BEKA Stream E 2520 Series Product guide

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BAL2520_2521_Barrel_pump_Stream_E_0720EN
Barrel pump
BEKA Stream E
Article-no. 2520 ….; 2521 ….
Revision 07-2020
Original operating-
and
assembly manual

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Table of contents
1.Technical data ................................................................................................................................................................................4
1.1General......................................................................................................................................................................................4
1.2Single pump...............................................................................................................................................................................4
1.3Pump – barrel version................................................................................................................................................................ 4
1.4Pump – container version..........................................................................................................................................................4
1.5Solenoid valve – single line version........................................................................................................................................... 4
1.6Level monitoring ........................................................................................................................................................................4
2.Applicable documents.....................................................................................................................................................................5
3.Order key........................................................................................................................................................................................5
4.Version............................................................................................................................................................................................7
5.General safety instructions .............................................................................................................................................................8
5.1Safety instructions .....................................................................................................................................................................8
5.2Qualification and training of staff ...............................................................................................................................................8
5.3Hazards in case of non-observance of the safety instructions ..................................................................................................9
5.4Obligations of the operator / user ..............................................................................................................................................9
5.5Safety instructions for maintenance, inspection and assembly .................................................................................................9
5.6Unauthorized modification and production of spare parts .........................................................................................................9
5.7Inadmissible modes of operation............................................................................................................................................. 10
5.8Electrostatic discharge............................................................................................................................................................. 10
5.9General hazard warning – residual risk ...................................................................................................................................10
6.Intended use................................................................................................................................................................................. 11
7.Scope of warranty.........................................................................................................................................................................11
8.Transport and storage ..................................................................................................................................................................12
9.Assembly instructions...................................................................................................................................................................13
9.1Line assembly..........................................................................................................................................................................13
9.2Power connection ....................................................................................................................................................................13
10.Start up .........................................................................................................................................................................................15
10.1Lubricant / pumping medium ...................................................................................................................................................15
10.2Ventilation of the lubrication system ........................................................................................................................................15
10.2.1General ...........................................................................................................................................................................15
10.2.2Prefilling of return connection .........................................................................................................................................15
10.3Adjustment of visual level monitoring (barrel version) .............................................................................................................17
10.4Initial filling of container with lubricant .....................................................................................................................................17
11.Functional description...................................................................................................................................................................18
11.1General....................................................................................................................................................................................18
11.2General components ...............................................................................................................................................................18
11.2.1Pump...............................................................................................................................................................................18
11.3Components ............................................................................................................................................................................18
11.3.1Level monitoring..............................................................................................................................................................18
11.3.2Ventilation valve.............................................................................................................................................................. 18
11.3.3Grease level dipstick.......................................................................................................................................................18
11.3.4Single line block..............................................................................................................................................................18
11.3.5Pressure limiting valve ....................................................................................................................................................18
12.Maintenance .................................................................................................................................................................................19
12.1General maintenance ..............................................................................................................................................................19
12.2Lubricant change .....................................................................................................................................................................19
12.3Filling of the container.............................................................................................................................................................. 19
12.4Exchange of barrel................................................................................................................................................................... 20
13.Repair ...........................................................................................................................................................................................21
13.1Exchange of pump element ............................................................................................................................................21
13.2Exchange of motor..........................................................................................................................................................25
13.3Exchange of sealing bush...............................................................................................................................................26
14.Shutdown......................................................................................................................................................................................28
15.Disposal........................................................................................................................................................................................28
16.Troubleshooting............................................................................................................................................................................28
17.Accessories ..................................................................................................................................................................................29
17.1Filling nipple ....................................................................................................................................................................29

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17.2Pressure limiting valve for progressive and dual line systems........................................................................................ 29
17.3Module with pressure limiting valve for progressive system, for direct attachment to BEKA Stream E..........................29
18.Spare part list................................................................................................................................................................................29
19.Spare part drawing .......................................................................................................................................................................29
20.Dimensional drawing pump without accessories..........................................................................................................................30
21.Details of the manufacturer...........................................................................................................................................................31

