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BEKA BEKA-MAX GIGA - User Manual

BEKA BEKA-MAX GIGA
64 pages
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© BEKA 201 All rights reserved!6
...a product of BEKA
BEKA-MAX
Central lubrication pump
GIGA without control unit
GIGA PLUS without control unit
for progressive central lubrication systems
Article-no. 2172A..., 2172P..., 2172E...,
2172Z...
Revision -20108 6
Original operating-
and
assembly manual
BAL2172_GIGA_and_GIGA_PLUS_without_control_unit_0816_EN
1

Table of Contents

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BEKA BEKA-MAX GIGA Specifications

General IconGeneral
Motor Power1.5 kW
Voltage230/400 V
Weight18 kg
Frequency50 Hz
CategoryWater Pump
Max Flow Rate50 m³/h
Power1500 W

Summary

Technical Data

Applicable Documents

General Safety Instructions

Safety Instructions

General safety warnings and symbols for hazards like voltage, hot surfaces, etc.

Qualification and Training of Staff

Requirements for personnel operating, maintaining, or assembling the pump.

Hazards in Case of Non-Observance of Safety Instructions

Risks to persons, environment, and device from not following safety guidelines.

Operators Obligations

Customer responsibilities regarding safety, leakages, legal provisions, and pipe maintenance.

Safety Instructions for Maintenance, Inspection and Assembly

Guidelines for safe execution of maintenance, inspection, and assembly tasks.

Unauthorized Modification and Production of Spare Parts

Manufacturer's stance on modifications and use of non-original parts, affecting safety and liability.

Inadmissible Methods of Operation

Warning against using the device outside its specified operational limits or intended use.

Electrostatic Discharge

Precautions to prevent damage to electronic components from static electricity.

General Hazard Warning - Residual Risk

Awareness of potential hazards even with compliant systems, emphasizing proper use and inspection.

Intended Use

Scope of Warranty

Transport and Storage

Functional Description

Function and Layout of a Progressive Central Lubrication System

Explanation of how progressive systems work, including pump, distributors, and lubricant flow.

Function and Setup of a Single Line Lubrication System

How the pump supplies single line systems, including pressure switch and valve functions.

Function and Setup of a Dual Line Lubrication System

Details on dual line lubrication systems, pump elements, and pressure switches.

Function and Layout of the Central Lubrication Pump

Overview of the pump's main components and general layout.

Function of the Central Lubrication Pump GIGA

Description of GIGA pump operation, delivery volumes, and level monitoring.

Function of the Central Lubrication Pump GIGA PLUS

Description of GIGA PLUS pump operation, delivery, and pressure/level monitoring.

Function of the Pump GIGA PLUS for Use in Single Line Lubrication Systems

How GIGA PLUS operates in single line systems, including pump elements and monitoring.

Function of the Pump GIGA PLUS for Use in Dual Line Lubrication Systems

How GIGA PLUS operates in dual line systems, including pump elements and pressure/level monitoring.

Pump Elements

Details on PE-120 G and PE-250 G pump elements, delivery rates, and connections.

Pump Elements for Central Lubrication Pump GIGA PLUS

Specifics on GIGA PLUS pump elements, including pressure limiting valves and microswitches.

Pressure Limiting Valves

Explanation of pressure limiting valves for system protection and safety precautions.

Pump Elements with Microswitch

Information on pump elements equipped with microswitches for electronic monitoring.

Outlet Fittings for the Central Lubrication Pump GIGA PLUS

Options for ordering pump outlets with different fittings.

Level Monitoring Device Min.

Description and function of the integrated minimum level monitoring device.

Momentum Sensor

Function of the momentum sensor for monitoring pump revolutions.

Magnetic Valve for Single Line and Dual Line Lubrication Systems

Role of magnetic valves in relieving main lines in single and dual line systems.

Integrated Pressure Switch

Function of integrated pressure switches in single line systems for pressure control.

