwith a basic filling. Proceed as described underitem 9.2. 7.4 Ventilate the central lubrication pump ‘+ Alter the start-up and after each complete emptying of the reservoir the central lubrication pump has to be ventilated! Unscrew main line from pump element. Activate the central lubrication pump until lubricant comes out of the pump element without air inclusions, Collect outcoming lubricant with a suitable receptacle (environmental predection, work safety) Do not reuse collected lubricant (risk of pollution)! Dispose collected lubricant professional! ‘Connect the main line to the pump elements. Operate the central lubrication pump. Check all connections visual during the first operating hours, Note! | Use the same procedure for the progressive distributors or lube points....@ product from a B E KA 8. Maintenance Stop the voltage feed, before starting with maintenance or repair. Maintenance and repair work may only be done at system's standstill and pressureless condition. Check the surface temperature of the central lubrication system, due to danger of burning by radiant heat. Always wear heat-resistance gloves! Soiled or contaminated surfaces have {0 be cleaned before maintenance works, wear predective cloths if necessary. Predect the ‘system from activation during maintenance and repair work! Tighten all fittings 6 weeks after start-up ‘+ Chock the level regular and refill clean lubricant if necessary ‘= Lubricant exchange depends on aging and pollution but should be made at least according to the machine manufacturer regulations Clean the reservoir thoroughly after each lubricant change ‘Take care that the lubricant quality of diferent lubricant suppliers, corresponds tothe prefilled lubricant! Check all components for leakages or damages at every four weeks 81 Preventive repair (wear parts) Check the system for the following items after itis put into operation again: © Function of the system ‘© Check the pipe lines (lubrication points, detached hoses, leakages) In the following years of operation, the condition of the hoses should be regularely checked (intervals see table). Due to the fact that the pump elementis subject to wear, the function has to be checked at least every two years. ‘The pump function and especially the proximity switch function has to be checked after each filing, lateral (year) 549. Preventive repair ( Y= control; X= replacement) Wear parts ~ Pump element Y x Proximity Switch jnasinesonce) x Distibutor Yiy x Hoses yY [yx “armatures: yYiyiy Fiings...@ product from a B E KA 82 Level of the central lubrication pump 8.2.1 Central lubrication pump without contro! unit and without level monitoring: Check the pump level regularely. Ifthe grease in the pump reservoir is at Fig. 59: nin. level, refllthe pump. Proceed as described underitem 9.2. Minimum The central lubrication pump must not fall below level Attention! | minimum tevel as the pump element then primes air and supplies itinto the system. 82.2 Centrallubrication pump with level moni ring: ‘The external signal is active, level is too low (depends on connection, see 5). Fillup the pump as described initem 9.2. 8.2.3 Centrallubrication pump with control unit: ‘The pump levelis electronically monitored. Ifall grease is used, the integrated level monitoring sends a signal to the control unit. The unit switches off the pump and indicates an error. The red LED in the control unit window, the external red lamp or the lamp of the collective fault signal are active. Fill up the pump as described under 9.2. lfthereis enough lubricantin the pump, the erroris deleted automatically. Grease levels toolow: Fig. 60: Loeunace nec Se LED green (cairt uit stay) + Lampe green (ester) Lubricant exchange lubricant change ‘The lubricant exchange has to be carried out acc. to the lubricant manufacturer's details; ambientinfluences like high temperatures or sollings can reduce the mentioned intervals. A change or exchange of lubricant has to be discussed with the manufacturer of the power Note! plant and of the central lubrication system. Please observe only to use greases that aro Suitable for the central lubrication system (e.g. do not use greases with solid contents with ‘MoS,), and that fulfil the requirements of use. Please also observe the compatibility of the “old” and “new” lubricant. Empty the lubicant reservoir complete and professional and clean it. Pay attention tothe details of lubricant or bearing manufacturer concerning specialities of a lubricant exchange within the distributor system and in the lubrication points (e.g. ball bearing). Sines rer! BERA201 rate earee...@ product from a B E KA 9. Repair Hyou recognise an error during the maintenance of the pump, you can read in this chapter how to proceed. 