BEKA FKGGM-EP Original Operating And Assembly Instructions Download Page 65

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10.

Troubleshooting

Faults

Possible cause

Possible elemination of faults

Pump does not operate

Exchange pump

Renew line

Pump defective

Control unit defective

electr. line is broken

Exchange pump

Ventilate pump

Exchange pump element

Pump operates but does not
deliver

Air below follow-up piston

No grease at one lubrication
point

Adjust lubrication time (PLC)

Renew main line

Pump element defective

Lubrication time (pump runtime)
too low

Main line burst or leaky

Distributor defective

Exchange distributor

Pump shows error
CPU / memory

Control unit defective

see 9.1 „pump does not operate“

Ventilate pump

Exchange pump element

Pump does not operate

Air below follow-up piston

Pump element defective

Exchange proximity switch

Replace line or exchange /
retighten fittings

Exchange cable

Proximity switch at distributor
defective

Main line burst or leaky

Cable of progressive distributor
defective

Pump shows pulse error

Replace pump

Pump shows level error

Refill reservoir

Replace level switch

Exchange cable

Level too low

Level switch defective

Cable of level switch is broken

Pump element not fixed

Exchange pump element

Refill reservoir

Level too low

Ventilate pump

Air cushion in the delivery piston

Check system/bearing points
No damage (interm lubrication
may be required 1 to 2 times

High system pressure

Pump speed reduced

Check voltage

Supply voltage too low

Check system

System pressure too high

Lubricant comes out
of saftey valve

Replace distributor

Progressive distributor blocked

Replair blocked/stuck bearing
points

System blocked

Exchange safety valve

Valve spring broken

Subject to alterations!

...a product from

BAL2076_central lubrication pump_01

19EN

Summary of Contents for FKGGM-EP

Page 1: ...ic 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 1 Subject to alterations a product from BAL2076_central lubrication pump_0119EN BEKA 2019 All rights reserved ...

Page 2: ...EP 22 4 1 1 Central lubrication pump FKGGM EP 1 9 liter reservoir 22 4 1 2 Central lubrication pump FKGGM EP 22 4 1 2 1 2 5 liter reservoir without level monitoring 22 4 1 2 2 2 5 liter reservoir with level monitoring 23 4 1 2 3 2 5 liter reservoir with filling cover 23 4 1 3 Central lubrication pump FKGGM EP 4 liter reservoir 24 4 1 4 Central lubrication pump FKGGM EP 8 liter reservoir 24 4 1 5 C...

Page 3: ... Control unit type EP tronic ZX S1 with intermediate housing 49 7 2 9 Control unit type EP tronic ZX S2 with intermediate housing 12 24 V DC 50 7 2 10 Control unit type EP tronic ZX S2 with intermediate housing 100 250 V AC 51 7 3 Basic filling of central lubrication pump 52 7 4 Ventilation of central lubrication pump 52 8 Maintenance 53 8 1 Preventive repair wear part 53 8 2 Level of central lubr...

Page 6: ...njuries of persons This also belongs to an intended use Pay attention to all notes in the operat manual ing Carry out all maintenance work Observe relevant instructions all for the work safety and accident prevention during all life cycles of the central lubrication system You have to have the required professional education and authorization of your company to carry out the necessary works at the...

Page 7: ...tails Notes directly attached at the unit must strictly be followed and held in readable condition 1 3 2 staff Qualification and training of The staff in charge for operation maintenance inspection and assembly has to have the according qualification for these tasks Competence responsibility and supervision of staff must be clearly defined by the operator In case the staff does not have the necess...

Page 8: ... condition Furthermore appropriate personal predective equipment goggles among others is necessary The shutdown procedure of the central lubrication system as described in the manual must be strictly followed Secure the device against intentional or unintentional recommissioning during maintenance or repair All safety and predection arrangements have to be put back in place again immediately after...

