Related Manuals for Timken GROENEVELD-BEKA PICO
Summary of Contents for Timken GROENEVELD-BEKA PICO
- Page 1 OPERATING MANUAL Pump Model PICO Original Instructions 00-1002971_BAL_2185_PICO_R11EN...
- Page 2 © Groeneveld-BEKA 00-1002971_BAL_2185_PICO_R11EN...
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Page 3: Table Of Contents
© Groeneveld-BEKA Table of Contents 146236683 1 General Safety Instructions ............................ 1.1 Importance of safety instructions ........................1.2 Signal words and symbols used ........................1.3 Personnel qualification and training ......................1.4 Safety instructions for assembly, inspection, maintenance ................. 1.5 Unauthorized modification / Production of spare parts ................1.6 Intended use and improper use ........................ - Page 4 © Groeneveld-BEKA 10.2 Lubricant change ............................43 11 Cleaning................................... 44 12 Troubleshooting..............................45 12.1 General Troubleshooting ..........................45 12.2 Signal indicators.............................. 47 13 Annex..................................49 13.1 Pump element PE-50............................49 13.1.1 Product description ..........................49 13.1.2 Technical Data ............................. 49 13.1.3 Pump element installation........................
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Page 5: General Safety Instructions
© Groeneveld-BEKA General Safety Instructions Importance of safety instructions DANGER Importance of safety instructions This operating manual contains important information on handling and safety. Read the operating manual carefully before you start any work with the product. Always have the operating manual available on site. Residual risk Despite the comprehensive safety measures considered for design and operation of our product, the product is not absolutely safe. - Page 6 © Groeneveld-BEKA Symbols used This symbol warns of electrical voltage. This symbol warns of danger to persons if not observed. This symbol warns of hot surfaces. This symbol warns of suspended loads. This symbol warns of possible material damage due to electrostatic discharge if not avoided. Information labels Notice Wear ear protection.
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Page 7: Personnel Qualification And Training
© Groeneveld-BEKA Personnel qualification and training This operating manual is intended for: Any person entrusted with tasks involving the product throughout its life cycle. Qualified personnel Only qualified personnel may handle the product. Qualified personnel can recognize and minimize possible haz- ards due to their skills and knowledge. -
Page 8: Intended Use And Improper Use
© Groeneveld-BEKA Intended use and improper use The product is used to convey lubricants within an automatic lubrication system. Intended use The product is intended for commercial use only. The product is a machine according to Machinery Directive 2006/42/EC. • Use the product only within the values as stated in the technical data. •... -
Page 9: Scope Of Warranty
© Groeneveld-BEKA Scope of Warranty Warranty is only granted by the manufacturer for the use as intended and under the following conditions: • Authorized qualified personnel carries out installation, connection and maintenance. • The product is used in accordance with the information in the operating manual. •... -
Page 10: Manufacturer
© Groeneveld-BEKA Manufacturer Company name and address of the manufacturer of the machine: Groeneveld-BEKA GmbH Beethovenstraße 14 91257 Pegnitz, Bayern, Germany Tel.: +49 9241729-0 Fax: +49 9241729-50 00-1002971_BAL_2185_PICO_R11EN... -
Page 11: General Product Information
© Groeneveld-BEKA General Product Information Product Description The PICO is an electrically actuated pump for the use in progressive systems, multi-line systems, and mixed lubric- ation systems. Mixed lubrication system means you have a progressive system and a multi-line system connected to the product. -
Page 12: Applicable Documents
© Groeneveld-BEKA PICO with follower plate: Reservoir The PICO reservoir is made of transparent plastic. PICO is available with a 1,5 l reservoir. Follower plate The follower plate ensures that all the lubricant in the reservoir is used up. The reservoir wall remains clean, which allows you to visually check the level. -
Page 13: Ce Declaration Of Conformity
© Groeneveld-BEKA CE Declaration of Conformity DIRECTIVE 2006/42/EC - Annex II A Company name and address of the manufacturer of the machine: Groeneveld-BEKA GmbH Beethovenstraße 14 91257 Pegnitz, Bayern, Germany Tel.: +49 9241729-0 Fax: +49 9241729-50 Name and address of the company authorised to compile the technical file: Groeneveld-BEKA Italia S.r.l. - Page 14 © Groeneveld-BEKA • ECE-R10, rev.6 (Automotive directive of the United Nations) E1 10R-057978 • EN ISO 12100:2010 • EN 809:2009 Via Pertini, 1, 23893 Cassago Brianza (LC), Italy 00-1002971_BAL_2185_PICO_R11EN...
