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BEKA EP-1 User Manual

BEKA EP-1
48 pages
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BAL_2152_EP1_Central grease lubrication pump_0816_EN EDV-Nr. 1090200430
Original operating and assembly
manual
for grease lubrication pumps
EP-1
FKGGM-EP
DC
FKGGM-EP with power supply unit, AC 1
without control unit
with integrated control units:
BEKA-troniX1
EP-tronic
EP-tronic T1
EP-T2
EN
BEKA 2016 All rights reserved!

Table of Contents

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BEKA EP-1 Specifications

General IconGeneral
BrandBEKA
ModelEP-1
CategoryWater Pump
LanguageEnglish

Summary

Declaration of Incorporation for Incomplete Machinery

Warranty and Warranty Conditions

Warranty Exclusions

Details conditions under which warranty claims may be invalidated due to improper use or components.

General Safety Information and Risk Reference

Safety Principles and Personnel Qualification

Covers general safety, risk references, personal qualifications, and training requirements.

Operational Safety and Hazards

Encompasses intended use, liability, assembly safety, operator safety, electrical/pressure hazards.

Specific Safety Precautions

Includes guidelines for modifications, spare parts, and hydraulic hose lines.

Technical Data and Lubricant Specifications

Lubricant Recommendations and Hazards

Specifies suitable grease types, environmental hazards, and handling precautions.

Operation Limits and Storage

Defines inadmissible operation methods and provides guidelines for pump transport and storage.

Motor Technical Specifications

Lists electrical and performance data for EP-1, FKGGM-EP, and FKGGM-EP with PSU motors.

Pump Specifications and Control Unit Data

Pump Operating Parameters

Details pump pressure, temperature, reservoir sizes, installation, and protection type.

Control Unit Specifications

Provides operating voltage, current load, fuse, and temperature for BEKA-troniX1, EP-tronic T1, and EP-T2 control units.

Assembly Manual and Safety Guidelines

General Assembly Conditions

States conditions for safe and health-conscious assembly of the pump into a complete machine.

Pipeline and Electrical Connection Safety

Covers safety for pipeline assembly and expert electrical connections.

Installation Dimensions and Overview

EP-1 and FKGGM-EP with Steel Reservoir Dimensions

Provides detailed dimensional drawings for pumps with steel reservoirs of different capacities.

Installation Dimensions with Transparent Reservoir

EP-1 and FKGGM-EP with Transparent Reservoir (Side & Top Views)

Shows side and top-view installation dimensions for pumps with transparent reservoirs of various capacities.

Installation Dimensions for Larger Reservoirs

8 kg and 16 kg Reservoir Installation Dimensions

Details installation dimensions and views for pumps with 8 kg and 16 kg reservoirs.

Terminal Diagrams for Basic Pump Connections

EP-1/FKGGM-EP Without Control Unit Terminal Diagram

Shows the wiring for pumps without an integrated control unit, using a simple connection.

EP-1 with Bayonet Connector Terminal Diagram

Illustrates the wiring for EP-1 pumps with a special bayonet connector.

Terminal Diagrams for Integrated Control Units

BEKA-troniX1 and EP-tronic T1 Control Unit Wiring

Details the terminal connections for BEKA-troniX1 and EP-tronic T1 control units with various options.

Terminal Diagrams for EP-T2 and EP-tronic Control Units

EP-T2 and EP-tronic Control Unit Wiring Diagrams

Provides wiring diagrams for the EP-T2 and EP-tronic control units with multiple options and signals.

FKGGM-EP with Power Supply Unit (PSU)

PSU Connection Voltage Warning

Advises checking the power supply unit voltage indicated on the motor shell sticker.

System Function and Design Principles

Progressive Lubrication System Operation and Protection

Explains system operation, sequential delivery, and pressure relief valve protection.

Central Lubrication Pump Functionality

Pump Operation and Control Options

Details general pump operation, control without unit, PE-120 V function, and level monitoring.

Grease Level Monitoring Connectivity and Types

Proximity Switch Wiring and Data

Shows proximity switch connection diagrams and technical data for external control and cubic plug types.

Micro Switch at Pressure Relief Valve

Micro Switch Wiring, Function, and Data

Covers AC wiring, function, hazards, terminal diagrams, and technical data for the micro switch.

Pump Elements and Delivery Rate Adjustment

Standard Pump Elements (PE-60, PE-120, PE-170)

Details output rates, order numbers, and fixed pressure relief settings for standard pump elements.

Adjustable PE-120 V Pump Element

Describes the PE-120 V element, its adjustable output rate, and provides an output rate graph.

Pump Element Adjustment and Installation

Pump Element Adjustment and Installation Procedures

Explains how to adjust delivery rate, install/remove elements, and ventilate the pump.

Malfunction Indicator for Pressure Relief Valve

Visual Malfunction Indicator Operation

Describes the visual indicator that shows when operating pressure exceeds 280 bar.

Control Unit Functions Overview

BEKA-troniX1 and EP-tronic Control Unit Operation

Explains how these units operate based on lubrication and cycle times, including LED indicators and data memory.

Control Unit Operating Modes and Signals

Control Modes and Reset Functions

Covers intermediate lubrication, malfunction reset, and comparison of time vs. revolution control.

Operating Mode: Cycle Control

Explains cycle control based on counting distributor piston strokes via a proximity switch and its technical data.

Control Unit Special Equipment and Adjustments

Internal Memory and Data Logging

Lists values saved in BEKA-troniX1 and EP-tronic memory, accessible via BEKA-DiSys.