9.1 The central lubrication pump does not operate 9.1.1 Central lubrication pump without control uni ‘The pump does not operate. The lubrication process can not be finished propery. Electric line is defect. Replace the cable as described under item 7. ‘The motor of the central lubrication pump is defect. Replace the central lubrication pump and send the pump in for being repaired. After installation of the central lubrication pump, check the correct function of the pump. 9.1.2 Central lubrication pump with control unit: ‘The central lubrication pump does not start automatically after the set cycle time and can not be started with the intermediate lubrication button. After the set monitoring time, the pump shows a pulse error but there is no error as described in the operating manual. Electric line defective. Exchange the lines, proceed as described under item 7. ‘The motor of the lubrication pump is defective, replace the pump and send itin for being repaired ‘The control unitis defective, the red LED in the control unit window flashes and the signal lamp of the collective fault signal glows. Replace the pump and senditin for being repaired. After installation of the pump, check the correct function of the central lubrication pump.‘aha ears eric ...@ product from a B E KA 9.2 Filling ofthe central lubricaton pump. ‘The reservoir has to be filled after the lubricant is used as well as after the delivery as the pump is delivered without fling. Proceed as described below. NOTE: The FKGGM-EPR central lubrication pump is delivered unfilled. Proceed at the basic filing as described in the enclosed instructions (1090200462) ‘Attention! | Thishas to be done only atthe first filing when the pump is emply. Later fillings can be done “| during the operation via the filing connection or the filing nipple! 9.2.1 Filling procedure: Connect the central lubrication pump as described under item 7. Put the pump in operation. ‘The pump shall be filled by means of the grease gun (fig. 62) via the installed filing connection. The filing press must be prepared before the filling so that no air is conducted into the system. For this purpose, press out about 40mm oflubricant (ig. 63). Unscrew the cover ofthe filling connection and fill up the pump until the max. level. Screwon the cover again ‘The pump can also be filled via the installed hand lever grease gun (fig. 65). The grease gun must be prepared to avoid air inclusions. For this purpose, press out about 10 mm of lubricant (fig. 66). Pull offthe cap from the lubricating nipple and fill up the pump until max. evel. Putthe cap on again, Fig. 61: Fig. 62: Example for BEKA Grease gun (accessories - suitable for ‘artidge aco to DIN 1284) BEKAorderno, 2123000" Overfl protection —_— Fling connection...@ product from a B E KA Fig. 65 —— Connection level monitoring Fe) hand lever grease gun (eonessores - suitable for ‘cartidge ace. DIN 1284) BEK/\order-no, 21590080008 Filing cover Fig. 66: Filling nipple | af Lubricant Absolutely prevent air from entering the system during the filing, as otherwise @ maifunction of the system is caused, Cleaning material that is contaminated with lubricant has to be disposed environmentaly friendly. 7" Take care of utmost cleanness! Attention! | The ventilation screws are only for the basic filing. Do notremove them. The overfill protection isfor the pump safety. Lubricant evades if he max. levelis exceeded. Observe that no ventilation openingis blocked. Observe the details of the lubricant manufacturer! Observe the safety data sheet of the lubricant manufacturer! Viscosity range of lubricant changes with operating temperature, Initiate @ lubrication interval to check the pump's function. ‘aha ears u i i 987eric ...@ product from a B E KA 9.2.2 _ Filling types of acentral lubrication pump: Fillup the reservoir with clean lubricant, ‘* Fill up via the filling nipple by means of manual actuated or pneumatic grease gun ‘+ Fill up via the filling coupling (special equippment) Fill up via the filing press (special equippment). ‘© Fill up via the reservoir with filling cover via the cover. Avoid this type of filing as this can cause air inclusions. ‘Standard filing via the cone type lubricating nipple with manual or pneumatic grease gun: Fig. 67 Fill-up lubricating nipple Filing via filling coupling Fig. 68: Remove lubricating nipple G2 replace ity DP coupling plug grease Order-no.: 2159 0061 012 Filling plug grease Order-no.: Grease sleeve 2159 0061 011 Order-no.: 2159 0062 011 Fill-up via grease gun: Fig. 69: Filling press Order-no.: 2081 030 269.2.3 Filling connection and filling tools: Fig.70: Filling press for grease cartridges acc. to DIN 1284 Order-no.: 208103026 ace. to drawing: FAZ02493_02 | I Order-no.: 10104288 2.50 Manx connection 90° no. 21820149 ‘drawing: FAZ02519_04 aox1.5 ing connection 90° Order-no.: 21520147 ace. to drawing: FAZ02519_06 2.57 ing connection 45° (pivotable) Order-no.: 21520146 ‘Straight filling connection ...