Page 9: ...ly and professionally Hydraulic hoses and polyamide pipes are subject to a natural aging process and thus have to be exchanged in regular intervals according to the manufacturer s specifications 1 5 Transport and storage Use a suitable lifting device for the transport Do not the central lubrication system or throw impose it to shocks Use a suitable lifting central lubrication system for transport ...

Page 10: ...6 ø 8 ø 10 Delivery rate Pump element PE 60 0 06cm stroke 3 Pump element PE 120 0 12cm stroke 3 Pump element PE 120 V 0 12 cm stroke can be regulated back to 0 05 cm stroke 3 Pump element PE 170 0 17cm stroke max operating pressure 350bar Pressure limiting valve set to 280 bar 15 Sense of rotation of agitator blade FKGGM EP EPR counter clockwise MOTOR Drive D Cmotor 12 24 V DC Power input 100 W DC...

Page 11: ...be points are lubricated successively Therefore this process to lubricate the lube points can easily be monitored by a pressure relief valve The central lubrication pump supplies lubricant to the main distributor This one supplies lubricant in the right relation to the secondary distributors From here lubricant is delivered to the lube points In case one lube point would not receive lubricant from...

Page 12: ...cation pump or by an external control unit The reservoir level is monitored optional During the pump operation lubricant is delivered into the pressure lines until the switch pressure is reached The switch pressure can be checked at the pressure gauge The pressure line has to be relieved by a 2 2 way valve in order to enable the displacement of lubricant in the distributor The pressure line is aut...

Page 13: ...tion pump has a level monitoring optional Functional description The motor powers the eccentric via a gear The eccentricity effects a suction and pressure movement of the supply piston The integrated non return valve avoids a return pumping of lubricant into the lubrication line The pump element is compulsory controlled by the eccentric thus a function at low temperatures is ensured The delivery r...

Page 14: ...ement of the supply piston The integrated non return valve avoids a return pumping of lubricant into the lubrication line The pump element is positively controlled by the eccentric thus a function at low temperatures is ensured The delivery rate depends on the installed pump element The grease reservoirs are equipped with an agitator for the FKGGM EPR only in the area of the pump housing in order ...

Page 15: ...monitors the piston movement The proximity switch sends a signal to the control unit at each piston movement If the signal is not send within an indicated monitoring time the connected control unit sends an error message Components Fig 5 example 2076 00118 Ventilation Reservoir 2 5 liter Level label BEKA WIND Filling nipple with dust cap Pump housing Type plate of pump Connection Distributor combi...

Page 16: ...ing movement of the eccentric ring effects that the supply piston closes the suction drilling whereby lubricant is supplied towards the outlet via the non return valve The pressure line shall only be connected if the pump element supplies air free The non return valve avoids that lubricant is drawn back Supplied lubricant always has to be clean to ensure the function of the non return valve The pu...

Page 17: ...m stroke alltypes not adjustable Operating pressure max 350 bar Pressure limiting valve setto 280 bar 15 Lubricant greases NLGI cl 00 000 to NLGI cl 2 Pressure limiting valve withor without Pipe connection ø6 ca 55 ca 90 M20x1 5 Pressure limiting valve set to 280 bar 15 AF 17 AF 19 AF 17 AF 24 AF 19 M14x1 5 Ø 8 Reduction fitting pipe Ø 6 Ø 8 AF 17 AF 17 AF 19 ca 51 Reduction fitting pipe Ø 6 Ø 10 ...

Page 18: ...f the adjusting disc 0 8 mm 2 notches Tighten screw plug Fig 10 Pos 1 including sealing ring Technical data Delivery rate PE 120 V 0 12cm stroke 3 Regulation possiblemin 0 05 cm stroke 6notches per turn 1 2 reduction0 013 cm per notch Operating pressure max 350 bar Pressure limiting valve setto 280 bar Lubricant grease up to NLGI cl 00 000 to NLGI cl 2 Pressure limiting valve withor without Fig 11...

