Control and Monitoring Devices

Control units
EP-tronic

Description
The EP-tronic control device is an integrated unit for
grease- / oil lubrication pumps of the series FKGGM-
... and OKGGM-...

Lubrication cycle means cycle time and lubrication

time. Cycle time is the period from the beginning of

Control units
one lubrication to the beginning of the next one.
Inspection window

Connection of the
system diagnosis

Lubrication time Rotary switch for adjustment of the cycle time

Cycle time
Rotary switch for adjustment of the lubrication time

There are two rotary switches in the inspection Technical data

window of the integrated EP-tronic control. The right Supply voltage: 10 to 60 V DC
one is for adjusting the cycle time and the left one for Max. current load: I = 6,0 A
adjusting the lubrication time. Fuse (not enclosed): F 6,3 A
Cycle time Lubrication time (5x20) semi time-lag
dependent on: Outlet for signal lamp: I = 0,4 A
(see period ranges) · time Temperature range: -35°C to +75°C
· strokes Protection class: IP 65
· revolutions
Observe the motor voltage of the pump before
The following additional functions can be connected connecting the voltage.
respectively evaluated.
Additional functions The control device is equipped with an operational
· Monitoring of the system pressure database, which records the following values with
· Level monitoring date and time (RTC Real-Time-Clock, other time
· External status signal
zones are also adjustable):
· Control data (e.g. type, control unit version, serial
number, among others)
· Current settings (e.g. cycle time, lubrication time,
among others)
· Statistical values (e.g. operating hours, pump
State: 01.16EN

operating time, number of intermediate

lubrications, number of stroke monitoring errors,
number of all diagnoses, ...)
· Date and time of the last diagnosis
· Error log of the last 100 malfunctions with error
type as well as time and date
· Event log of the last 100 changes of the settings
09-1-50-01
09-1-50-02

with time and date

1090200400

© BEKA 2016 All rights reserved! Subject to alterations!

BAIER + KÖPPEL GmbH +BAIER
Co. KG+ KÖPPEL
BEETHOVENSTR.
GmbH + Co.14KG TEL.: +49
D-91257 PEGNITZ
BEETHOVENSTR.
FAX: +49
9241 729-0
D-91257
9241 729-50
WEB:
14 www.beka-lube.de
POSTFACH 1320
PEGNITZ E-MAIL: [email protected]
D-91253 PEGNITZ X +49 9241 729-50
TEL.: +49 9241 729-0
FAX:
WEB: www.beka-lube.de
Contents
E-MAIL: [email protected]
 Control and Monitoring Devices
Control units
EP-tronic

Cycle time A proximity switch is attached to one of these pistons

The EP-tronic control operates lubrication cycle- which sends a signal to the control with each piston
dependent. A lubrication cycle is defined by the cycle stroke. The signals are counted by the control.
time. The following ranges are possible for the cycle
time: 2 to 32 minutes, If the signals are due for a longer period than the set
0,5 to 8 hours, monitoring time (12 min. as a standard), the control
2 to 32 hours will indicate a malfunction. The green and the red
LED in the window of the control at the lower motor
part or the possibly installed green and red signal
Control units

A new lubrication cycle will be started when the

lamps start flashing.
Control units

adjusted cycle time has been completed.

Diagram of a lubrication cycle:

Diagram of a lubrication cycle:

Lubrication time
Cycle time
2 to 32 min (16 notches à 2 min) Lubrication time by
0,5 to 8 h (16 notches à 0,5 h) strokes at the distributor
2 to 32 h (16 notches à 2 h) 1 to 16 strokes (16 notches à
17 to 32 strokes 1 stroke)
33 to 48 strokes
Lubrication time Zyklusdauer
proximity
switch for
There are three different operation modes for the stroke control
lubrication time: time control, stroke control at
Revolution control
the distributor and revolution control!
With the integrated electronic EP-tronic control, the
Time control lubrication time can also be defined by the number of
Lubrication time can be set in ranges of seconds and revolutions of the pump motor, e.g. in the case of
minutes in the time-dependent control mode (see fluctuations in rotary speed due to low temperatures
diagram). or high torques.

The pump motor is connected to the control by

means of a sliding contact. A signal is sent to the
Diagram of a lubrication cycle: control with each motor revolution and these
incoming signals are counted.

If these signals of the pump motor are due for a

Lubr.time 1 to 16 min (16 notches à 1 min)
2 to 32 min (16 notches à 2 min) longer period than the adjustable monitoring time (30
2 to 32 s (16 notches à 2 s)
sec. as standard) after start of a lubrication process,
Cycle time the control will indicate a malfunction.
The red LED in the window at the lower motor part of
State: 01.16EN

Stroke control at the distributor the pump or an externally installed signal lamp
With the integrated electronic EP-tronic control unit, (option) starts flashing.
lubrication time can also be defined via the number
of lubrication cycles at the progressive distributor. Diagram of a lubrication cycle:
Lubricant delivery is also monitored thereby.