@ product from a B E KA Version for pump with follow-up piston Filling press for grease cartridges acc. to DIN 1284 Order-no.: 20830001 ‘acc. to drawing: FAZ02493_03 ca 488 oe1s Straight filling connection with non-return valve Order-no.: 21520152 ace. to drawing: FAZ03177_00 ling connection 90° ith non-return valve Order-no.: 21520174 § ace. to drawing: FAZ03177_01 Mzox1eric ...@ product from a B E KA 9.3. Exchange distributor of a central lubrication pump with installed distributor Demount lube point line of progressive distributor. Loosen the screw and pull out the distributor. Insert a new distributor with sealing ring and observe the position of the reservoir feedback. Fasten the distributor at he pump element by means ofthe screw and observe the according torque (fig. 71). Ventilate the distributor and fasten the lubrication pinion line atthe outlets. Fig. 71: _/ Pump element 7 Sealing ting / distributor Sealing tng / Screw S/N A ‘Weare notliable for damages or injuries caused by improper assembly works. ‘Check the correct function ofthe central lubrication pump after exchange of the distributor 9.4 Exchange of proximity switch Check the fun: ‘Check the function of the proximity switch = NS. Activate the pump and check if the orange LED at the proximity switch flashes (fig. 72). I not readjust the reacting distance. Readjustment of reacting distance: Loosen the counter nut of the proximity switch and carefully screw in the proximity switch until stop, Then screw ‘out the proximity switch by 1/4 tum, so that the reacting distance is about 1,8 mm. Tighten the counter nut to ‘secure the proximity switch. Then check the function of the switch, Perhaps the proximity switch has to be set anew or the proximity switch is defective and must be exchanged. Exchange of pro: ity switch: Fig. 72: Proximity switen Exchange the defective proximity switch and LED orange — . proceed as described in readjustment of reacting sseveuin sith um E distance. op, then unscrew it 8 by tiatum q After the readjustment or after installation of the proximity switch, check the function of the complete pump....@ product from a B E KA 9.5 Exchange of pump element 9.5.1 Exchange pump element at central lubrication pump FKGGM EP and FKGGM-EPR, Unscrew the pump element with pressure limiting valve (fig. 74) but do not pull it out yet (fig. 75). Then tilt up the pump element with pressure limiting valve (piston head) and take it out the housing in this position (fig. 76). Attention! | The delivery piston must not remain in the pump housing. Unscrew the defective pump element from the socket. Fasten the new pump element and tighten it with the according torque (see fig. 73). Fig. 73: AF 19 48Nm £10% Pressure limiting valve 9) / Pump element Delivery piston AF 24| Socket 45Nm #10% ‘When installing the pump element with pressure limiting valve, pull out the delivery piston partly. Then insert the ump element with pressure limiting vaive from a sloping upward position into the housing until the piston head touches the thrust ring (fig. 76). Put the element in horizontal position (fig. 68). The piston head must be in the groove of the guide ring (fig. 74). Tighten the pump element with the according torque (fig. 73). ‘Attention! | Pumeelementor pump are going tobe damaged ifthe element was not properly installed Ventilate the pump as described under chapter 7.4. After installation of the pump element, check the proper function of the central lubrication pump. Fig. 74: Fig. 75: Fig. 76: Piston head Thrust ring/’ 61‘aha ears 3 i i ...@ product from a B E KA 9.5.2 Exchange pump element of central lubrication pump FKGGM-EP with installed distributor Demountdistributor as described under 9.3, Unscrew the pump element (fig. 78) but do not pullitout yet (fig. 79). Then tit up the pump element (piston head) and take it out he housing in this position (fig. 60).. Attention! upward position Attention! Fig. 77: ‘The delivery piston must not remainin the pump housing. ‘When installing the pump element, pull out the delivery piston partly. Then insert the pump elementtroma sloping into the housing until the piston head touches the thrust ring (fig. 80). Put the element in horizontal position. The piston head must be in the groove of the guide ring (fig. 79). Tighten the pump element with the according torque (fig. 77). Pump element or pump are going to be damaged if the element was not properly installed / / Pump element / B28 Distributor / Screw (/ 2545 Nm Finally fasten the distributor as described under 9.3. Fig. 78 Fig. 79: Fig. 80: Piston head Thrust ri 5 CCH “tens...