Adjusting Modes and Ranges via BEKA-DiSys

Details how modes and ranges are adjusted using diagnostic software and lists BEKA-troniX1 ranges.

EP-tronic Adjusting Ranges and Sticker Management

EP-tronic Adjusting Ranges and Sticker Exchange

Lists EP-tronic ranges and instructs on sticker exchange after setting changes, with orderable sticker sets.

Optional Equipment: Monitoring Systems

Grease Level and Pressure Relief Valve Monitoring

Details optional grease level monitoring with proximity switch and pressure relief valve monitoring with micro switch, including technical data.

EP-tronic Optional Signals and Adjustments

Optional Signals and Application Condition Adaptation

Covers starter release, collective fault signals, external indicators, and adapting EP-tronic for load conditions.

EP-tronic T1 Control Unit Functionality

EP-tronic T1 Operation, Load Adjustments, and Cycle Summation

Explains T1 operation, load-based cycle time adjustments, and summing lubrication times.

EP-tronic Extras and Sticker Management

EP-tronic Extras and Label Ordering

Details EP-tronic adjusting ranges via BEKA-DiSys and provides information on ordering custom labels.

EP-T2 Control Unit Function Sequence

EP-T2 Operation: Brake Activation and Duration Limiting

Explains how the EP-T2 unit limits lubrication based on brake signals, including interruptions.

Control Unit Parameter Adjustment

Control Unit Adjustment Procedures and Warnings

Details how to adjust control unit parameters and warns about water entry if covers are not replaced properly.

Pump Filling Procedures

Various Pump Filling Methods and Cleanliness

Describes standard filling, filler coupling, filling press, and emphasizes cleanliness and lubricant quality.

Pump Status Signals and Indicators

LED Indicators and Signal Interpretation

Explains LED indicators for pump functions, errors, and test lubrication, including how to activate permanent lubrication.

Pump Ventilation Procedure

Steps for Pump Ventilation

Provides a step-by-step guide for ventilating the pump if the reservoir is emptied by mistake.

Service, Maintenance, and Inspection

Maintenance Safety and Regular Inspections

Covers safety precautions for maintenance, regular visual inspections, and authorized personnel.

Disposal Guidelines

Lubricant and Pump Disposal

Advises heeding lubricant manufacturer's advice and regional regulations for pump disposal.

Spare Parts Drawing: 1.9 kg Reservoir Assembly

Components for 1.9 kg Reservoir

Diagram showing exploded view of parts for the 1.9 kg reservoir assembly.

Cable for Grease Level Monitoring

Highlights the cable used for grease level monitoring across various reservoir sizes.

Spare Parts Drawings: 2.5 kg and 4.2 kg Reservoirs

Components for 2.5 kg Reservoir

Exploded view of parts for the 2.5 kg reservoir assembly.

Components for 4 resp. 4.2 kg Reservoir

Diagram showing exploded view of parts for the 4 and 4.2 kg reservoir assemblies.

Spare Parts Drawings: 8 kg and 16 kg Reservoirs

Components for 8 kg Reservoir

Exploded view of parts for the 8 kg reservoir assembly.

Components for 16 kg Reservoir

Diagram showing exploded view of parts for the 16 kg reservoir assembly.

Spare Parts List: Pump Housing to Pump Element PE-120 V

Pump Housing and Motor Components

Lists parts including pump housing, motor housing, DC gear motors, and connection elements.

Pump Elements and Valves

Details order numbers for pump elements (PE-60, PE-120, PE-170, PE-120 V) and pressure relief valves.

Connectors and Housing Parts

Details bayonet connectors, sealing, and motor housing parts with integrated control units or PSU.

Spare Parts List: Reservoir Covers and Connectors

Reservoir Components for 1.9 kg and 2.5 kg Reservoirs

Details parts for 1.9 kg and 2.5 kg reservoirs, including covers, connectors, and levels.

Parts for 4 kg and 4.2 kg Reservoirs

Lists components for 4 and 4.2 kg reservoirs, such as agitator blades, O-rings, and screws.

Spare Parts List: Larger Reservoirs and Components

Parts for 8 kg and 16 kg Reservoirs

Details components for 8 kg and 16 kg reservoirs, including stickers, nuts, and covers.

Order Key for Level Monitoring Components

Level Monitoring Selection Criteria

Defines selection codes for temperature range, voltage, reservoir size, connection type, cable, and switch type.

Order Key for EP-tronic Control Units

EP-tronic Configuration Options

Lists codes for connector version, additional equipment, parameter combinations, and fault signals for EP-tronic.

Order Key for EP-tronic T1 and BEKA-troniX1 Control Units

EP-tronic T1 Configuration Options

Lists codes for EP-tronic T1 connector version, settings, parameter, and cycle time combinations.

BEKA-troniX1 Configuration Options

Lists codes for BEKA-troniX1 connector version, additional equipment, parameter, and cycle time combinations.

Order Key for EP-T2 Control Unit

EP-T2 Configuration Options

Specifies codes for EP-T2 connector version, lubrication time range, and special models.

Troubleshooting Guide: Malfunctions and Remedies (Part 1)

Troubleshooting Specific Malfunctions

Covers issues like pump not operating, no lubricant supply, no grease collar, and reduced pump speed.

Troubleshooting Guide: Malfunctions and Remedies (Part 2)

Troubleshooting System Faults and Errors

Addresses leakage at pressure relief valve, indicator pin/LED errors, level errors, and function mismatches.

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