Page 19: ...to the reservoir return The main line is relieved and lubricant is supplied to the lube points by the distributor Fig 12 Technical data Way seat valve VP1 S A24 Type of actuation 24V DC electric Switch symbol S Connection 1 4 Volume flow Q 15 l min max Operating pressure p 400 bar max Central plug Nominal power 20 P W N Current 0 83 l A N Manual emergency button Press the button max actuation pres...

Page 20: ...ug for solenoid valve 24 V DC K1291_1 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 Connection of solenoid valve via flange socket M12 at housing Fig 14 Round plug M12 angled Oil flex line 110 2 x 1 without PE Plug for solenoid valve K1370 24 V DC Flange socket M12 20 ...

Page 21: ...Variation 100 250 V AC with intermediate housing for integrated PSU without integrated control Variante 100 250 V AC with intermediate housing for integrated PSU with integrated control 4 Installation dimensions Installation dimensions of construction variation of motor housing with or without integrated control Fig 15 133 172 Variation 12 24 V DC without integrated control 21 ...

Page 22: ...rved 4 1 Central lubrication pump FKGGM EP 4 1 1 Central lubrication pump FKGGM EP 1 9 Liter reservoir Fig 16 4 1 2 Central lubrication pump FKGGM EP 4 1 2 1 2 5 Liter reservoir without level monitoring Fig 17 343 5 132 248 130 ø152 107 172 342 ø9 5 ø6 239 172 342 107 130 248 239 ø9 5 ø6 306 132 ø152 22 ...

Page 23: ...ubrication pump_0119EN BEKA 2019 All rights reserved 4 1 2 2 2 5 liter reservoir with level monitoring Fig 18 4 1 2 3 2 5 liter reservoir with filling cover Fig 19 239 ø9 5 ø6 354 132 172 342 130 248 107 ø152 132 363 ø9 5 ø6 239 172 342 248 130 107 ø152 23 ...

Page 24: ...r Fig 20 4 1 4 Central lubrication pump FKGGM EP 8 liter reservoir Fig 21 436 132 ø6 ø9 5 130 172 342 ø229 107 400 132 ø180 112 130 172 349 ø6 ø9 5 24 Subject to alterations a product from BAL2076_central lubrication pump_0119EN BEKA 2019 All rights reserved ...

Page 25: ... alterations a product from BAL2076_central lubrication pump_0119EN BEKA 2019 All rights reserved 4 1 5 Central lubrication pump FKGGM EP 12 liter reservoir Fig 22 ø11 587 285 ø11 40 128 ø6 230 142 172 342 257 25 ...

Page 26: ...ubrication pump FKGGM EP 16 liter reservoir Fig 23 172 342 230 257 142 ø6 230 526 128 11 40 657 ø11 40 285 26 Subject to alterations a product from BAL2076_central lubrication pump_0119EN BEKA 2019 All rights reserved ...

Page 27: ...brication pump FKGGM EP 20 liter reservoir Fig 24 11 ø6 758 617 126 40 735 230 11 ø11 142 284 172 342 ø278 27 Subject to alterations a product from BAL2076_central lubrication pump_0119EN BEKA 2019 All rights reserved ...

Page 28: ...ations a product from BAL2076_central lubrication pump_0119EN BEKA 2019 All rights reserved 4 1 8 Central lubrication pump FKGGM EP 30 liter reservoir Fig 25 ø6 11 993 852 126 970 40 230 11 ø11 142 172 342 285 ø278 28 ...

Page 29: ...iter reservoir Fig 26 4 2 2 Central lubrication pump EPR 8 liter reservoir Fig 27 130 ø9 5 172 342 117 236 ø232 ø6 442 132 40 ø6 172 342 230 ø11 142 261 ø232 537 40 124 29 Subject to alterations a product from BAL2076_central lubrication pump_0119EN BEKA 2019 All rights reserved ...

Page 30: ...ations a product from BAL2076_central lubrication pump_0119EN BEKA 2019 All rights reserved 4 2 3 Central lubrication pump EPR 12 liter reservoir Fig 28 50 681 9 12 ø6 40 127 498 588 43 ø11 230 278 142 ø272 172 342 30 ...