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1. Technical data
1.1 General
Pump
Delivery rate: ......................................................................................................................................................................... 120 cm³/min
Lubricant:........................................................greases up to NLGI class 2 without solid contents (other delivery quantities on demand)
Operating pressure basis system:.......................................................... max. 350 bar (pressure limiting valve not enclosed in delivery)
Operating pressure single line system: ..................................................................max. 350 bar (pressure limiting valve set to 240 bar)
Operating temperature: .......................................................................................................... -40°C up to +65°C (depends on lubricant)
Number of outlets:...................................................................................................................................................................................1
Pressure connection:.................................................................................................................................................................... 1x G1/2
Return connection (integrated in pump pipe): .............................................................................................................................. 1x G1/2
Sound pressure level:.................................................................................................................................................................<70dB(A)
Motor
Drive type: ........................................................................................................................................................................... electric motor
Motor power: ................................................................................................................................................................................0,18 kW
Motor voltage:............................................................................................................................................................................... 24V DC
Current consumption: ................................................................................................................................................................max. 15 A
Connection type: ............................................................................................................................................................cable (10 meter)
Protection type: .................................................................................................................................................................................IP 65
1.2 Single pump
Weight: ......................................................................................................................................................................................... 19,1 kg
1.3 Pump – barrel version
Barrel capacity:.....................................................................................................................................................................213 l (200kg)
1.4 Pump – container version
Container capacity:....................................................................................................................41 l (60 lbs) / 54 l (90 lbs) / 68 l (120 lbs)
1.5 Solenoid valve – single line version
Operating voltage:........................................................................................................................................................................ 24V DC
Nominal power: ..................................................................................................................................................................................26W
Protection type: .................................................................................................................................................................................IP 65
1.6 Level monitoring
Operating voltage:.......................................................................................................................................................... 10 up to 30V DC
Current consumption:........................................................................................................................................................15A at 24V DC
Electric version: ..................................................................................................................................................................... DC PNP NO
Connection plug: ..........................................................................................................................................M12X1, 4-poles
Protection type: .................................................................................................................................................................................IP 67
Please see the attached data sheets and manuals of the corresponding manufacturers for missing details and further
technical data.
The barrel pump is subsequently called a device.

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2. Applicable documents
Technical documentation of individual parts enclosed:
Level switch
Please observe these documents for all work with and at the device!
3. Order key
Caution!

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4. Version
Pump Pump - barrel version
Pump container - version
Symbol Symbol (basis system) Symbol (single line system)

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5. General safety instructions
All persons that are in charge with the assembly, start-up, maintenance and operation of the device must carefully read these
instructions. Furthermore, this manual must permanently be available at the site of operation!
Basic notes for setup, operation and maintenance can be found below.
5.1 Safety instructions
Please observe the safety instructions within this main point as well as special safety instructions that are included in other parts of
this documentation.
Warning of electrical voltage.
Safety instructions, which in case of non-observance might cause hazards to persons, are marked with the general
danger symbol.
This symbol warns of hot surfaces.
Warning of suspended loads.
Warning of material damage due to electrostatic discharge! Marks potential risks which may result in material damage,
if not avoided.
This heading is used if the improper or general non-observance of the operating manual, specified work flow
and the like might result in device damage.
This term is used to point out particular details.
Instructions which are directly attached to the device have to be strictly observed and kept in readable condition!
5.2 Qualification and training of staff
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 necessary knowledge it has to be instructed and trained accordingly. The operator is obliged
to ensure that the staff fully understands the contents of this user information.
Notice!
Caution!

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5.3 Hazards in case of non-observance of the safety instructions
Results of non-observance of the safety instructions can be hazards to persons, the environment and for the
device. Non-observance of the safety instructions may result in the loss of any liability claims. In detail the non-
observance could entail the following hazards:
 Failure of important device functions.
 Failure of prescribed methods for maintenance and repair.
 Danger to persons by electrical, mechanical and chemical effects.
 Danger to the environment by leakage of hazardous substances.
5.4 Obligations of the operator / user
 If movable, rotating, hot or cold parts of the device bear risks, the customer must protect these parts against
contact. This protection must not be removed.
 Any leakages of hazardous substances must be drained in a way that no risks for persons or the environment
arise.
 Keep to all legal provisions.
 Hazards due to electricity are to be excluded.
 Examination of pipes and hoses regarding safe provision, use, proper assembly and function has to be carried out
according to regionally applicable directives. Inspection intervals may not be exceeded.
 Defective pipes or hoses must be replaced immediately 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.
 A safety data sheet of the currently used lubricant must be provided at the device.
5.5 Safety instructions for maintenance, inspection and assembly
All maintenance, inspection and assembly work may only be carried out by qualified personnel who is sufficiently
informed by thorough reading of the user information.
Generally any work at the device may only be carried out at complete standstill and in pressureless as well as
disconnected condition. Furthermore appropriate personal protective equipment (goggles among others) is
necessary. The shutdown procedure of the device as described in the manual must be strictly followed.
Secure the device against intentional or unintentional recommissioning during maintenance or repair. All safety and
protection arrangements have to be put back in place again immediately after finishing work.
Environmentally hazardous media must be disposed of professionally and in correspondence to relevant legal
provisions. Polluted and contaminated surfaces have to be cleaned before maintenance. Please wear protective
equipment to that purpose. See the lubricant manufacturers‘ safety data sheets hereto, respectively the data sheets
provided by the manufacturers of auxiliaries and working materials.
Check the surface temperature of the device as a possible heat transfer bears the risk of burns. Wear heat resistant
protective gloves!
Open flame and fire are strictly forbidden during maintenance, inspection and repair due to fire hazard.
5.6 Unauthorized modification and production of spare parts
Modification, repair and alterations of the device are only accepted after manufacturer feedback. Original spare parts
and authorized accessories from the manufacturer contribute to safety. The use of other parts can result in the loss of
any liabilities for the resulting consequences. BEKA does not assume liability for parts that are retrofit by the operator.