Assembly Instructions

Assembly of the Lubrication Pump

Checks before assembly, installation conditions, and general mounting advice.

Assembly of the Pump Elements

Step-by-step guide for removing and installing pump elements.

Combining the Delivery Volumes for the Central Lubrication Pump GIGA PLUS

How to combine delivery rates of GIGA PLUS pump elements and discharge options.

Functional Description for the Outlets of the Central Lubrication Pump GIGA PLUS

Detailed description of pump outlets, non-return valves, and pressure limiting valves.

Example 1: Combining Delivery Volumes and Discharging from Outlet 1

Specific steps to combine all outlet volumes and discharge from outlet 1.

Example 2: Combining Delivery Volumes and Routing Out of Outlet 4

Specific steps to combine all outlet volumes and discharge from outlet 4.

Line Assembly

Guidelines for professional pipe assembly, pressure tightness, and component suitability.

Electric Connection

Instructions for safe and correct electrical connection by qualified personnel.

Terminal Plan for the Microswitch at Pump Element

Wiring details for microswitch connections on pump elements.

Terminal Plan for the Level Monitoring Device

Wiring diagram for the level monitoring device.

Terminal Plan for the Momentum Sensor

Wiring diagram for the momentum sensor.

Start Up

Filling with Lubricant

Important precautions for filling the lubricant reservoir, emphasizing cleanliness and correct lubricant.

Standard Filling via Tapered Lubrication Nipple with Manual or Pneumatic Grease Gun

Method for filling the reservoir using a grease gun and nipple.

Refilling via Refill Coupling

Method for refilling the reservoir using a refill coupling.

Filling via Filler Gun

Method for filling the reservoir using a filler gun.

Ventilation of the Lubrication System

Procedures for ventilating progressive and single line lubrication systems.

Rotation Control of the Pump

How to check and correct pump rotation direction to avoid damage.

Maintenance

General Maintenance

Routine checks like retightening fittings and inspecting for leaks and damage.

Refilling with Lubricant

Guidelines for refilling lubricant, checking levels, and lubricant quality.

Repair

Exchange or Retrofit the Level Switch and;or the Angular Momentum Sensor

Step-by-step guide for replacing level switches and momentum sensors.

Replacing the Momentum Sensor Cable

Procedure for replacing the cable connected to the momentum sensor.

Exchange Pressure Switch Cable

Procedure for replacing pressure switch cables.

Exchange Magnetic Valve Cable

Procedure for replacing magnetic valve cables.

Exchange the Cable of Magnetic Valve 1 and;or 2

Procedure for replacing magnetic valve cables 1 and 2.

Shutdown

Disposal

Trouble-shooting

Spare Part List

Spare Part Drawing

Lubrication Pump GIGA without Control Unit for the Use in Progressive Lubrication Systems

Exploded view diagram of GIGA pump parts for progressive systems.

Lubricant Reservoir for GIGA- and GIGA PLUS-Lubrication Pumps

Exploded view of lubricant reservoirs for GIGA and GIGA PLUS pumps.

Central Lubrication Pump GIGA PLUS without Control Unit for the Use in Single Line Lubrication Systems

Exploded view diagram of GIGA PLUS pump parts for single line systems.

Central Lubrication Pump GIGA PLUS without Control Unit for the Use in Dual Line Lubrication Systems

Exploded view diagram of GIGA PLUS pump parts for dual line systems.

Ordering Key

For the Central Lubrication Pump GIGA without Control Unit for Use in Progressive Central Lubrication Systems

Guide to constructing the order code for GIGA pumps in progressive systems.

Order Key for Lubrication Pump GIGA PLUS without Control Unit for the Use in Single Line Lubrication Systems

Guide to constructing the order code for GIGA PLUS pumps in single line systems.

Order Key for Lubrication Pump GIGA PLUS without Control Unit for the Use in Dual Line Lubrication Systems

Guide to constructing the order code for GIGA PLUS pumps in dual line systems.

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