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Central lubrication pump
Article-no.
2076 . ......
FKGGM-EP / EPR
FKGGM-EP / EPR
FKGGM-EP
- without control unit
- with integrated control unit EP-tronic 2157. .....
- with integrated control unit BEKA-troniX1 2175. .....
- with integrated control unit EP-tronic ZX 2060. .....
- with integrated control unit EP-tronic ZX - S1 2060. .....
- with integrated control unit EP-tronic ZX - S2 2060. .....
State of art: 01 / 2019
Original operating
and
assembly instructions
...a product from
V DC
V AC
with installed MX-F distributor
1
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Summary of Contents for BEKA FKGGM-EP V DC
- Page 1 - without control unit - with integrated control unit EP-tronic 2157..- with integrated control unit BEKA-troniX1 2175..- with integrated control unit EP-tronic ZX 2060..- with integrated control unit EP-tronic ZX - S1 2060..
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Page 2: Table Of Contents
...a product from Content Page Declaration of incorporation ..............4-5 General Intended use . - Page 3 7.2.4 Control unit type: BEKA-troniX1 - with intermediate housing ......45 7.2.5 Control unit type: EP-tronic ZX .
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Page 4: Declaration Of Incorporation
...a product from Declaration of incorporation... - Page 5 ...a product from...
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Page 6: General
· The mentioned technical data must not be exceed 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. -
Page 7: 1.3 Safety Instructions
...a product from 1.3 Safety instructions All persons that are in charge with the assembly, start-up, maintenance and operation of the device must carefully read these instructions. Furthermore this manual must permanently be available at the site of operation! Basic notes 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. -
Page 8: 1.3.4 Owner's / Operators' Obligations
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 consequences. BEKA does not assume liability for parts that are retrofit by the operator. 1.3.7... -
Page 9: 1.3.8 Electrostatic Discharge
Disposal of the central lubrication system must be done properly and professionally and according to the national and international laws and regulations. Moreover, BEKA central lubrication systems could contain batteries. Professionally and properly disposed batteries will be recycled. They contain important raw materials. -
Page 10: Technical Data Fkggm-Epr /Epr
Motor cover / control unit housing:.......................plastic Pump parts: ..........................steel C4 / 720 h acc. to BEKA company standard corrosivity category A ................zinc-nickel coated acc. to DIN 50979 Missing details and technical data can be found on the data sheets and operating manuals of the manufacturers (on request). -
Page 11: Functional Description
...a product from Functional description Function and setup of a central lubrication system Wind power plants, compressors, tool machines, textile machines, print machines, packing machines, presses, plastic-, wood-, or metal processing machines, etc. 3.1.1 Function and setup of a progressive central lubrication system The progressive central lubrication system consists of a central lubrication pump, a main distributor and secondary distributors (related on the system). -
Page 12: Function And Setup Of A Single Line Central Lubrication System
...a product from 3.1.2 Function and setup of a 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. It shall be installed at the end of the longest line in the system. -
Page 13: Function Of The Central Lubrication Pump
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 large version WS-fitting Straight filling connection... -
Page 14: Central Lubrication Pump Fkggm - Epr
The agitator pushes the medium into the suction chamber; at the same time rising gas bubbles can escape. Components: Fig. 4 (example 2076 00584): Reservoir Ventilation 4 liter Level sticker BEKA WIND Filling nipple follow-up piston with dust cap spring loaded Overfill predection 0,5 bar fitting... -
Page 15: Central Lubrication Pump Fkggm - Ep / Epr With Installed Mx-F Distributor
Components: Fig. 5 (example 2076 00118): Ventilation Reservoir 2,5 liter Distributor combination Level label BEKA WIND MXF 5/5 Pump element PE-170 Filling nipple with dust cap Greaser with dust cap... -
Page 16: Pump Element (Pe)
...a product from Pump element (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. -
Page 17: Pump Elements Pe-60, Pe-120 Und Pe.170
...a product from 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 ø6, ø8 or ø10 (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. -
Page 18: Pump Element Pe-120 V
...a product from 3.3.2 Pump element PE-120 V The pump element PE-120 V with controllable output rate is set to full lift by default. Fig.10: Regulation of metering volume: · Remove the sealing screw (fig. 10, pos. 1) by means of a hexagon socket wrench Af5 ·... -
Page 19: Pu Mp Element With Solenoid Valve At Cen Tral Lubrication Pumps For Single Line Systems
...a product from 3.3.3 mp element with solenoid valve at cen tral 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. - Page 20 ...a product from 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 line 110 24 V/DC 3G x 1 with PE Contact box for connection...
