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Summary of Contents for BEKA EP-1
- Page 1 Original operating and assembly manual for grease lubrication pumps EP-1 FKGGM-EP FKGGM-EP with power supply unit, AC 1 without control unit with integrated control units: BEKA-troniX1 EP-tronic EP-tronic T1 EP-T2 BEKA 2016 All rights reserved!
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Page 2: Table Of Contents
7.3. Central lubrication pump EP-1 and FKGGM-EP with integrated control unit BEKA-troniX1 ......14 7.4. - Page 3 21.3 Control unit BEKA-troniX1 ........
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Page 4: Declaration Of Incorporation
The special documentation that responds to the machine, has been prepared according to annex VII part B. The manufacturer (documentation department, phone +49 9241 729-779, email: tb3@beka-lube.de) obliges itself to pass on electronically the special documentation for partly completed machinery to individual national authorities upon request. Pegnitz, 27.03.2013 ppa. -
Page 5: Legend
All guarantees and warranties expire for damages to central lubrication systems that are caused by operation with improper lubricants (e.g. piston wear, piston jamming, pluggings, embrittled sealings). BEKA does not assume liability on damages caused by lubricants, even Attention! if these lubricants have been tested and released by laboratory tests, as damages caused by lubricants (e.g. - Page 6 The pumps of the series EP or FKGGM-EP serve only for the supply of central lubrication pumps at vehicles, systems and machines. Any use beyond this scope is regarded as being not in conformity with the intended purpose. Disclaimer of liability; BEKA is not liable for damage caused by: · lack of lubricant ·...
- Page 7 The use of other parts may rule out liability for the consequences of such use. For components, which are retrofitted by the operator, BEKA does not assume liability nor claims for compensation. Danger caused by the electrics: The units may be connected to the power supply exclusively by appropriately trained qualified personal in conformity with the local connection conditions and regulation (e.
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Page 8: Technical Data
115 V AC / 60 Hz (via installed PSU) Current consumption: max. 0.2 A (230 V AC) Speed: 15 U / min. Duty cycle: 10 % ED (10 min) Operating temperature: -20° C to +70° C BEKA 2016 All rights reserved! - Page 9 IP5K9K at DIN 40050 Weight: EP-1, FKGGM-EP DC: approx. 5.1 kg FKGGM-EP with PSU: approx. 5.8 kg Control units BEKA-troniX1, EP-tronic, EP-tronic T1: Operating voltage: 10 to 60 V DC Max. current load: I = 6 A Fuse (not including in device): F 6.3 A (5x20) medium...
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Page 10: Assembly Manual
The electrical components of the system must be wired expert. · Compare the voltage details with the existing mains voltage Overview and installation dimensions: 6.1. Central lubrication pump EP-1 and FKGGM-EP with steel reservoir: “X” Model with Ø150 4 kg reservoir View “X”... - Page 11 6.2. Central lubrication pump EP-1 and FKGGM-EP with transparent reservoir: Option with screw cover Option Ø180 with screw cover Model with Ø153 4 kg reservoir Model with Ø150,5 2,5 kg reservoir Model with 1,9 kg reservoir Ø9,5 Ø9,5 Pipe Pipe...
- Page 12 ...a product of BEKA “X” Model with Ø225 kg reservoir “X” Model with 8 kg reservoir Ø225 “Z” Ø9,5 Pipe connection dia. 6 Connection cable length 10 m View “X” View “Z” 152,5 BEKA 2016 All rights reserved!
