BEKA BEKA-MAX PICO Original Operating And Assembly Manual Download Page 1

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BAL2185_Grease_lubrication_pump_PICO_with_PICO-troniX1_-tronic_0519EN 10158410

...a product of

BEKA-MAX

Grease lubrication pump PICO
with integrated control unit
PICO-troniX1
PICO-tronic

Version

-201

Original operating
and
assembly manual

Summary of Contents for BEKA-MAX PICO

Page 1: ...85_Grease_lubrication_pump_PICO_with_PICO troniX1_ tronic_0519EN 10158410 a product of 1 BEKA MAX Grease lubrication pump PICO with integrated control unit PICO troniX1 PICO tronic Version 201 05 9 Or...

Page 2: ...O tronic 11 6 3 Assembly of pump elements 12 6 3 1 Disassembly of a pump element 13 6 3 2 Assembly of a pump element 14 7 Start up 15 7 1 Lubricants 15 7 2 Filling with lubricant 15 7 2 1 Initial fill...

Page 3: ...pendent lubrication duration 44 9 2 8 Function 44 System pressure monitoring 9 2 9 Function 44 Level monitoring 9 2 10 Function 45 Line break monitoring 9 2 11 Special function 45 External status sign...

Page 4: ...systems Operating temperature 35 C up to 70 C Transport and storage temperature 40 C up to 70 C Reservoir material plastic transparent Reservoir size 1 5 l Effective volume 1 2 l Installation position...

Page 5: ...ervance are marked with the generaldangersymbol Thissymbolwarnsofhotsurfaces Warningofsuspendedloads Warningofmaterial damageduetoelectrostatic discharge Marks potentialrisks whichmayresultinmaterial...

Page 6: ...tivepipesorhosesmustbereplacedimmediatelyandprofessionally Hydraulic hoses and polyamide pipes are subject to natural aging and have to be exchanged in regular intervalsaccordingtothemanufacturer sspe...

Page 7: ...anual Neverexceedorfallbelowthelimitvalues asstatedinthetechnicaldata 2 8 Electrostaticdischarge Avoid electrostatic discharge There are electronic components integrated into the devices which might b...

Page 8: ...thedevice having the necessary professional training and authorization of your company to operate the device and to carry out thenecessaryworkonthedevice Anotheruseorausebeyondthisscopeisdeemedimprope...

Page 9: ...ice and other components Mindaproperandeco friendlyassemblywithoutimpairmentofpersons healthandsafety Devices with agitator blade have to be assembled balanced at both sides at the setup location and...

Page 10: ...ion plug for the additional are included in the scope of delivery The equipment without connection cable see fig 40 is supplied If you need a connection cable it hastobeordered ordernumbersonrequest s...

Page 11: ...or adjustment to operating conditions External signal lamp optional black brown blue black grey brown free black brown blue Operational mode of pulse dependent cycle duration e g proximity switch at l...

Page 12: ...d5to9 seefig 4 Remove the screw plug with anAllen keyAF 10 outlets 4 and 10 see fig 4 orAF 6 outlets 1 to 3 and 5 to 9 see fig 4 fromtheoutletintowhichyouwanttoscrewinthepumpelement Exchangethesealing...

Page 13: ...13 6 3 1 Disassemblyofapumpelement A Disconnectthedevicefromthepowersupply pos 1 seefig 5 andsecureitagainstrecommissioning Fig 5 B Unscrewthepumpelement Fig 6 Makesurethatthepistonofthepumpelementdoe...

Page 14: ...sired position has been reached Tightenthepumpelementwiththebelowindicatedtighteningtorque seefig 7 Fig 7 TightenthepumpelementsPE 5toPE 50withatighteningtorqueof20Nm 10 Tighten the pump elements PE 6...

Page 15: ...cifications Collectleakinglubricantinasuitablereservoiranddisposeitprofessionally Observethesafetydatasheetofthelubricantmanufacturer Thelubricantviscositychangeswiththeoperatingtemperature Checkthele...

