BEKA BEKA-MAX OC-1 User manual

1
Multi line pump OC-1
with integrated control unit BEKA-troniX1 (12-24V DC)
FU2174280409GB Subject to alterations!
The BEKA-MAX grease central lubrication pump type OC-1
is electrically driven. It has up to 21 independently form
each other, lubrication outlets, but can also be delivered in
Models with 10, 22 and 34 outlets to which the lubricating
points are directly connected. One pump element is
necessary for each outlet. Five pump elements with
different output rates are on disposal.
This enables adjusting the output rate according to the
demand of each lubricating point.
Having a working pressure of max. 200 bar, this pump
enables the supply of commercial greases up to NLGI-cl.2.
The pump only differs from reservoir and outlet types and is
controlled by the integrated BEKA-troniX1.
Technical data:
Motor:
Operating voltage: 12 V DC / 24 V DC
Speed: 15 r/min.
Current consumption:
No-load operation at + 20°C: 0,8A/ 0,4A
Full load at + 20°C: 2,2A/ 1,1A
Fuse: 5A/ 3A
Integrated control unit
16
1
Cycle time (h)
Service
EA/ PA Controller
Typ BEKA-troniX1
Lubrication time (min.)
8
0,5
8
0,5
Pump:
Max. operating pressure: 200 bar
Permit. operating temperature: -28°C to +70°C
Reservoir content:
Reservoir transparent: 1,9 kg, 2,5 kg, 4 kg or 8 kg
Sense of revol. of agitator blade: counter-clockwise
Installation position: Reservoir vertical
Output rate: depending on pump element (see page 6)
Protection class: IP6K9K acc. to DIN 40050
Lubricant: greases up to NLGI-cl. 2
(without solid lubricants)
mineral oils of 40 mm /s (cSt)
2
Control unit: BEKA-troniX1
Supply voltage: 10 to 60 V DC
Current max.: I = 6,0A
Fuse (not included in device): F 6,3A
(5x20) semi time-lag
Outlet for signal lamp: I = 0,4A
Temperature range: -35°C to +75°C
Multiline pump OC-1 with 2,5 kg reservoir, 21 outlets and
integrated BEKA-troniX1.
...een product van BEKA

2
A d.c. motor (9) drives the eccentric (5) with the bearing (6)
continuously. The eccentricity effects the prime- and
pressure stroke of the delivery piston (7), whereby the
integrated non-return valve (8) prevents the medium from
being reprimed into the main line.
The agitator blade (2) presses the lubricant out of the
supply container (1), through a screen (4), which reduces
air inclusions, into the suction area in the pump housing (3).
A scraper at the agitator blade (2) enables a visual control
of the existing grease level in the transparent reservoir (1).
Multi line pump OC-1
Function
Subject to alterations!
1
5
9
2
4
7
8
6
3
...een product van BEKA

The multiline pump OC-1 can be delivered with 5
transparent reservoirs and 4 outlet Models.
Model with 22 outlets:
3
M8 / 8 deep at 8 kg reservoir
130
152
106
197
273,5
172
176
239
172
273,5
Model with
1,9 kg reservoir
Model with
2,5 kg reservoir
Option
with screw cover
Ø151
207
175
Plug
connection Ø6
Ø9,5
Connection cable
length 10 m
130
152
106
182,5
172,5
273,5
Model with 10 outlets:
Connection cable
length 10 m
Model with
8 kg reservoir
2-part
Model with
4 kg reservoir
Option
with screw cover
Option
with screw cover
Ø180
245
448
256
176
Plug
connection Ø6
Ø9,5
239
172
273,5
Reservoir Models and installation dimensions:
Multi line pump OC-1
Dimensional drawings
Subject to alterations!
...een product van BEKA

4
M8 / 8 deep at 8 kg reservoir
130
152
106
197
273,5
172
176
239
172
273,5
Model with
1,9 kg reservoir
Model with
2,5 kg reservoir
Option
with screw coverl
Ø151
248
216
Plug
connection Ø6
Ø9,5
Connection cable
length10 m
130
152
106
182,5
172,5
273,5
Connection cable
length 10 m
Model with
8 kg reservoir
2-part
Model with
4 kg reservoir
Option
with screw cover
Option
with screw cover
Ø180
286
499
297
176
239
172
273,5
Plug
connection Ø6
Ø9,5
Model with 34 outlets:
Multi line pump OC-1
Dimensional drawings
Subject to alterations!
...een product van BEKA