Page 31: ...ions a product from BAL2076_central lubrication pump_0119EN BEKA 2019 All rights reserved 4 2 4 Central lubrication pump EPR 15 liter reservoir Fig 29 60 80 ø6 160 11 8 230 126 5 731 5 583 5 40 172 342 ø290 160 304 5 31 ...

Page 32: ... alterations a product from BAL2076_central lubrication pump_0119EN BEKA 2019 All rights reserved 4 2 5 Central lubrication pump EPR 20 liter reservoir Fig 30 19 709 525 3 164 5 ø6 160 11 ø329 348 185 172 362 32 ...

Page 33: ...tion pump FKGGM EPwith installed MX F distributor Fig 31 172 250 130 ø152 107 224 342 133 5 x grease outlet ø6 33 Subject to alterations a product from BAL2076_central lubrication pump_0119EN BEKA 2019 All rights reserved ...

Page 34: ...d via a capacitive proximity switch When the min level is reached the capacitive proximity switch sends a signal NC or NO contact depending on electric connection Switch off the central lubrication pump to avoid that air is drawn into the system Connect the level monitoring by means of a suitable cable Put the angled bush onto the level monitoring and tighten the knurled nut Assemble the high pres...

Page 35: ...V PE optional white NC contact black NO contact Fig 35 Fig 34 Attention 5 1 3 FKGGM EPPump Proximity switch connection cubic plug acc to DIN 43650 90 250 VAC View onto plug brown 1 L 90 250 V AC blue 3 NO contact Fig 36 5 1 2 FKGGM EPPump 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 s...

Page 36: ...e level monitoring connection and tighten the knurled nut Mount the cable away from hot parts max 50 C and avoid chafe marks Fig 37 Technical data inductive proximity switch Contact function PNP NC contact Operating voltage 10 60 V DC Switching current max 200 mA View onto plug 1 Ub 10 60V brown 2 NC contact white 3 ground blue 2 1 4 3 bush M12x1 for connection at level monitoring white brown blue...

Page 37: ...a pressure relief valve installed at the micro switch If there is a malfunction in the system the micro switch is actuated The signal of the switch can be processed by an already existing signal transmitter e g on board computer or an external or integrated control unit Lubricant comes out of the pressure relief valve under high pressure 250 bar Wear safety goggles and do not remain in the danger ...

Page 38: ...rication is active fig 39 Fig 43 Fig 44 Lubrication time lubrication active Cycle time Pulse off time Lubrication button to activate an intermediate lubrication The green LED glows during lubrication or function display The red LED glows until the reservoir is refilled or the display shows a malfunction 8 0 5 16 1 Service EA PA Controller Typ EP tronic Cycle time cycle time h Takte cycles 5 3 2 Co...

Page 39: ...sure a safe operation Also observe the indicated data in the dimensional drawing regarding the fastening drillings When choosing the assembly position take care that the pump is predected against environmental and mechanic effects Ensure a full access for example for lubrication filling 6 1 Installation position central lubrication pump FKGGM EP Assemble the pump in vertical position 6 2 Installat...

Page 40: ...tilation screw 7 Start up Observe the following items before the pump start up in order to guarante a perfect function of the pump 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 Alonger operation with the wrong sense of rotation can damage motor and pump The electric connection of the pump must ...

Page 41: ...supply unit RS 100 24 green red 1 2 X2 24V 4 5A 24V GND K1296 2 Color cable 2 cores Ub blue Ground brown L Pin 5 N Pin 6 PE Pin 7 PE 7 1 3 12 24 V DC with cubic plug 7 1 4 100 250 V AC with Hirschmann plug Diagram X1 View onto plug PIN 1 UB 24 V PIN 2 ground 0V X 90 X 1 Number cable Ub wire 1 PIN 5 bayonet plug GND wire 2 PIN 7 bayonet plug 2 Color cable 2 cores Ub blue Pin 5 bayonet plug GND brow...