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Page 15: Conformity Marking
© Groeneveld-BEKA Conformity marking This product is CE certified. This product is E1 certified. Shutdown and Disposal WARNING Product under pressure and connected to power You can get injured by: a) liquids which escape due to high pressure. b) electrical power due to high voltage. Mind all relevant national and international laws and regulations for disposal. -
Page 16: Transport And Storage
© Groeneveld-BEKA Transport and storage Transport WARNING Suspended loads You might get injured if suspended loads fall down. a) Keep distance to suspended loads. b) Wear appropriate protective clothing. • Make sure that the means for transportation or the lifting device has sufficient carrying capacity. •... -
Page 17: Technical Data
© Groeneveld-BEKA Technical Data General Delivery volume per stroke and outlet depending on pump element Number of outlets max. 2 (for PE-60 F to PE-170 F) max. 8 (for PE-5 to PE-50) Outlet connection thread M10x1 (for multi-line systems) G1/4 (for progressive sys- tems) Lubricant greases up to NLGI 2 (greases with solid content on re-... -
Page 18: Installation Instructions
© Groeneveld-BEKA Installation Instructions 1) Check the product for transport damage and completeness before installation. 2) Remove transport protection. 3) Select the place of installation so that the product is protected against environmental and mechanical im- pacts. 4) Ensure unhindered access. 5) Observe the information on fastenings from the dimensional drawing. -
Page 19: Pico-Tronix1 Connection Diagram
© Groeneveld-BEKA 7.3.1 PICO-troniX1 connection diagram brown (PIN 7) - (mass) black (PIN 5) + Ub External signal lamps green (PIN 1) Lamp green red (PIN 2) Lamp red orange (PIN 6) Intermediate lubrication button NOTICE The bayonet connector and a 10m connection cable are included for products with PICO-troniX1 control with bayonet connection. -
Page 20: No Control Connection Diagrams
© Groeneveld-BEKA 7.3.2 No control connection diagrams Product with paddle and bayonet connection blue (PIN1) brown (PIN2) - (mass) NOTICE The bayonet connector and a 10m connection cable are included for products with paddle and bay- onet connection. 00-1002971_BAL_2185_PICO_R11EN... - Page 21 © Groeneveld-BEKA Product with follower plate and bayonet connection brown (PIN7) - (mass) black (PIN5) + Ub green (PIN1) Level OK red (PIN2) Level empty orange (PIN6) COM Level NOTICE The bayonet connector and a 10m connection cable are included for products with follower plate and bayonet connection.