Model with 21 outlets:
5
“Z”
113,5
106
(112,5)
9
Ø9,5
49
130
152
View “Z”
Ø225Ø225
212
297
176
239
172
273,5
Ø9,5
Connecting cable
length 10 m
Plug
connection Ø6
Model wtih 34 outlets:
345
7,5
Model with 8 kg
1-part
Multi line pump OC-1
Dimensional drawings
Subject to alterations!
...een product van BEKA

M10x1
Plug connection Ø6
17
25,2
Plug connection Ø6
16,7
Pipe vonntection Ø6
22
Pipe connection Ø4
21
6
With pipe connection Ø6 with
retaining screw and
olive:
(standard)
Those pump elements can be delivered with five different
connection posibilities.
The pump elements PE-5 respectively 10/15/25/50 can be
delivered in five different output rates per stroke.
PE-5 = 5 mm³ / stroke or revolution
PE-10 = 10 mm³ / stroke or revolution
PE-15 = 15mm³ / stroke or revolution
PE-25 = 25mm³ / stroke or revolution
PE-50 = 50mm³ / stroke or revolution
Order key for pump elements PE-5 to PE-50:
Caution: Pump elements PE-5 resp. 10/15/25/50 have to
be ordered separately.
With threaded connection
M10x1:
With plug connection 90°
for pipe-Ø6:
With straight plug
connection for pipe-Ø6:
With pipe connection Ø4
with retaining screw
and olive:
Description of pump elements PE - 5/10/15/25/50
A maximum of 34 pump elements PE-5 respectively
10/15/25/50, can be installed in the multi line pump OC-1.
Those are directly connected with the lubricating points.
Install the pump in a way, that the length of the separate
pipe lines does not exceed 8 m.
Multi line pump OC-1
Pump elements
Type-no.: 2154 . 9000 . 01
Designation
PE-5
PE-10
PE-15
PE-25
PE-50
output rate / stroke
5 mm³
10 mm³
15 mm³
25 mm³
50 mm³
9001
9002
9003
9000
9010
Connection designation
Threaded connection M10x1
Pipe connection Ø6 with ÜS6 a. DKR6
Plug connection straight for pipe-Ø6
Plug connection 90° for pipe-Ø6
Pipe connection Ø4 with ÜS4 a. DKR4
00
01
02
03
04
Subject to alterations!
Caution: 1 sealing ring per pump element has to be
ordered separately, it is not already installed in the existing
pump!
Cu-sealing ring 14x18x1,5
Order-no.: 090760300611
...een product van BEKA

The pump elements PE-5 to PE-50 can be installed into the
outlets in any position.
7
Multi line pump OC-1
Installation of pump elements
Multi line pump OC-1
Installation of pump elements
16
1
Cycle time(h)
Service
Lubrication time (min.)
8
0,5
8
0,5
Pump element
Screw plug
Subject to alterations!
- Remove screw plug and USIT ring
- Screw in pump element and Cu- sealing ring
If a pump element is removed, the outlet position has to be
sealed with an according screw plug and USIT ring.
Screw plug and USIT ring
USIT ring 14x18,7x1,5
Order-no.: 100150010148
Screw plug M14x1
Order-no.: 090090801450
...een product van BEKA

8
Integrated electronic controlling device BEKA-troniX1:
Whatever program is being used, once the ignition has
been switched on the green and the red LED or the green
and the red signal lamp (optional) lights up on the control
panel for 1 5 sec. and shows that the controller is.
operational (activation control).
Every time the controller is activated for the first time, a
lubrication process begins. The green LED in the control
half shell is lit during the entire lubrication procedure.
The BEKA-troniX1 integrated electronic controlling device
has memory at its disposal. This also serves to keep a
record of time elapsed. Should the ignition be switched off
during lubrication or operational pauses occur, then the
time is stopped and recorded. Once the ignition is switched
on again the remaining lubrication or pause time is read
from the memory and the sequence will be resumed where
it was interrupted.
At any time when the ignition is on, an interim lubrication
occurs when the button on the side of the pump motor
housing or the illuminated button on the control panel is
activated, this serves as a check of functionality. The pump
then immediately starts its lubrication cycle, the lubrication
or cycle duration recorded up to that point is reset and starts
from the beginning.
An interim lubrication can also be triggered via an external
button, and the indication of the red and green LEDs can
also be displayed by a red and green signal lamp in the
driver´s cab.
A error can be reset by pressing the interim lubrication
button and the pump starts the lubrication process anew.
The lamp on the illuminated button (green) shows the
functionality of the controller and the current lubrication
sequence.
Multi line pump OC-1
Function of BEKA-troniX1
Subject to alterations!
Button for
triggering
an intermediate
lubrication
Green LED to show function
Red LED to show malfunctions
16
1
Cycle time (h)
Service
EA / PA Controller
Typ BEKA-troniX1
Lubrication time (min.)
8
0,5
8
0,5
...een product van BEKA