Page 42: ...ication pump_0119EN BEKA 2019 All rights reserved See also description EP tronic 7 2 Connection central lubrication pump FKGGM EPor 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 42 blue red green yellow ...

Page 43: ...erations a product from BAL2076_central lubrication pump_0119EN BEKA 2019 All rights reserved 7 2 2 Control unit type EP tronic with intermediate housing Fig 50 See also description EP tronic 43 green yellow blue red ...

Page 44: ...ons a product from BAL2076_central lubrication pump_0119EN BEKA 2019 All rights reserved 7 2 3 Control unit type BEKA troniX1 Voltage Ub 10 60 V DC nominal 12 24 V DC Fig 51 See also description BEKA troniX1 44 green red ...

Page 45: ...ns a product from BAL2076_central lubrication pump_0119EN BEKA 2019 All rights reserved See also description BEKA EP tronic_ZX 7 2 4 Control unit type BEKA troniX1 with intermediate housing 100 250 V AC Fig 52 45 red green ...

Page 46: ...t from BAL2076_central lubrication pump_0119EN BEKA 2019 All rights reserved See also description BEKA EP tronic_ZX 7 2 5 Control unit type EP tronic ZX Voltage Ub 10 60 V DC nominal 12 24 V DC Fig 53 46 green silver yellow blue red ...

Page 47: ...ct from BAL2076_central lubrication pump_0119EN BEKA 2019 All rights reserved See also description BEKA EP tronic_ZX 7 2 6 Control unit type EP tronic ZX with intermediate housing 100 250V AC Fig 54 47 yellow silver red yellow blue ...

Page 48: ...BAL2076_central lubrication pump_0119EN BEKA 2019 All rights reserved 7 2 7 Control unit type EP tronic ZX with intermediate housing and temperature sensor 100 250 V AC Fig 55 See also description BEKA EP tronic_ZX 48 blue silver yellow red ...

Page 49: ...duct from BAL2076_central lubrication pump_0119EN BEKA 2019 All rights reserved 7 2 8 Control unit type EP tronic ZX S1 with intermediate housing 100 250 V AC Fig 56 See also description BEKA EP tronic_ZX 49 silver yellow red blue ...

Page 50: ...om BAL2076_central lubrication pump_0119EN BEKA 2019 All rights reserved 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 See also description BEKA EP tronic_ZX 50 red blue ...

Page 51: ...uct from BAL2076_central lubrication pump_0119EN BEKA 2019 All rights reserved 7 2 10 Control unit type EP tronic ZX S2 with intermediate housing 100 250 V AC Fig 58 See also description BEKA EP tronic_ZX 51 silver yellow red blue ...

Page 52: ...usions Collect outcoming lubricant with a suitable receptacle environmental predection work safety Do not reuse collected lubricant risk of pollution Dispose collected lubricant professional Connect the main line to the pump elements Operate the central lubrication pump Check all connections visual during the first operating hours Use the same procedure for the progressive distributors or lube poi...

Page 53: ... Take care that the lubricant quality of different lubricant suppliers corresponds to the prefilled lubricant Check all components for leakages or damages at every four weeks 8 1 Preventive repair wear parts Check the system for the following items after it is put into operation again Function of the system Check the pipe lines lubrication points detached hoses leakages In the following years of o...

Page 54: ...ror is deleted automatically Grease level is too low Fig 60 Minimum level Fig 59 Until reservoir is filled ON OFF ON OFF LED red Lampe red control unit display extern LED green Lampe green control unit display extern Lubricant exchange lubricant change The lubricant exchange has to be carried out acc to the lubricant manufacturer s details ambient influences like high temperatures or soilings can ...

Page 55: ...nit The central lubrication pump does not start automatically after the set cycle time and can not be started with the intermediate lubrication button After the set monitoring time the pump shows a pulse error but there is no error as described in the operating manual Electric line defective Exchange the lines proceed as described under item 7 The motor of the lubrication pump is defective replace...