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Page 21: Installation Dimensions
...a product from Installation dimensions Installation dimensions of construction variation of motor housing (with or without integrated control) Fig. 15: Variation 12/24 V DC Variation 100-250 V AC without integrated control with intermediate housing for integrated PSU without integrated control Variante 100-250 V AC Variation 12/24 V DC with intermediate housing for integrated PSU... -
Page 22: Central Lubrication Pump Fkggm - Ep
...a product from Central lubrication pump FKGGM - EP 4.1.1 Central lubrication pump FKGGM - EP 1,9 Liter reservoir Fig. 16: ø6 4.1.2 Central lubrication pump FKGGM - EP 4.1.2.1 2,5 Liter reservoir - without level monitoring Fig. 17: ø6... -
Page 23: Liter Reservoir - With Level Monitoring
...a product from 4.1.2.2 2,5 liter reservoir - with level monitoring Fig. 18: ø6 4.1.2.3 2,5 liter reservoir - with filling cover Fig. 19: ø6... -
Page 24: Central Lubrication Pump Fkggm - Ep 4 Liter Reservoir
...a product from 4.1.3 Central lubrication pump FKGGM - EP 4 liter reservoir Fig. 20: ø6 4.1.4 Central lubrication pump FKGGM - EP 8 liter reservoir Fig. 21: ø6... -
Page 25: Central Lubrication Pump Fkggm - Ep 12 Liter Reservoir
...a product from 4.1.5 Central lubrication pump FKGGM - EP 12 liter reservoir Fig. 22: ø6... -
Page 26: Central Lubrication Pump Fkggm - Ep 16 Liter Reservoir
...a product from 4.1.6 Central lubrication pump FKGGM - EP 16 liter reservoir Fig. 23: ø6... -
Page 27: Central Lubrication Pump Fkggm - Ep 20 Liter Reservoir
...a product from 4.1.7 Central lubrication pump FKGGM - EP 20 liter reservoir Fig. 24: ø6 ø11... -
Page 28: Central Lubrication Pump Fkggm - Ep 30 Liter Reservoir
...a product from 4.1.8 Central lubrication pump FKGGM - EP 30 liter reservoir Fig. 25: ø6 ø11... -
Page 29: Central Lubrication Pump Fkggm - Epr
...a product from Central lubrication pump FKGGM - EPR 4.2.1 Central lubrication pump EPR 4 liter reservoir Fig. 26: ø6 ø9,5 4.2.2 Central lubrication pump EPR 8 liter reservoir Fig. 27: ø6 ø11... -
Page 30: Central Lubrication Pump Fkggm - Epr 12 Liter Reservoir
...a product from 4.2.3 Central lubrication pump EPR 12 liter reservoir Fig. 28: ø6 ø11... -
Page 31: Central Lubrication Pump Fkggm - Epr 15 Liter Reservoir
...a product from 4.2.4 Central lubrication pump EPR 15 liter reservoir Fig. 29: ø6... -
Page 32: Central Lubrication Pump Fkggm - Epr 20 Liter Reservoir
...a product from 4.2.5 Central lubrication pump EPR 20 liter reservoir Fig. 30: ø6... -
Page 33: Central Lubrication Pump Fkggm - Ep With Installed Mx-F Distributor
...a product from Central lubrication pump FKGGM - EP with installed MX-F distributor Fig. 31:... -
Page 34: Accessories
...a product from Accessories Level monitoring The level monitoring is connected with the integrated control unit by default. Anyway it can be also connected to an external control unit. 5.1.1 FKGGM - EP Pump Proximity switch with plug-type M12x1 - 10-60 V/DC: Fig. -
Page 35: Fkggm-Ep Pump - Proximity Switch With Plug-Type Connection M12X1 - 90-250 V/Ac
...a product from 5.1.2 FKGGM - EP Pump Proximity switch - connection cubic plug acc. to DIN 43650 - 10-60 V/DC The NO / NC function must be selected when ordering. Connect the level monitoring by means of a suitable cable at the contact box. Connect this to the level monitoring of the pump and tighten the fsastening screw. -
Page 36: Fkggm-Epr Pump - Proximity Switch With Plug-Type Connection M12X1
...a product from 5.1.4 FKGGM - EPR Pump: 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 off the pump to avoid that air is pumped into the system. -
Page 37: Fkggm-Epr Pump - Ultrasonic Sensor With Plug-Type Connection M12X1