9
Multi line pump OC-1
Operation method of BEKA-troniX1
If no signal is received from the pump motor for longer than
the adjustable monitoring time (standard 30 sec.) after the
lubricating process has begun, then the controller will
indicate a fault.
The red LED in the pump´s lower motor casing display or an
externally attached signal lamp (optional) will start to flash.
A) Time controller:
When the central lubrication processor is time controlled,
the cycle and the lubrication time can be adjusted.time
Cycle means the period from the beginning of onetime
lubrication process to the beginning of another lubrication
process.
B) Revolution controller:
In the case of revolution fluctuations at lower temperatures
or high torque, the lubrication for the BEKA-troniX1time
integrated electronic controller is determined by the
number of pump motor revolutions.
The pump motor is connected to the controller via sliding
contacts. With every engine revolution a signal is sent to the
controller, which counts the incoming signals.
Diagram of cycle sequence:
Lubrication time
Cycle time
Subject to alterations!
...een product van BEKA

10
Integrated electronic controlling device BEKA-troniX1:
Multi line pump OC-1
Parameter adjusting of BEKA-troniX1
16
1
Cycle time (h)
Service
EA / PAC
ontroller
Typ BEKA-troniX1
Lubrication time (min.)
8
0,5
8
0,5
Resolution indicator to adjust lubrication time
Resolution indicator to adjust cycle time
Connection for
system diagnosis
The cycle time or lubrication time and the number of
revolutions can be set by means of graduating switches in
the controller´s sight glass.
To adjust the time setting, remove the red frame on the
pump´s motor housing a flat screwdriver, loosen theusing
four Phillips screws and remove the transparent protective
cover.
The cycle during or lubrication time can be adjusted ausing
flat screwdriver.
If the cover plate is not replaced properly, water may enter
the controller and damage it. In this case the guarantee is,
no longer valid.
The modes and the adjusting ranges can be changed over
by means of the diagnostic software BEKA-DiSys, even on
site if the controller has already been operated before at the
customer´s.
All adjusting ranges for the lubrication period and all cycle
time ranges can be combined at random.
Adjusting the parameters:
Lubrication times:
1 to 16 min. (16 notches every 1 min.)
2 to 32 min. (16 notches every 2 min.)
2 to 32 sec. (16 notches every 2 sec.)
Revolutions of pump:
1 to 16 revolutions (16 notches every 1 revolution)
10 to 160 revolutions (16 notches every 10 revolutions)
170 to 320 revolutions (16 notches every 10 revolutions)
When changing the activation modes and the a justingd
ranges, the label in the controller window must be
replaced.
To this effect, a label kit consisting of 18 different label
Model is available; these can also be ordered individually
afterwards.
Ref.-no. for label kit: 0490000342 German
Ref.-no. for label kit: 0490030343 English
Cycle :times
0 5 to 8 h. notches .
(16 every 0 5 h)
2 to 32 min. (16 notches every 2 min.)
2to32h(16 notches every 2 h)
Subject to alterations!
...een product van BEKA

11
Multi line pump OC-1
Summary of signal indicators of BEKA-troniX1
The pump´s functions are indicated via two control LEDs
(green/red) in the display on the pump´s motor casing,
where the red LED always indicates an error in the program
sequence.
These control LED functions may be indicated in the
driver´s cap of the vehicle via built-in signal lamps. These
must be specially ordered.
a) Standby
b) Lubrication activated
c) Grease level error
d) Speed error
e) Memory error
f) Test lubrication (constant lubrication)
To adjust the time controlling to continual lubrication for
servicing purposes, the lubrication time must be set ato
higher value than the cycle duration.
BEKA-troniX1 integrated electronic controller:
Subject to alterations!
Standby: 1,5 sec.
ON
OFF
OFF
ON
LED red
LED green
Standby indicator:
LED green
During whole lubrication
ON
OFF
OFF
ON
LED red
Lubrication sequence:
16
1
Cycle time (h)
Service
EA/ PA Controller
Typ BEKA-troniX1
Lubrication time (min.)
8
0,5
8
0,5
Red LED error indicator
Green LED function indicator
LED red
Until the reservoir is filled
ON
OFF
ON
OFF
LED green
Grease level too low:
LED red
1 sec.
1 sec.
OFF
ON
ON
OFF
LED green
Speed error at pump element:
LED red
0,5 sec.
0,5 sec.
ON
OFF
ON
OFF
LED green
Memory error:
LED green
LED red
1 sec.
1 sec.
ON
OFF
ON
OFF
Test lubrication:
...een product van BEKA