Page 16: ...nlubricant When dirt particles get into the device the pistons of the pump elements can wear which results in the destructionofthepumpelements Thedirtparticlescanalsogetintothelubricationsystemandcan...

Page 17: ...fill protection seefig 11 Fig 11 Fig 12 D Screwtheoverfillprotectionbackinandtightenitwithatighteningtorqueof15Nm 10 Fig 13 E Turn the device around again and fill it up to the maximum level see fig 1...

Page 18: ...d overfilling the device otherwise lubricant might leak out which can cause environmental damage A Fillingviathecone typezerkwithafillinggun standard Removetheprotectivecapoftheexistingcone typezerk c...

Page 19: ...isiblyattheoutlet approx 10mm seefig 17 Connectthefillinggu thefillingconnectionM20x1 5andfillthedeviceuptothemaximumlevel nto Remove the filling connection M20x1 5 after finishing the filling process...

Page 20: ...ation system mainly consist of a lubrication pump and one or several progressive distributors The s lubrication pump supplies the lubricant into a main distributor This distributor distributes the lub...

Page 21: ...1 Fig 19 1 11 3 4 5 6 7 2 12 8 9 10 Lines to the lube points Secondary distributor e g MX F Secondary distributor e g MX I Main distributor e g SXE 2 Secondary distributor e g LX 4 Main distributor e...

Page 22: ...agitator blade Pump element PE 120 FV Pump housing Protective housing with integrated control unit PICO troniX1 and bayonet plug type connection Connection plug Hirschmann 7 pole Connection plug bayo...

Page 23: ...centric shaft is located above the centering ring pos 7 whichis usedasgreasestrainer Theagitatorbladepushes thelubricant towardsthepumpelements There is a follow up piston pos 10 in the reservoir pos...

Page 24: ...roke Non returnvalvesareintegratedinthepumpelementswhichpreventthatlubricant whichhasalreadybeendisplaced is sucked back An agitator blade pos 8 which is firmly connected with the eccentric shaft is l...

Page 25: ...deliveryrate A revolution of the set screw corresponds to 2 detents The set screw can be adjusted by a maximum of 6 detents 3revolutions seefig 24 Retighten the set screw 1 incl sealing ring with a ti...

Page 26: ...tingvalve seefig 25 Fig 25 withpressurelimitingvalve withoutpressurelimitingvalve Eachtypeofpumpelementhasitsownmarkinginordertoenableavisualdifferentiation seefig 26 Fig 26 PE 60F PE 120F PE 170F add...

Page 27: ...ent Pipe connection Order no PE w o PLV Order no PE with PLV PE 60 F 6 mm 2152990671000 2152990671003 8 mm 2152990671101 2152990671004 10 mm 2152990671102 2152990671005 G 1 4 2152990671100 21529906710...

Page 28: ...d cannot be adjusted The pump elements are deliverable with differentpipeconnections seefig 27 Fig 27 ThreadconnectionM10x1 Pipeconnection 6with S6 unionscrew andDKR6 doubleconicalring Straightplug ty...

Page 29: ...ed in the scope of deliveryandhastobeorderedseparatelyifneeded USITringU18 7x14x1 5 orderno 100150010148 Notice Pipe connection 4 with S4 and DKR4 04 2154 9000 01 Construction type no Pump element PE...

Page 30: ...miting valve the pressure limiting valve opensandthelubricantleaksoutatthetopatthevalve seefig 28 Fig 28 Lubricantcanleakoutatthepressurelimitingvalveunderhighpressure 290bar Wear corresponding person...

Page 31: ...specifically e g for switching off the device or it is evaluated by the integrated control unit PICO tronic see chapter 9 2 8 Function System pressure monitoring Fig 30 Technicaldataofthemicroswitch...