Page 56: ...talled filling connection The filling press must be prepared before the filling so that no air is conducted into the system For this purpose press out about 10 mm of lubricant fig 63 Unscrew the cover of the filling connection and fill up the pump until the max level Screw on the cover again The pump can also be filled via the installed hand lever grease gun fig 65 The grease gun must be prepared ...

Page 57: ...taly friendly Take care of utmost cleanness The ventilation screws are only for the basic filling Do not remove them The overfill protection is for the pump safety Lubricant evades if the max level is exceeded Observe that no ventilation opening is blocked Observe the details of the lubricant manufacturer Observe the safety data sheet of the lubricant manufacturer Viscosity range of lubricant chan...

Page 58: ...an cause air inclusions Standard filling via the cone type lubricating nipple with manual or pneumatic grease gun Fig 67 Filling via filling coupling Fig 68 Fill up lubricating nipple Remove lubricating nipple and replace it by coupling plug grease Order no 2159 0061 012 Filling plug grease Order no 2159 0061 011 Grease sleeve Order no 2159 0062 011 Fill up via grease gun Fig 69 Straight grease co...

Page 59: ... 56 ca 50 Ø 34 M20x1 5 M20x1 5 ca 446 ca 57 ca 57 Filling connection 90 with non return valve Order no 21520174 acc to drawing FAZ03177_01 Straight filling connection with non return valve Order no 21520152 acc to drawing FAZ03177_00 Filling press for grease cartridges acc to DIN 1284 Order no 20830001 acc to drawing FAZ02493_03 Fettinhalt max 500 cm Version for pump with follow up piston ca 448 6...

Page 60: ...ation of the proximity switch check the function of the complete pump Proximity switch LED orange Counter nut ca 1 8mm switching distance Screw in switch until stop then unscrew it by 1 4 turn ca 38 5mm 9 3 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 distr...

Page 61: ...nsert the pump element with pressure limiting valve from a sloping upward position into the housing until the piston head touches the thrust ring fig 76 Put the element in horizontal position fig 68 The piston head must be in the groove of the guide ring fig 74 Tighten the pump element with the according torque fig 73 Pump element or pump are going to be damaged if the element was not properly ins...

Page 62: ...t not remain in the pump housing When installing the pump element pull out the delivery piston partly Then insert the pump elementfrom a sloping upward position into the housing until the piston head touches the thrust ring fig 80 Put the element in horizontal position The piston head must be in the groove of the guide ring fig 79 Tighten the pump element with the according torque fig 77 Pump elem...

Page 63: ...off the plug Unscrew the head nut of the tie rods and disassemble the reservoir cover The new cover with installed level monitoring can be installed now Take care of the monitoring position Assemble the cover and tighten the head nuts on the tie rods Put the angled plug onto the level monitoring and tighten the knurled nut The plug can only be put on in a certain position Fig 81 The cable connecti...

Page 64: ...nurled nut from the plug and take off the plug Measure dimensionAof the new proximity switch fig 84 and table Screw the new switch into the housing and tighten the hexagon nut Observe reference dimension C fig 84 and 85 Put the straight plug onto the proximity switch and tighten the knurled nut The plug can only be put on in a certain position Metal surface LED orange connected to control unit Fig...

Page 65: ...etighten fittings Exchange cable Proximity switch at distributor defective Main line burst or leaky Cable of progressive distributor defective Pump shows pulse error Replace pump Pump shows level error Refill reservoir Replace level switch Exchange cable Level too low Level switch defective Cable of level switch is broken Pump element not fixed Exchange pump element Refill reservoir Level too low ...

Page 66: ...tral lubrication systems Dual line central lubrication pumps Oil circulation central lubrication systems Oil air and spray lubrication Wheel flange central lubrication systems Rolling mill central lubrication systems Commercial vehicle lubrication Progressive distributors Control and monitoring units Subject to alterations We are not liable for errors technical errors and printing errors 66 Subjec...

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BEKA FKGGM-EP, Original Operating And Assembly Instructions

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