...a product from 5.1.5 FKGGM - EPR Pump: Ultrasound sensor with plug-type connection M12x1 Signal minimum level / maximum level / reserve: Connect the level switch at the pump by means of a suitable cable acc. to the circuit diagram. Put the straight bush onto the ultrasound sensor on top of the pump and tighten the knurled nut. -
Page 38: Control Unit
...a product from Control unit NOTE: See also the separate description in chapter 7, depending on the control unit. 5.3.1 General The following actuation types can be selected by means of a diagnosis device: A) Time control B) Pulse control C) Speed control D) Pulse cycle control Automatic start of lubrication intervals:... -
Page 39: Assembly Instruction Of Central Lubrication Pump
...a product from 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 health of persons. There are no special actions to arrange regarding the oscillation reduction and noise prevention when installing the pump. -
Page 40: Start-Up
...a product from Start-up Observe the following items before the pump start-up in order to guarante a perfect function of the pump. Attention! The electric 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. A longer operation with the wrong sense of rotation can damage motor and pump. -
Page 41: Connection Of The Central Lubrication Pump Fkggm - Ep Or Epr Without Control Unit
...a product from Connection central lubrication pump FKGGM - EP or EPR without control unit: Fig. 48: 7.1.1 12 / 24V DC with line connection: X 90° 1. Number cable: +Ub = wire 1 Ground = wire 2 2. Color cable (2-cores) +Ub = blue Ground = brown 7.1.2... -
Page 42: Connection Of The Central Lubrication Pump Fkggm - Ep Or Epr With Control Unit
...a product from Connection central lubrication pump FKGGM - EP or EPR with control unit: 7.2.1 Control unit type: EP-tronic: Voltage: Ub 10-60 V DC (nominal 12/24 V DC) Fig. 49: blue green yellow See also description EP-tronic... -
Page 43: Control Unit Type: Ep-Tronic With Intermediate Housing
...a product from 7.2.2 Control unit type: EP-tronic - with intermediate housing: Fig. 50: green yellow blue See also description EP-tronic... -
Page 44: Control Unit Type: Beka-Tronix1
...a product from 7.2.3 Control unit type: BEKA-troniX1 Voltage: Ub 10-60 V DC (nominal 12/24 V DC) Fig. 51: green See also description BEKA-troniX1... -
Page 45: Control Unit Type: Beka-Tronix1 - With Intermediate Housing
...a product from 7.2.4 Control unit type: BEKA-troniX1 - with intermediate housing (100-250 V AC) Fig. 52: green See also description BEKA-EP-tronic_ZX... -
Page 46: Control Unit Type: Ep-Tronic Zx
...a product from 7.2.5 Control unit type: EP-tronic ZX Voltage: Ub 10-60 V DC (nominal 12/24 V DC) Fig. 53: blue silver yellow green See also description BEKA-EP-tronic_ZX... -
Page 47: Control Unit Type: Ep-Tronic Zx - With Intermediate Housing
...a product from 7.2.6 Control unit type: EP-tronic ZX - with intermediate housing (100-250V AC) Fig. 54: silver yellow blue yellow See also description BEKA-EP-tronic_ZX... -
Page 48: Control Unit Type: Ep-Tronic Zx - With Intermediate Housing And Temperature Sensor
...a product from 7.2.7 Control unit type: EP-tronic ZX - with intermediate housing and temperature sensor (100-250 V AC) Fig. 55: silver yellow blue See also description BEKA-EP-tronic_ZX... -
Page 49: Control Unit Type: Ep-Tronic Zx-S1 - With Intermediate Housing
...a product from 7.2.8 Control unit type: EP-tronic ZX-S1 - with intermediate housing (100-250 V AC) Fig. 56: silver yellow blue See also description BEKA-EP-tronic_ZX... - Page 50 ...a product from 7.2.9 Control unit type: EP-tronic ZX-S2 - with intermediate housing Voltage: Ub 10-60 V DC (nominal 12/24 V DC) Fig. 57: blue See also description BEKA-EP-tronic_ZX...