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Page 22: Pico-Tronic2 Connection Diagram
© Groeneveld-BEKA 7.3.3 PICO-tronic2 connection diagram brown (PIN 7) - (mass) black (PIN 5) + Ub white (PIN 3) gray (PIN 4) Three-position switch for adaptation to the operating conditions External signal lamps green (PIN 1) Lamp green red (PIN 2) Lamp red orange (PIN 6) Intermediate... -
Page 23: Pico-T2 Connection Diagram
© Groeneveld-BEKA 7.3.4 PICO-T2 connection diagram blue (PIN 1) Brake light (terminal 54) brown (PIN 2) - (mass) (terminal 31) NOTICE The bayonet connector and a 10m connection cable are included for products with PICO-T2 control with bayonet connection. Lubricants Lubricant greases up to NLGI 2 (greases with solid content on re- quest) -
Page 24: Lubricant Filling
© Groeneveld-BEKA Lubricant filling There are different possibilities to fill the reservoir. Refer to following paragraphs: • Filling at zerk with filling press ( 7.5.1: Filling at zerk with filling press) [} 26] • Filling at filling connection with filling coupling ( 7.5.2: Filling at filling connection with filling coupling) [} 27] •... -
Page 25: Overfill Protection
© Groeneveld-BEKA Initial filling for products with follower plate NOTICE Different procedure Products with follower plate require a different procedure for initial filling to remove the air inside the product. a) Follow the procedure below for initial filling Initial filling: 1) Connect the product to power supply. -
Page 26: Filling At Zerk With Filling Press
© Groeneveld-BEKA 7.5.1 Filling at zerk with filling press 1) Remove the protective cap from the zerk. 2) Connect a suitable filling press (manually operated or pneumatic) at the zerk. 3) Fill up to maximum level. 4) Put the protective cap on the zerk again after filling. 00-1002971_BAL_2185_PICO_R11EN... -
Page 27: Filling At Filling Connection With Filling Coupling
© Groeneveld-BEKA 7.5.2 Filling at filling connection with filling coupling 1) Remove the screw plug or the zerk. 2) Connect a filling coupling G1/4. 3) Connect a suitable filling pump to the filling coupling. 4) Fill up to maximum level. 5) Disconnect the filling pump from the filling coupling. -
Page 28: Vent The Lubrication System
© Groeneveld-BEKA Vent the lubrication system • Vent the lubrication system with initial start-up and after each lubricant change. • Only vent the lubrication system when depressurized and with open outlets. • Operate the product until the lubricant comes out from the pressure connection free of air bubbles. Line assembly Please comply with the following for line assembly: •... -
Page 29: Control Unit And Settings
© Groeneveld-BEKA Control unit and Settings General settings You can control progressive lubrication systems, multi-line lubrication systems and mixed lubrication systems with an integrated control unit. The following integrated control units are available for the product: • PICO-troniX1 • PICO-tronic2 •... -
Page 30: Pico-T2
© Groeneveld-BEKA PICO-T2 The PICO-T2 is an integrated control unit. You can set the lubrication duration time-dependent. The PICO-T2 is especially suitable when the product is attached to a vehicle and has no continuous voltage avail- able. Functional description Sticker (example) in inspection window Switch with detents to set the lubrication duration Voltage connection Inspection window... - Page 31 © Groeneveld-BEKA Setting the parameters You can change the lubrication duration at the indexing switch in the inspection window. 1) Detach the frame of the inspection window with a flat screwdriver. 2) Detach the four recessed head screws and take off the transparent inspection window. NOTICE Water in the control unit If you do not reinstall inspection window and the frame properly after setting the parameters, wa-...
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Page 32: Pico-Tronic2
© Groeneveld-BEKA Possible setting values for the time-dependent lubrication duration: • 1s, 2s • 4 s, 6 s, 8 s, 10 s • 14 s, 18 s, 22 s, 26 s, 30 s • 36 s, 42 s, 48 s, 54 s, 60 s PICO-tronic2 The PICO-tronic2 is an integrated control unit. - Page 33 © Groeneveld-BEKA Functional description Sticker (example) in inspection window Connection for diagnosis software BEKA-DiSys Functional status LEDs Switch with detents to set the cycle time Switch with detents to set the lubrication duration Plug-type connection M12x1 (blue) for cycle signals of the distributor Voltage connection Frame of inspection window...
- Page 34 © Groeneveld-BEKA Setting the parameters NOTICE Order and exchange the sticker in the inspection window of the protective housing when you have changed the parameters. You can change the lubrication duration and cycle time within a setting range at the indexing switches in the in- spection window.