The additional functions can not be activated subsequent at
control unit’s, which are missing the mentioned
connections at the lower motor casing.
12
Plug connection
for additional
function
16
1
Cycle time(h)
Service
EA / PAController
TypBEKA-troniX1
Lubrication time(min.)
8
0,5
8
0,5
Marking ring
green
Marking ring red
16
1
Cycletime(h)
Service
EA/ PA Controller
TypBEKA-troniX1
Lubricationtime(min.)
8
0,5
8
0,5
Multi line pump OC-1 with integrated electronic controlling
device BEKA-troniX1 and grease level monitoring.
View of integrated electronic controlling device BEKA-
troniX1 around the bottom.
The integrated electronic controlling device BEKA-troniX1
can be delivered with an additional function
- grease level monitoring
The additional function can be installed under every
operational mode of the control device.
Next to the bayonet plug, two 4 - pole plug connectors at the
motor’s lower casing can be found at the addional
function’s delivery.
The additional plug connections and the cable for the
button are marked in colours.
The plug connection with the red marking ring is for
connecting the grease level monitoring.
The plug connection with the green marking ring, always
has to be sealed by a cover, as it is inactive.
The red one also has to be sealed, if the grease level
monitoring is not connected.
The connection of the additional function at the control
device can be choosen when ordering.
Seal for unused plug connections, regarding additional
functions of the integrated electronic controlling device
BEKA-troniX1.
Order-no.: 1000913004
Multi line pump OC-1
Additional equippment
Subject to alterations!
...een product van BEKA

13
16
1
Cycle time(h)
Service
EA / PAController
TypBEKA-troniX1
Lubrication time(min.)
8
0,5
8
0,5
Connection cable
0,6 m long
EDP-Nr.:
1000912998
red
marking
ring
16
1
Cycletime(h)
Service
EA/PACo
ntroller
TypBEKA-troniX1
Lubricationtime(min.)
8
0,5
8
0,5
Multi line pump OC-1 with integrated electronic control
device BEKA-troniX1 with grease level monitoring.
Connection at the control device:
The grease level monitoring can be installed at the control
device BEKA-troniX1 under every operational mode.
Technical data of capacitive proximity switch:
Operating voltage: 10 to 60 V DC
Switching type: PNP-contact
Switching current max.: 250 mA
Protection class: contact: IP 67
Ambient temperature range: -25°C to +70°C
Connection: 4-pole, M12x1 pluggable
Multi line pump OC-1
Grease level monitoring
The integrated electronic controller BEKA-troniX1
facilitates monitoring of the grease level in the storage tank.
For purpose a capacitive proximity switch has been built in
to the pump´s reservoir.
As long as there is enough grease available in the reservoir,
the proximity switch sends a signal to the controller. If the
grease level sinks below minimum the proximity switch
turns the signal off.
If the signal remain off for more than 10 sec. then the
controller switches the pump off, so that no air is pumped
into the system.
The red LED on the controller display, situated on the
pump´s motor housing or a built-in red signal lamp, if
available, starts to illuminate.
Once the grease has been refilled, the controller restarts
itself.
The g ease level controller can ber delivered already
connected to the controller n this case, a connecting.I
cable, length 0,6 m, with a right-angle plug M12x1 for
connection to the plug-and-socket connector and a right-
angle plug M12x1 for connection to the controller is
included in the scope of supplies. The grease level
monitoring system is activated.
The grease level monitoring can be retrofitted. It can be
connected to the control unit, if the pump has been ordered
with additional functions.
In this case, the function must be activated by means of the
software BEKA-DiSys. The function must not be activated if
no grease level monitoring is activated, as this would result
in a permanent error.
Retrofitting the grease level monitoring, the connection
cable must be ordered separately (see drawing on the right
side).
The connection of BEKA-troniX1 control unit is done via the
red ring marked plug connection at the motor’s lower
casing.
For this purposes, remove the contact plug’s cover.
Subject to alterations!
...een product van BEKA