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5.7 Inadmissible modes of operation
The operational safety of the device is only guaranteed for appropriate application as indicated in the operating manual. Never exceed
or fall below the limit values, as stated in the technical data.
5.8 Electrostatic discharge
Avoid electrostatic discharge! There are electronic components integrated into the devices which might be destroyed
by electrostatic discharge. Observe the safety precautions against electrostatic discharge according to DIN EN 61340-
5-1/-3. Ensure that the environment (persons, workplace and packing) is well grounded when handling these devices.
5.9 General hazard warning – residual risk
All components are designed according to valid regulations of the construction of technical systems in regards to
operational safety and accident prevention. Independently from this the use can lead to hazards for the user or third
parties as well as for other technical facilities. Therefore, the device may only fulfil its intended use in a technically
acceptable and faultless condition. This has to happen in adherence of the according safety regulations and under
observance of the operating manual. Inspect the device and its attachment parts regularly and check them for
possible damage or leakages. Liquids could escape under high pressure from pressurized components which
become leaky.

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6. Intended use
The device is only approved for the industrial use.
Only operate the device if it is installed in/to another machine and operated together with it.
Use only lubricant according to the machine manufacturer’s specification, that is suitable for the central
lubrication system.
The device must only be used according to the technical data (see chapter 1 „technical data”). Never exceed
or fall below the mentioned values. Never operate the device without lubricant.
Unauthorized alterations of the device are not permitted. BEKA is not liable for damage of machine or persons that results thereof.
Use according to the regulations means also:
 Observance of all chapters and notes in the operating manual.
 Carrying out all maintenance work.
 Observance of all regulations concerning work safety and accident prevention during all life cycles of the device.
 Having the necessary professional training and authorization of your company to operate the device and to carry out the necessary
work.
Another use or a use beyond this is deemed improper.
7. Scope of warranty
Warranties regarding operational safety, reliability and performance will only be granted by the manufacturer if the device is used
according to the regulations and under the following conditions:
 Assembly, connection and maintenance are carried out by authorized professional staff.
 The device is only used according to the operating manual.
 Never exceed or fall below the limit value indicated in the technical data.
 Modifications and repairs at the device may only be done by BEKA.
Guarantee and warranty for any damage at the device caused by improper lubricant (e.g. wear of piston,
piston jamming, blockades, brittled sealings etc.) will expire.
BEKA will generally not assume guaranty claims for any damage caused by lubricants, although those have
been laboratory tested and released by BEKA, as such damage (e.g. by over-stored or incorrectly stored
lubricants, batch fluctuations, etc.) cannot be verified or reconstructed later.
Caution!
Caution!
Caution!

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8. Transport and storage
Use suitable lifting devices for transport.
Do not throw the device or impose it to shocks.
Secure the device against toppling down or slipping during transport.
The device may only be transported when it is completely drained. The barrel version implies that the device is transported without
barrel.
Please note the max. load of 100 kg when lifting the device
at the bow. The device may only be lifted without barrel or
container.
Observe all valid safety and accident prevention regulations for the transport. Wear suitable protective equipment if
necessary. Keep adequate distance to suspended loads. The transport help or the elevating device must have the
adequate carrying capacity.
When storing the device pay attention that the storage area is cool and dry in order to avoid corrosion of the individual parts of the
device.
Caution!