- Page 35 © Groeneveld-BEKA Lubrication duration clock pulse-dependent In this operational mode, you can determine the lubrication duration by the number of incoming clock pulses from a signaling device. The signaling device can be a proximity switch at a progressive distributor for example. The control unit signals error if it does not receive a clock pulse signal within an adjustable monitoring time (de- fault setting 12 min).
- Page 36 © Groeneveld-BEKA NOTICE BEKA-DiSys diagnosis software You can change setting ranges or the revolution monitoring time (where applicable) with the BEKA-DiSys diagnosis software. Special functions Adaption to the operating conditions This function is available in all three operational modes. Within 30 s after applying the voltage, you can customize the lubrication intervals with a 3-position rocker switch.
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Page 37: Pico-Tronix1
© Groeneveld-BEKA Insufficient lubrication This function is available in the operational mode: clock pulse-dependent. Insufficient lubrication occurs when the lubrication cannot be completed during one cycle. The product needs more time for processing the lubrication duration than available by the set cycle time. The control unit signals error, but does not switch off the product. - Page 38 © Groeneveld-BEKA Functional description Sticker (example) in inspection window Connection for diagnosis software BEKA-DiSys Functional status LEDs Switch with detents to set the cycle time Switch with detents to set the lubrication duration Voltage connection Frame of Intermediate inspection window lubrication button Inspection window A lubrication process will start with the first connection of the integrated control unit.
- Page 39 © Groeneveld-BEKA Setting the parameters NOTICE Order and exchange the sticker in the inspection window of the protective housing when you have changed the parameters. You can change the lubrication duration and cycle time within a setting range at the indexing switches in the in- spection window.
- Page 40 © Groeneveld-BEKA Lubrication duration revolution-dependent In this operational mode you can set the lubrication duration by the number of counted pump revolutions. A sensor in the product emits a signal to the control unit with each pump revolution. The control unit signals an error if it does not receive a signal within a monitoring time (default setting 30 s).Refer to Signal indicators PICO-troniX1 ( 12.2: Signal indicators) [} 47]...
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Page 41: Start-Up And Operation
© Groeneveld-BEKA Start-up and Operation WARNING Movable, rotating, hot or cold parts Movable, rotating, hot or cold parts of the product can cause serious injuries. a) Protect movable, rotating, hot or cold parts of the product against contact. Please check the following before you start up the product: •... -
Page 42: Maintenance
© Groeneveld-BEKA Maintenance WARNING Risk of burns due to hot surfaces a) Check the surface temperature of the product. b) Wear heat-resistant gloves. Before any maintenance work or repair, do the following: 1) Disconnect the product from voltage. 2) Depressurize the product. 3) Put the product at standstill. -
Page 43: Lubricant Change
© Groeneveld-BEKA 10.2 Lubricant change NOTICE Pay attention to utmost cleanliness when filling lubricant. • Carry out the lubricant change according to the specifications of the lubricant manufacturer. • Ambient influences like temperature or pollution might effect the recommended intervals. •... -
Page 44: Cleaning
© Groeneveld-BEKA Cleaning Basics Clean the product regularly to ensure proper function. Only use cleaning detergents that do not damage the product. Interior cleaning You need to clean the inside of the product only if incorrect or contaminated lubricants accidentally enters the product. -
Page 45: Troubleshooting
© Groeneveld-BEKA Troubleshooting 12.1 General Troubleshooting Error Possible cause Possible troubleshooting Product does not operate Fuse defective Replace fuse Electrical line interrupted Replace electrical line Product defective Replace product Integrated control unit defective Replace integrated control unit Product operates, but does not deliver Air bubbles in the delivery piston Vent the product Air bubbles in the reservoir Vent the product... - Page 46 © Groeneveld-BEKA Error “system pressure too high” Check lubrication system, repair if ne- cessary Reset error with intermediate lubrica- tion Revolution error in operating mode re- Check lubrication system or product, volution – dependent lubrication dura- repair if necessary tion Reset error with intermediate lubrica- tion Product functions (operating mode,...