@ product from a B E KA 9.6 Levelerror Check the cable of the level monitoring visual and electrical. Find the error and replace the cable. Ifthere isno problem with the cable, the level monitoring is defective. Exchange the reservoir cover with installed level monitoring, 9.6.1 Centrallubrication pump FKGGM -EP Exchange of cable: Loosen the knurled nut from the angled plug of the level monitoring (figl. 81). Pull off the plug. Now put the new cable on and tighten the knurled nut. The plug can only be put on in a certain position, Now connect the other end asdescribed under item 5. Exchange of reservoir cover with installed level monitoring: Loosen the knurled nut from the angled plug and pull off the plug. Unscrew the head nut of the tie rods and disassemble the reservoir cover. The new caver with installed level monitoring can be installed now. Take care of the monitoring position. Assemble the cover and tighten the head nuts on the tie rods. Put the angled plug onto the level monitoring and tighten the knurled nut. The plug can only be put on in a certain position. Fig. 81: 6 ~ Head nut — Reservoir cover with installed level monitoring Angled plug level ‘monitoring eric ‘The cable connection of the reservoir with level monitoring must be done by professional staff. We are not liable for damages or injuries due to improper assembly works. After exchanging the cable or the reservoir with level monitoring, check the correct function of the pump....@ product from a B E KA 9.6.2 Centrallubrication pump FKGGM-EPR Exchange of cable: Fig. 82: Metal surtacs LED oran Loosen the knurled nut from the plug of the proximity switch ie ‘as well as from the red marked ring at the control unit (fig. £83; pos. 1 and 2). Pull offthe plug. Putthe new cable on and tighten the knurled nut. The plug can only be put on in a certain position, \\ connected to ‘switch next. Demount the proximity switch by loosening the hexagon nut, then take out the switch. Move the still connected proximity switch over a metal surface (fig. 82). If Fig. 83: the orange LED does not flash during the movement, the proximity switch s defective. Replace it. poamuch de trageectaere from the plug, and take off the plug. Measure dimensionA of the new proximity switch (fig. 84 and table). Screw the new ——— ‘switch into the housing and tighten the hexagon nut. yf Observe reference dimension C (fig. 84 and 85)! Put the 1 straight plug onto the proximity switch and tighten the knurled nut. The plug can only be put on in-a certain position. = Cable of level monitoring Proximity switch is demounted. Loosen the knurled nut | Fig. 84: Hexagon nut Proximity switch _/ eam iv § . ost ate t 4 5 40 . x 2 z —— i Sealing ring $ a The cable connection of the reservoir with level monitoring must eeyagon nut a be done by professional staff. We are not liable for damages or Be injuries due to improper assembly works. : After exchanging the cable or the reservoir with level monitoring, check the correct function of the pump. Sine a...@ product from a B E KA 10. Troubleshooting Faults Possible cause Pos Pump does not operate Pump defective Control unit defective electr ine is broken Pump element not fxed Exchange pump Exchange pump Renew line Exchange pump element Pump operates but does not deliver Level too low Pump element defective Air below follow-up piston Air cushion in the delivery piston Refill reservoir Exchange pump element Ventilate pump Ventilate pump No grease at one lubrication point Lubrication time (pump runtime) too low Main line burst or leaky Distributor defective Adjust lubrication time (PLC) Renew main line Exchange distributor Pump shows level error Level too low Level switch defective Cable of level switch is broken Refill reservoir Replace level switch Exchange cable Pump shows error CPU/ memory Control unit defective Replace pump Pump shows pulse error Pump does not operate Air below follow-up piston Pump element defective Proximity switch at distributor defective Main line burst or leaky Cable of progressive distributor defective ‘see 9.1 ,pump does not operate” Ventilate pump Exchange pump element Exchange proximity switch Replace line or exchange / retighten fittings. Exchange cable Pump speed reduced High system pressure Supply voltage too low ‘Check system/bearing points No damage (interm lubrication may be required 1 to 2 times. Check voltage ‘aha ears 3 Lubricant comes out of saftey valve ‘System pressure too high Progressive distributor blocked ‘System blocked Valve spring broken ‘Check system Replace distributor Replair blocked/stuck bearing points Exchange safety valve i iSines rer! BERA201 rate earee ...@ product from = B E KA BEKA BAIER + KOPPEL GmbH + Co. KG BeethovenstraRe 14 91257 PEGNITZ/BAVARIA Tel. 449 9241 / 729-0 FAX +449 9241 / 729-50 POSTFACH 1320 91253 PEGNITZ WEB: http:/iwww.beka-lube.de E-MAIL: [email protected] Other products from our range of supplies: Gear pumps Multiline oil pumps Multiline grease pumps Single line central lubrication systems Dual line central lubrication pumps il circulation central lubrication systems Oilair and spray lubrication Wheel flange central lubrication systems Rolling mill central lubrication systems ‘Commercial vehicle lubrication Progressive distributors Control and monitoring units ‘Subject to alterations! We are not liable for errors, technical errors and printing errors!