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9. Assembly instructions
Check the device for possible transport damage and for completeness before the assembly. Any installed equipment for transportation
safety has to be removed.
Comply with the following conditions for assembly of the device in order to obtain a properly built together machine of
all parts without compromise of safety or persons’ health:
Assemble the device in balance on the installation location in order to ensure safe operation. Observe the information on the fastening
holes given in the dimensional drawing. When selecting the set-up location, please mind that the device should be protected against
ambiental and mechanic influences. Ensure full access, e.g. for filling with lubricant.
Special measures concerning noise prevention or oscillation reduction do not have to be taken.
9.1 Line assembly
 Professional layout!
 When using pipes, observe that they are clean, seamless and of precision steel!
 Assemble the pipes professionally and free from distortion!
 Pay attention to pressure tightness of fittings!
 All components must be approved for max. operating pressure (see technical data).
9.2 Power connection
 Power supply must be done by a professional electrician!
 Electrical device components must be wired professionally!
 Compare voltage details with the existing mains voltage!
 Equipotentional bonding must be done professionally by the operator via an according ground connection!
 Wire the device according to the terminal diagram!
Terminal diagram Motor
If the motor braids are not connected correctly, the motor does not start to operate.
Note!

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Terminal diagram of solenoid valve for single line version
Terminal diagram of level monitoring

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10. Start up
10.1 Lubricant / pumping medium
The device is configured for commercial multipurpose greases up to NLGI class 2 without solid contents.
A detailed description of the barrel exchange or the container filling can be found in chapter „maintenance“.
Observe the following notes:
 Use greases with high pressure additives (EP- grease).
 Observe the machine manufacturer’s lubricant details! Only use lubricants according to machine manufacturer’s specifications!
 Collect outcoming lubricant in a suitable receptacle and dispose it professionally!
 The lubricant viscosity changes with the operating temperature.
 Check the level several times in equal intervals during the first hours of operation and refill lubricant, if necessary.
 Observe utmost cleanness when refilling the reservoir!
 Use only greases with the same saponification.
 Observe the safety data sheet of the lubricant manufacturer!
10.2 Ventilation of the lubrication system
10.2.1 General
 Ventilate the whole lubrication system with first start-up and after each lubricant change!
 Ventilation is done by operating the system in pressureless condition and with open system outlets!
 Operate the pump until lubricant comes out of the pressure connection without air inclusions.
10.2.2 Prefilling of return connection
In order to avoid that air is pumped into the container / barrel, while lubricant flows back, the return connection in the pump pipe shall
be filled with lubricant.
Always take care of utmost cleanness during the filling.
1. Step:
If the return connection shall be sealed, the screw plug has to be screwed out with a hexagon key AF10.
The return connection is marked with an „R“ at the pump.
Notice!
1 2
Caution!

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2. Step
Screw the filling nipple (3) with AF 27 into the return connection (G1/2).
The filling nipple is not enclosed in delivery (see chapter accessories).
3. Step:
Fill up the return connection (G1/2) with a filling press until the lubricant flows out of the return pipe (see picture).
4. Step:
After the filling, the nipple can be demounted again. If the return connection is not used, it has to be closed again.
3

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10.3 Adjustment of visual level monitoring (barrel version)
1. Step:
Evaluate height of barrel (dimension B)
2. Step:
Set the visual sensor to dimension B – 7 cm (empty message). If also a prewarning
is necessary, another switching point of the visual sensor at an optional height before
the empty signal, shall be adjusted.
Observe the separate technical documentation of the level
sensor enclosed.
10.4 Initial filling of container with lubricant
 Open the ventilation screw on the reservoir back (hexagon
socket AF 10) for the initial filling.
 Remove the screw plug from the filling connection G1 (1)
(hexagon socket AF 17).
 Fill up lubricant via the filling connection G1 (1) until lubricant
comes out of the ventilation screw!
 Tighten the ventilation screw again.
 Other procedures are described in 8.2, lubricant filling.
 Fill up the reservoir via the filling connection G1 (1) until
lubricant comes out of the overfill protection (2)!
Attention!
B
2
3 1