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Page 47: Signal Indicators
© Groeneveld-BEKA 12.2 Signal indicators With the integrated control unit the functions of the device are displayed via two LEDs (green and red) in the viewing window of the protective housing, whereby the red LED always indicates an error in the program se- quence. - Page 48 © Groeneveld-BEKA Signal indicators PICO-tronic2: Signal indicators Function Shows function standby when voltage is switched on for the first time Lubrication cycle Cycle locked (is not displayed via the special function “Ex- ternal status signal” Cycle error in operating mode time-dependent lubrication duration Error “low level”...
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Page 49: Annex
© Groeneveld-BEKA Annex 13.1 Pump element PE-50 13.1.1 Product description This pump element is used in piston pumps without eccentric ring. The pump element is spring-operated. It is used in multi-line lubrication systems and is intended to convey clean mineral oil and greases up to NLGI-2 without solids content. -
Page 50: Pump Element Installation
© Groeneveld-BEKA 13.1.3 Pump element installation Before installation You can install this pump element into the outlets 1 to 3 and 5 to 9. Remove the screw plug from the selected outlet. Use an Allen key with AF 6. If you replace a pump element, ensure to replace the seal also. Installation 1) Disconnect the product from power supply and secure it against recommissioning. -
Page 51: Lubricants
© Groeneveld-BEKA 13.1.4 Lubricants Lubricant Grease: up to NLGI - 2 Oil: Mineral from 40mm²/s (cSt) • Use lubricants with high-pressure additives. • Use only lubricants of the same saponification type. • Comply with the lubricant specifications of the machine manufacturer. •... -
Page 52: Pump Element Pe-120 F
© Groeneveld-BEKA 13.2 Pump element PE-120 F 13.2.1 Product description PE-120 F without pressure limiting valve This pump element is used in piston pumps without eccentric ring. The pump element is spring-operated. It is used in progressive lubrication systems and is intended to convey clean mineral oil and greases up to NLGI-2 without solids content. -
Page 53: Technical Data
© Groeneveld-BEKA PE-120 F with pressure limiting valve This pump element provides an integrated pressure limiting valve. Maximum pressure is set to 290 bar. The PE-120 F with pressure limiting valve flow rate is set to 0,12 cm /stroke and cannot be adjusted. 13.2.2 Technical Data Metering volume 0,12 cm³... -
Page 54: Pump Element Installation
© Groeneveld-BEKA 13.2.3 Pump element installation Before installation You can install this pump element into the outlets 4 and 10. Remove the screw plug from the selected outlet. Use an Allen key with AF 10. If you replace a pump element, ensure to replace the seal also. Installation 1) Disconnect the product from power supply and secure it against recommissioning. -
Page 55: Pressure Limiting Valve
© Groeneveld-BEKA Installation and removal of a PE-120 F with pressure limiting valve In case you have the pump element PE-120 F equipped with a pressure limiting valve: If necessary, remove the pressure limiting valve before installation of the pump element. Then follow the steps as described and attach it to the pump element after installation again with a torque of 30Nm ±10%. -
Page 56: Indicator Pin
© Groeneveld-BEKA 13.2.6 Indicator pin Monitoring with the indicator pin is the mechanical solution. It is only possible for the operation with grease. The pressure limiting valve will open at a pressure of 290 bar and the indicator pin in the cap will be extracted by the escaping grease. -
Page 57: Start-Up And Operation
© Groeneveld-BEKA 13.2.8 Start-up and operation Before starting up the product, please make sure of the following: • the environment is clean • pump elements are fitted correctly • pump elements are vented WARNING High-pressure If your pump element is equipped with a pressure limiting valve, lubricant might flow out at the pressure limiting valve under high pressure. - Page 58 This document is intended solely as a means of evaluation and to provide you with data to assist you in using our product. Product performance is influenced by many factors outside the control of Groeneveld-BEKA. Groeneveld- BEKA products are sold in accordance with the Groeneveld-BEKA terms and conditions of sale, which include our limited warranty and remedies.
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