14
Connecting cable 5-wire, length 10 m with bayonet plug
Order -no.: FAZ02499-19
Multi line pump OC-1
Retrofitting
The integrated control BEKA-troniX1 can be retrofittedunit
to the pump -1, i. e. to pumps which have beenmulti line OC
delivered without controller and to replace existing
controllers.
However, retrofitting to pumps without controller is only
possible after the year of construction 2004.
Control delivered for retrofitting or replacement areunits
not provided with connection cable, as this is normally
already ling deviceavailable. If the control is to be installed
in a pump which has not been equipped with a control unit
so far, or to be eplaced by a control with anotherr unit
connector, the connecting cable must be ordered
separately.
The connecting cables for any supplementary features
available must also be ordered separately.
In order to connect the grease level monitoring, see page
12.
Subject to alterations!
...een product van BEKA

Multi line pump OC-1
Wiring diagram - all connections
Ground, terminal 31
Ignition, terminal 15 black (nr. 3)
brown (ge/gr)
Intermediate lubrication
button
orange (Nr. 4)
red (nr. 2)
Signal lamp red
green (nr. 1)
Signal lamp green
External signal lamp
Filling level switch for
grease level monitoring
green
red
(Nr. ...) = Cable-nr. at unicolored cables
Subject to alterations!
15
...een product van BEKA

16
c) Filling via filling gun:
Filling lubricating nipple
16
1
Cycletime(h)
Service
EA/PAC
ontroller
TypBEKA-troniX1
Lubricationtime(min.)
8
0,5
8
0,5
a) Standard filling via lubricating nipple with manual or
pneumatic grease gun:
Multi line pump OC-1
Filling of the pump
b) Filling via filling coupling
Subject to alterations!
Coupling plug grease
EDP-no.: 2159 0061 012
Coupling sleeve grease
EDP-no.: 2159 0062 011
Reduction
EDP-no.: F2185/57-00
16
1
Cycletime(h)
Service
EA/PAC
ontroller
TypBEKA-troniX1
Lubricationtime(min.)
8
0,5
8
0,5
Straight filling connection
EDP-no.: 2152 0150
Grease gun
EDP-no.: 2081 030 26
Reduction
EDP-no.: FWZ01889-03
16
1
Cycletime(h)
Service
EA/PAC
ontroller
TypBEKA-troniX1
Lubricationtime(min.)
8
0,5
8
0,5
...een product van BEKA

2174 . X . XX . X . X . X . X . 000
17
Multi line pump OC-1
Order key OC-1 with integrated controlling device BEKA-troniX1
Pump elements must be ordered separately!
The operational modes respectively the setting range can be adjusted subsequent by means of the diagnosis software at
the PC!
The grease level monitoring can be activated or shut down at every time, if the control unit has been ordered with the plug
connection M12x1 at the lower motor casing.
Subject to alterations!
Reservoir Size (kg) 1,9 2,5 4
without grease level monitoring
with grease level monitoring
88
2-part 1-part
14238
ST
UW
Control unit
with BEKA-troniX1 2
Additional equipment at BEKA-troniX1:
without connection plug M12x1 for additional equipment
with grease level monitoring, connected at the control unit
with plug M12x1 for grease level monitoring, not activated
1
2
3
Parameter at BEKA-troniX1:
Cycle time
Lubricating time 0,5 to 8 h 2 to 32 min. 2 to 32 h
I
II
III
1 to 16 min.
2 to 32 min.
2 to 32 sec.
Revolutions of the pump
I
II
III
1 to 16 Umdr.
10 to 160 revol.
170 to 320 revol.
1AJ
2BK
3CL
7GP
8HQ
9IR
Special models 000
Nr. of outlets drilled
10 10
Code-nr.
21 21
22 22
34 34
12 V 24 V
34
Moto voltage
Type
...een product van BEKA

18
Subject to alterations!
2175 . 90 . XX . X . X . 000
Type
Plug model
with bayonett plug 10
Parameter: Cycle time
Lubrication time: 0,5 to 8 h 2 to 32 min. 2 to 32 h
I
II
III
1 to 16 min.
2 to 32 min.
2 to 32 sec.
Revolutions of the pump
I
II
III
1 to 16 revol.
10 to 160 revol.
170 to 320 revol.
1AJ
2BK
3CL
7GP
8HQ
9IR
Special models 000
without plug connection M12x1 for additional equipment
mit grease level monitoring, connected at the control unit
with plug M12x1 for grease level monitoring, not activated
0
1
4
Additional equipment
Multi line pump OC-1
Order key control unit BEKA-troniX1 installed in the lower case
The operational modes respectively the setting range can be adjusted subsequent by means of the diagnosis software at
the PC!
The grease level monitoring can be activated or shut down at every time, if the control unit has been ordered with the plug
connection M12x1 at the lower motor casing.
...een product van BEKA