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11. Functional description
11.1 General
The device helps to supply the central lubrication system or individual lube points, with lubricant. Depending on the type of application,
the pump can be used for single line, dual line or progressive systems. There are various accessories for the barrel pump BEKA
Stream E, like barrel cover, follower piston or container (see accessories).
11.2 General components
11.2.1 Pump
The pump is driven by a brushless DC motor. Due to an eccentric in the housing, the rotation motion of the motor is transformed to a
stroke movement of the piston rod. The delivery piston of the pump is connected with the piston rod, thus a suction and pressure stroke
is effected. Hence lubricant is pumped into the end of the conveying pipe and supplied to the pressure outlet. A reverse pumping of
lubricant is avoided by a non-return valve. The integrated return connection can be used to led back surplus lubricant to the barrel.
11.3 Components
11.3.1 Level monitoring
The ultra sound sensor monitors the lubricant level in the reservoir and sends a signal at minimum level. The ultra sound sensor sends
a signal for barrel exchange as soon as the barrel is empty. The signal evaluation is done by the customer.
Two TEACH methods may be used to configure the sensor:
 • Teach individual minimum and maximum limits, or
 • Use Auto-Window feature to center a sensing window around the taught position.
Also observe the technical documentation of the ultra sound sensor enclosed.
In order to avoid that air is pumped into the lubrication circulation, we recommend to switch off the device
when receiving the empty signal.
11.3.2 Ventilation valve
The ventilation valve in the reservoir cover helps to filter the incoming air during the pressure compensation that is caused by varying
level. The ventilation filter element has regularly to be checked and renewed at visible pollutions.
11.3.3 Grease level dipstick
When the grease level dipstick is pulled out of the reservoir, you can see the lubricant level at the stick. In order to avoid that dirt enters
the reservoir, the dipstick has to be put completely into the drilling.
11.3.4 Single line block
A relief valve can be attached as a block at the pump pipe at a device for single line systems. It is directly flanged at the pressure and
return connection.
11.3.5 Pressure limiting valve
Optionally, a pressure limiting valve can be attached to the device for progressive and dual line systems. It is available as component
for a customer-specific attachment in the entire system or as a module for direct attachment at the pump pipe. It has an opening
pressure of 280 bar.
Attention!

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12. Maintenance
Disconnect the device from power supply before maintenance or repair.
Maintenance and repair may only be carried out at complete standstill and under pressureless condition.
Check the surface temperature of the device, as there is the risk of burns by radiant heat. Wear heat-resistant gloves
and safety goggles! Soiled or contaminated surfaces have to be cleaned before maintenance, wear protective
equipment to this purpose, if necessary! Protect the device against recommissioning during maintenance/repairs!
Further information and technical details regarding the components can be found in the enclosed operating manuals
of the components.
12.1 General maintenance
 Retighten all fittings 6 weeks after start up!
 Check all components for leakages and damage at least every four weeks!
If leakages are not repaired, lubricant might come out there under high pressure. Remove possible puddles of
lubricant immediately.
12.2 Lubricant change
Observe utmost cleanness when refilling lubricant!
 Check the level regularly and refill clean lubricant as necessary, see chapter start up.
 Lubricant change has to be done according to the specifications of the lubricant manufacturer. Environmental influences like
increased temperature or pollution may make it necessary to shorten these intervals!
 Please take care to only use lubricants that are suitable for the device as well as the lubricated machine and that comply with the
requirements of the particular operating conditions.
 In case of different lubricant manufacturers, ensure that the lubricant quality corresponds to the quality of the previously used
one! As precautionary measure, drain the lubricant reservoir professionally and clean it!
12.3 Filling of the container
1. Step:
Depressurize the pump and protect it against unintentional operation.
2. Step:
Remove the screw plug at the filling connection G1 (1) (hexagonal socket
SW 17) and connect the filling pump at the filling connection of the device.
3. Step:
Slowly fill up the device with lubricant, until lubricant comes out of the overfill
protection (2). Dispose surplus lubricant environmental friendly.
4. Step:
Remove the filling pump and close the filling connection (1).
Caution!
2
1

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12.4 Exchange of barrel
1. Step:
Depressurize the pump and lock it against unintentional operation.
2. Step:
Install suitable lifting straps or chains at the bracket (1).
3. Step:
Loosen the connecting rods (if available) from the cover (2) and remove them.
Unscrew the wing screws (3).
4. Step:
Pull out the device with cover, by means of a suitable lifting device. Absolutely
observe the regulations for the lifting of loads. Do not lift the grease barrel.
Also take care that the pump pipe (5) is not damaged or polluted.
5. Step:
Pull out the grease follower plate (4) from the empty barrel. Press the follower
plate into the new barrel and install the device in reverse order. Also observe
that the old and the new barrel have the same diameters and height. Tighten
the three wing screws at the cover. Install the connecting rods (if available).
Use only barrels with original grease filling!
Do not use refillable barrels.
Device may only be lifted without barrel.
Attention!
1
3
2
4
5