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Page 13: Terminal Diagrams
Terminal diagrams: 7.1. Central lubrication pump EP-1 and FKGGM-EP without control unit: blue brown - (Ground) 7.2. Central lubrication pump EP-1 without control unit: Special model with bayonet connector: blue (PIN 1) brown (PIN 2) - (Ground) (PIN ...) = Assignement of the line socket... -
Page 14: Central Lubrication Pump Ep-1 And Fkggm-Ep With Integrated Control Unit Beka-Tronix1
...a product of BEKA 7.3. Central lubrication pump EP-1 and FKGGM-EP with integrated control unit BEKA-troniX1: Option Option micro switch for Switch for grease pressure relief valve level monitoring monitoring green (no. 1) Signal lamp green red (no. 2) Signal lamp red... -
Page 15: Central Lubrication Pump Ep-1 And Fkggm-Ep With Integrated Control Unit Ep-Tronic
- (Ground, terminal 31) blue (PIN 5) + (Brake light, terminal 54) (PIN ...) = Assignment of the line socket 7.6. Central lubrication pump EP-1 and FKGGM-EP with integrated control unit EP-tronic: Option Terminal 50 starter Option and ignition optional... -
Page 16: Central Lubrication Pump Fkggm-Ep With Power Supply Unit
230 V). Function and design of the system: The central lubrication system into which an electrical pump EP-1 or FKGGM-EP is installed, is a progressive system. Progressive means that the lubrication points are lubricated in sequence. The sequential lubrication means a pressure relief valve can easily monitor the progressive central lubrication system. -
Page 17: Function Of The Central Lubrication Pump
Function of the central lubrication pump: The central lubrication pump EP-1 or FKGGM-EP is designed for delivering lubricant up to NLGI class 2. The agitator blade pushes the lubricant through a grease sieve to the intake section of the pump element. The pump element is positively driven by an eccentric so that function is also ensured at low temperatures. -
Page 18: Grease Level Monitoring With Cubic Plug Acc. To Din 43650
10 to 60 V DC Connection method: PNP-NO (normally open contact) Switching current: at 70°C: 250 mA Current consumption: without load: <20 mA Protection class: switch: IP 67 switch: IP 54 Ambient temperature range: -20°C - +70°C BEKA 2016 All rights reserved! -
Page 19: Micro Switch At The Pressure Relief Valve
NO (normally open blue Contact type: 1 changeover switch contact) Temperature range: -25° C to +85° C brown NC (normally closed Protection class: IP 67 contact) Connection: Cable, length 0.5 m, welded brown black blue BEKA 2016 All rights reserved! -
Page 20: Pump Elements
PE-60, PE-120, PE-170: There are different pump elements available for the installation Pressure relief valve into a central lubrication pump EP-1 or FKGGM-EP. You cannot set at 280 bar adjust the output rate at the pump elements PE-60, PE-120 and permanently PE-170 but at the pump element PE-120 V this is possible. -
Page 21: Installation And Removal Of The Pump Elements
- Screw back the adjusting screw (3) by 1 notch per revolution of the agitator blade - Operate the pump until oil comes out of the screw plug thread - Assemble the screw plug (2) incl. sealing ring and tighten it BEKA 2016 All rights reserved! -
Page 22: Special Accessory Malfunction Indicator At Pressure Relief Valve
...a product of BEKA 10.5. Special accessory malfunction indicator at pressure relief valve: The pump elements for the electric pump EP-1 can be equipped with a visual malfunction indicator. If a Malfunction malfunction occurs in the central lubrication system indicator on... -
Page 23: Operating Mode Cycle Control
Function display: LED yellow Connection method: PNP-NO Housing material: stainless steel (normally open contact) Protection class of switch: IP 67 Power rating: 200 mA Ambient temperature range:-40° C to +85° C Connection: 4 poles, M12x1 pluggable BEKA 2016 All rights reserved! -
Page 24: Special Equipment - Internal Data Memory
...a product of BEKA 11.1.3.Special equipment Internal memory: The below listed values are saved at the control unit BEKA-troniX1. They can be read out or changed with the diagnosis software BEKA-DiSys: Controlling type Version of control unit Serial number Manufacturing date... - Page 25 Sets of stickers can be ordered for this purpose, the control unit but the stickers can also be ordered indivivually. Sticker set for BEKA-troniX1 in German Sticker set for EP-tronic in German Order-no.: 0490000342 Order-no.: 0490000317 Sticker set for BEKA-troniX1 in English Order-no.: 0490000343...
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Page 26: Optional Equipment
The pump starts to operate again automatically with refilling of the reservoir. Pressure relief valve monitoring at the BEKA-troniX1 and the EP-tronic: With a micro switch, which is mounted at the pressure relief valve of the Micro switch pump element, the operating pressure of the system can be monitored. -
Page 27: Starter Release Or Collective Fault Signal At Ep-Tronic
You can select between “normal, light or heavy duty” adjustment. The adjustment “normal” is the standard setting, cycle time is effected as adjusted. Cycle time 100 % e. g. 2 h Lubrication time BEKA 2016 All rights reserved! -
Page 28: Function Of The Control Unit Ep-Tronic T1
The control unit assumes that the vehicle is no longer in motion. The total lubrication time sums up of several short ones: SZ3 SZ4 Cycle time (ZZ) SZ1 + SZ2 + SZ3 + SZ4 = sum of lubrication times BEKA 2016 All rights reserved! -
Page 29: Extras