Page 32: ...cro switch loose cable Order no 2152990610028 Sealing ring DIN 7603 8x12x1 Order no 090760302911 approx 85 M14x1 5 M14x1 5 G1 4 M14x1 5 G1 4 M14x1 5 M14x1 5 6 Socket for pump element PE 120 FV only fo...

Page 33: ...endsasignaltotheintegratedcontrolunit Thecontrolunitdisplaystheerror andswitches Leveltoolow thedeviceoffinordertopreventthatairispumpedintothelubricationsystem Whenthereservoirofthedeviceisrefilled t...

Page 34: ...ators ThefollowingmessagesaredisplayedbytheintegratedcontrolunitbytheredandgreenLEDintheinspectionwindowof theprotectivehousing seechapter13 1 SignalindicatorsoftheintegratedcontrolunitPICO troniX1 Op...

Page 35: ...an intermediate lubrication can be triggered at any time by pushing the push button for intermediatelubrication Thecurrentdataofthecycleisdeletedandanewlubricationcyclestartsimmediately Some errors h...

Page 36: ...rotective housing using a flat screwdriver loosen the four crosspointscrewsandremovethetransparentinspectionwindow After setting the parameters the inspection window and the frame have to be closed pr...

Page 37: ...ion duration can be set within a setting range using the left grid switch in the inspection windowoftheprotectivehousing seefig 36 9 1 5 Operationalmodeofrevolution dependentlubricationduration At the...

Page 38: ...Thefollowingfunctionscanbeevaluatedwiththeintegratedcontrolunit Systempressuremonitoring monitoringofthelinepressureinthelubricationsystem Levelmonitoring onlyfordeviceswithfollow uppiston seechapter...

Page 39: ...deficit lubricationcannotbefinishedduringthelubricationduration CPU memorydefective Triallubricationinprocess Operationaldatabase Theintegratedcontrolunithasanoperationaldatabaseinwhichthefollowingval...

Page 40: ...mediate lubrication can be triggered at any time by pushing the push button for intermediatelubrication Thecurrentdataofthecycleisdeletedandanewlubricationcyclestartsimmediately Some errors have to be...

Page 41: ...nt cycle duration the cycle duration can be set in hours or minutes depending on the selected setting range The setting range can be changed using the diagnosis software with the BEKA DiSys currentver...

Page 42: ...ratedcontrolunitPICO tronic When the integrated control unit receives a pulse signal again the error is automaticallyresetandthecyclecontinuesnormally Thesensorcanbeconnectedtotheintegratedcontrolunit...

Page 43: ...t a progressive distributor see fig 45 If the integrated control unit receives no pulse signal within the adjustable pulse monitoring time of lubrication duration standard setting 12 min it displays a...

Page 44: ...dependent lubrication duration can be set within a setting range using the left grid switch in the inspectionwindowoftheprotectivehousing seefig 40 9 2 8 FunctionSystempressuremonitoring The operating...

Page 45: ...ng are connected in series If a micro switch does not switch on the signal the signal is absent at the integrated control unit The error is automatically reset when the pressure rebuilds in all lines...

Page 46: ...can be done via a 3 notch switch see fig 50 withinthefirst30secondsafterswitchingonthevoltage The 3 notch switch is not included in the scope of delivery however it can be ordered separately orderno 1...

Page 47: ...operating conditions 9 2 14 ErrorLubricationdeficit Theerror occurswhenalubricationcannotbefinishedduringacyclesequence Inthiscase thedevice Lubricationdeficit needs more time for processing the lubri...

Page 48: ...es like increasedtemperatureorpollutionmayshortentheseintervals Please make sure to only use lubricants that are suitable for the device as well as the lubricated machine and that complywiththerequire...

Page 49: ...F3 Fig 55 C Remove the protective housing pos 1 see fig 56 and loosen the receptacles of the connection cables pos 2 andpos 3 seefig 56 Makesurethattheconnectioncablesdonottearoff Fig 56 D Attach the...