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Page 51: Control Unit Type: Ep-Tronic Zx-S2 - With Intermediate Housing (100-250 V Ac)
...a product from 7.2.10 Control unit type: EP-tronic ZX-S2 - with intermediate housing (100-250 V AC) Fig. 58: silver yellow blue See also description BEKA-EP-tronic_ZX... -
Page 52: Basic Filling Of Central Lubrication Pump
...a product from Basic filling of the central lubrication pump You receive the pump without grease filling. In order to operate it you have to equipp it with a basic filling. Proceed as described under item 9.2. Ventilate the central lubrication pump ·... -
Page 53: Maintenance
...a product from 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. -
Page 54: Level Of Central Lubrication Pump
...a product from Level of the central lubrication pump 8.2.1 Central lubrication pump without control unit and without level monitoring: Fig. 59: Check the pump level regularely. If the grease in the pump reservoir is at „min. level“, refill the pump. Proceed as described under item 9.2. Minimum The central lubrication pump must not fall below level... -
Page 55: Repair
...a product from Repair If you recognise an error during the maintenance of the pump, you can read in this chapter how to proceed. The central lubrication pump does not operate 9.1.1 Central lubrication pump without control unit: The pump does not operate. The lubrication process can not be finished properly. Electric line is defect. -
Page 56: Filling Of The Central Lubrication Pump
For this purpose, press out about 10 mm of lubricant (fig. 66). Pull off the cap from the lubricating nipple and fill up the pump until max. level. Put the cap on again. Fig. 61: Fig. 62: Example for BEKA Grease gun (accessories - suitable for cartridge acc. to DIN 1284) BEKA-order-no. - Page 57 ...a product from Fig. 64 Fig. 65 Connection level monitoring Filling cover Example for BEKA hand lever grease gun (accessories - suitable for cartridge acc. to DIN 1284)) BEKA-order-no. 21590080008 Fig. 66: Filling nipple Lubricant Absolutely prevent air from entering the system during the filling, as otherwise a malfunction of the system is caused.
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Page 58: Further Filling Variants Of Central Lubrication Pump
...a product from 9.2.2 Filling types of a central lubrication pump: Fill up 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) ·... -
Page 59: Filling Connection And Filling Tools
...a product from 9.2.3 Filling connection and filling tools: Fig. 70: Filling press for grease cartridges acc. to DIN 1284 Version for pump with follow-up piston Order-no.: 208103026 acc. to drawing: FAZ02493_02 Filling press for grease cartridges acc. to DIN 1284 Order-no.: 20830001 ca. -
Page 60: Exchange Distributor Of A Central Lubrication Pump With Installed Distributor
...a product from 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 the pump element by means of the screw and observe the according torque (fig. -
Page 61: Exchange The Pump Element
...a product from 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. -
Page 62: Exchange Pump Element Of The Central Lubrication Pump With Installed Distributor
...a product from 9.5.2 Exchange pump element of central lubrication pump FKGGM-EP with installed distributor Demount distributor as described under 9.3. Unscrew the pump element (fig. 78) but do not pull it out yet (fig. 79). Then tilt up the pump element (piston head) and take it out the housing in this position (fig. -
Page 63: Level Error
...a product from Level error Check the cable of the level monitoring visual and electrical. Find the error and replace the cable. If there is no problem with the cable, the level monitoring is defective. Exchange the reservoir cover with installed level monitoring. 9.6.1 Central lubrication pump FKGGM - EP Exchange of cable:... -
Page 64: Central Lubrication Pump Fkggm - Epr
...a product from 9.6.2 Central lubrication pump FKGGM - EPR Metal surface Exchange of cable: Fig. 82: LED orange Loosen the knurled nut from the plug of the proximity switch as well as from the red marked ring at the control unit (fig. 83;... -
Page 65: Troubleshooting
...a product from Troubleshooting Faults Possible cause Possible elemination of faults Pump does not operate Pump defective Exchange pump Control unit defective Exchange pump electr. line is broken Renew line Pump element not fixed Exchange pump element Pump operates but does not Level too low Refill reservoir deliver... - Page 66 91257 PEGNITZ/BAVARIA Tel. +49 9241 / 729-0 +49 9241 / 729-50 POSTFACH 1320 91253 PEGNITZ WEB: http://www.beka-lube.de E-MAIL: beka@beka-lube.de Other products from our range of supplies: Gear pumps Multi line oil pumps Multi line grease pumps Single line central lubrication systems...
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