11.2.2.Extras: Adjustment of the adjusting ranges: The adjusting ranges can be changed by means of the diagnostic software BEKA-DiSys. All adjusting ranges for the lubrication time can be combined with all cycle time ranges. Connection of the Adjusting ranges: system diagnosis... -
Page 30: Function Sequence Of The Control Unit Ep-T2
Short interruptions of the brake process of less than 1 sec. are ignored by the control device. Braking with short interruptions: Brake Pump Adjusted Interruption lubrication time of braking Short interruption of braking Duration of braking Braking shorter than the lubrication time: Brake Pump Duration of braking Adjusted lubrication time BEKA 2016 All rights reserved! -
Page 31: Adjustment Of The Control Units
If the cover plate is not replaced properly, water may enter the control unit Attention! and damage it. Your guarantee expires in this case. System diagnosis port Graduating switch for setting the cycle time Graduating switch for setting the lubricating time BEKA 2016 All rights reserved! -
Page 32: Filling Of The Pump
Filling connection, straight Order-no.: 2152 0150 Utmost cleanness is essential for this work! Attention! Only fill in clean lubricant! The service life of the pump elements highly depends on the quality Note! (impurities) of the used lubricant. BEKA 2016 All rights reserved! -
Page 33: Signals
1 sec. lubrication LED green 1 sec. In order to activate permanent lubrication for service purposes in the mode “time control”, the lubrication time has to be set on a higher value than the cycle time. BEKA 2016 All rights reserved! -
Page 34: Ventilation Of The Pump
- Check the perfect function of the control unit by triggering an intermediate lubrication - Only replace defective fuses by equivalent ones - Check all components for leakages or damages every four weeks. All further works may only be carried out by the staff of BEKA or by staff Attention! trained by BEKA. -
Page 35: Spare Parts Drawing
18. Spare parts drawing: 1,9 kg reservoir Ø 150 mm Reservoir 1,9 kg 2,5 kg 4 / 4,2 kg 8 kg 16 kg Cable for grease level monitoring for all reservoirs 13.1 13.2 15.1 27.1 27.2 BEKA 2016 All rights reserved! - Page 36 ...a product of BEKA 2,5 kg reservoir 4 resp. 4,2 kg reservoir Ø 150 mm Ø 180 mm 50.1 63.1 59.1 48.1 56.1 BEKA 2016 All rights reserved!
- Page 37 8 kg reservoir, 16 kg reservoir, Ø 226 mm Ø 226 mm 78.1 BEKA 2016 All rights reserved!
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Page 38: Spare Parts List
21520068 with lubrication nipple without connecting piece Pressure relief valve for PE-60 to PE-170 215299115 with micro switch for BEKA-troniX1 and EP-tronic Pressure relief valve for PE-60 to PE-170 215299100 with micro switch without plug M12x1 Pump element PE-120 V without pressure relief 2152990630014 valve incl. - Page 39 7-pole Hirschmann connector for FKGGM-EP with PSU 1.9 kg lubricant reservoir: Agitator blade f. 1.9 kg reservoir w. fastening material 21520053 Transparent reservoir 1.9 kg FMZ00460-00 Filling level sticker for 1.9 kg reservoir BEKA-MAX 0490030103 Socket head cap screw M4x12 , Tuflok coated 0900912003232 2.5 kg lubricant reservoir (outside dia.
- Page 40 Item number Filling level sticker for 4 resp 4.2 kg reservoir 0490030219 model for grease with BEKA-MAX-Logo Reservoir cover 4 kg with level monitoring min. with plug connection M12x1, standard version with order key or w/o connection cable, incl. O-ring, head nut a. ventilation 59.1...
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Page 41: Order Key Of Level Monitoring
Socket w. Cable connection socket plug socket plug Switch type NO contact NC contact Code Filling cover Code Special version Code * Version for connection at integrated control unit (only at min. 10-60 V DC) BEKA 2016 All rights reserved! -
Page 42: Control Unit Ep-Tronic
1 to 16 strokes 17 to 32 strokes 33 to 48 strokes Pump revolutions 1 to 16 10 to 160 170 to 320 with collective fault signal (stat. error) (Standard) with starter release Special models BEKA 2016 All rights reserved! -
Page 43: Control Unit Ep-Tronic T1
2 to 32 h 1 to 16 min. II 2 to 32 min. III 2 to 32 sec. Revolutions of the pump 1 to 16 II 10 to 160 III 170 to 320 Special models 000 BEKA 2016 All rights reserved! -
Page 44: Control Unit Ep-T2
...a product of BEKA 20.4. Control unit EP-T2: Type 2184 . 90 . 10 . X . XXXXX Connector version with bayonet connector 10 Lubrication time range Code 1 sec. to 60 sec. without Special models Code 00000 BEKA 2016 All rights reserved! - Page 45 - Fitting leaky Re-tighten or renew the fitting - High pressure in the Reduced pump speed system Check system / bearing - Low ambient temperature points Not defectiveness (1 or 2 intermediate lubrication cycles might be useful) BEKA 2016 All rights reserved!
- Page 46 - Adapt the adjustment to the inspection window of the control unit the sticker in the inspection window or exchange the sticker BEKA 2016 All rights reserved!
- Page 47 For your notes: BEKA 2016 All rights reserved!
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Page 48: Details On The Manufacturer
Dual line central lubrication systems Oil circulation central lubrication systems Oil/air and spray lubrication Wheel flange central lubrication systems Rolling mill central lubrication systems Commercial vehicle lubrication Progressive distributors Control and monitoring units BEKA 2016 All rights reserved! Subject to alterations!
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