Page 50: ...see fig 57 and screw the hexagon socketheadcapscrews pos 3 seefig 57 backin Make sure that the pos 4 see fig 57 is not otherwise can enter into flat gasket damaged water theintegratedcontrolunitandca...

Page 51: ...sfordisassembly 12 Disposal Observethedisposalinstructionsofthelubricantmanufacturerwhenlubricantischanged Lubricants or cloths contaminated with lubricant etc must be collected in specially markedres...

Page 52: ...tem blocked See malfunction Lubricant leakage at pressure limiting valve Lubrication duration pump operating time too short Extend lubrication duration T is shown he error Lubrication deficit See chap...

Page 53: ...ation Check and possibly renew external sensor and connected cable Reset error with intermediate lubrication Error Lubrication deficit No malfunction see chapter 9 2 14 Error Lubrication deficit Trigg...

Page 54: ...Function Operable 1 5 s ON ON OFF OFF LED red LED green Indication of the operational capability after switching on the voltage for the first time During the whole lubrication ON ON OFF OFF LED red LE...

Page 55: ...thesametime theyaredisplayedoneaftertheotherwithabreakofapprox 2seconds Signal indicators Function Operable 1 5 s ON ON OFF OFF LED red LED green Indication of the operational capability after switchi...

Page 56: ...o low only for devices with follow up piston ON ON OFF OFF LED red LED green 1 s 1 s Trial lubrication permanent lubrication In order to initiate a permanent lubrication for service purposes in the op...

Page 57: ...naldrawing 15 1 DimensionaldrawingfordeviceswithintegratedcontrolunitPICO troniX1 Fig 58 128 approx 42 approx 187 35 39 approx 261 9 5 approx 242 76 approx 111 150 approx 171 80 approx 148 approx 132...

Page 58: ...58410 a product of BEKA 201 All 9 rights reserved 58 15 2 DimensionaldrawingfordeviceswithintegratedcontrolunitPICO tronic Fig 59 128 approx 42 approx 187 35 39 approx 261 9 5 approx 242 76 approx 111...

Page 59: ...1 Notice 2185 X X X 7X XXXX Contruction type no Motor voltage 12 V DC 24 V DC with Hirschmann plug type connection with bayonet plug type connection 1 2 3 4 Pump elements Outlet position PE 120 F PE 1...

Page 60: ...ubr duration 1 16 min 2 32 min 2 32 s 1 16 pulses 17 32 pulses 33 48 pulses 1 16 rev 10 160 rev 170 320 rev 21 22 23 25 2A 2B 2C 2E 24 29 2D 2J 30 3A 31 32 36 3J 37 38 3C 3K 3D 3E 51 52 53 55 5A 5B 5C...

Page 61: ...tioncable ion Required connection plugs or connection cables have to be ordered separately order numbers on request Notice Parameters Time dependent cycle duration 0 5 8 h 1 16 min 2 32 min 2 32 h Tim...

Page 62: ...1 16 rev 10 160 rev 170 320 rev 21 22 23 25 2A 2B 2C 2E 24 29 2D 2J 30 3A 31 32 36 3J 37 38 3C 3K 3D 3E 51 52 53 55 5A 5B 5C 5E 5L 5M 5N 5R Pulse dependent cycle duration 1 16 20 320 100 1600 500 8000...

Page 64: ...BAL2185_Grease_lubrication_pump_PICO_with_PICO troniX1_ tronic_0519EN 10158410 a product of BEKA 201 All 9 rights reserved 64...

Page 66: ...BAL2185_Grease_lubrication_pump_PICO_with_PICO troniX1_ tronic_0519EN 10158410 a product of BEKA 201 All 9 rights reserved 66 18 Foryournotes...

Page 68: ...E Mail beka beka lube de beka beka max de Our range of supply Gear pumps Multi line oil pumps Multi line grease pumps Single line central lubrication systems Dual line central lubrication systems Oil...

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