To this purpose, it is necessary that the number of Lubrication time by

09-1-50-02
09 1 50 01

revolutions of the pump motor

piston strokes at the progressive distributor are 1 to 16 min-¹ (16 notches à 1 revolution)
counted. When lubricant is supplied into a distributor, 10 to 160 min-¹ (16 notches à 10 revolutions)
170 to 320 min-¹ (16 notches à 10 revolutions)
the piston is moved permanently and progressively.
1090200400

Cycle time
Subject to alterations! © BEKA 2016 All rights reserved!
BAIER
BAIER++KÖPPEL
KÖPPELGmbH
GmbH++Co.
Co.KG
KG BEETHOVENSTR.
BEETHOVENSTR.14 14TEL.: +49
POSTFACH
9241 729-0
1320 WEB: TEL.:
www.beka-lube.de
+49 9241 729-0 WEB: www.beka-lube.de
D-91257
D-91257
PEGNITZ
PEGNITZ FAX: +49 D-91253
9241 729-50
PEGNITZ E-MAIL:
FAX:
[email protected]
+49 9241 729-50 E-MAIL: [email protected] Contents
 Control and Monitoring Devices
Control units
EP-tronic

Additional functions For grease pump with spring-loaded follower piston

in the reservoir (FKGGM-EPR) is the proximity
Monitoring of the system pressure switch fixed at the pump housing.
(Pressure limiting valve with micro switch)
The maximum operational pressure of the central
lubrication system can be monitored with the
integrated electronic EP-tronic control unit. A micro
switch (see documentation on pump elements) is

Control units
attached to the pressure limiting valve of the pump
element to that purpose.

inductive
If there is an error in the system, e.g. by a blocked proximity switch
lube point, the pressure in the system will build up too
high. The pressure limiting valve actuates a micro
min. level
switch and a signal is sent to the control. The pump is monitoring
switched off and the malfunction is indicated by
flashing of the red LED and constant light of the
green LED or by the possibly installed external signal
lamps.

Level monitoring External status signal

It is possible to equip the integrated electronic EP- A status signal can optionally be evaluated as error
tronic control unit with a level monitoring. signal (standard) or OK-signal by the integrated
electronic EP-tronic control.
To this purpose, a capacitive proximity switch is
installed into the pump reservoir (see accessory for Errors signal means that a permanent signal is
piston pumps). displayed in the case of an error, like e.g.:
a level error
This capacitive proximity switch sends a signal to the a stroke error
control as long as there is enough grease in the a revolution error
reservoir. This signal by the proximity switch is an over-pressure error (in the line system).
stopped when the level falls below minimum.
OK-signal means that the permanent signal is
If there is no signal for more than 10 sec., the pump interrupted in the case of an error.
will be switched off so that no air is pumped into the
system. Assignment of the M12x1 bushing at the control
housing:
min. level PIN wire function
State: 01.16EN

monitoring
1 brown +Ub
pressure
limiting valve 2 - -
with micro switch
3 blue OV
capacitive
proximity switch 4 black ®

Evaluation can be realized e.g. by a relay or a lamp. It

has to be wired between PIN 3 (-) and PIN 4.
09-1-50-03
09-1-50-04

Steuerung EP-tronic
inspection window
Schmierzeit (min.)
Zykluszeit (h)
Service
1 0,5

16 8

red LED
1090200400

green LED

© BEKA 2016 All rights reserved! Subject to alterations!

BAIER + KÖPPEL GmbH +BAIER
Co. KG+ KÖPPEL
BEETHOVENSTR.
GmbH + Co.14KG TEL.: +49
BEETHOVENSTR.
9241 729-0 WEB:
14 www.beka-lube.de
POSTFACH 1320 TEL.: +49 9241 729-0 WEB: www.beka-lube.de
D-91257 PEGNITZ FAX: +49
D-91257
9241 729-50
PEGNITZ E-MAIL: [email protected]
D-91253 PEGNITZ FAX: +49 9241 729-50 Contents
E-MAIL: [email protected]
 Control and Monitoring Devices
Control units
EP-tronic

Change of the parameters

The operational modes (cycle time and
lubrication time), the additional functions and
the setting ranges can be changed by means of
the BEKA-DiSys diagnosis software.

When the operational mode of the lubrication time is

changed from e.g. time-dependent to clock-
Control units

dependent or the other way round, the sticker in the

inspection window of the control also has to be
Control units

changed. The same goes for changes of the setting

range of cycle or lubrication time.

These stickers can be ordered at BEKA.

Function
The integrated electronic EP-tronic control unit has a
data memory. It serves for the storage of expired
parameters, among other things. When the supply
voltage is interrupted during lubrication or a cycle,
the cycle time, lubrication time, the number of
lubrication cycles, resp. the revolutions is stopped
and recorded. As soon as the supply voltage is
provided again, the remaining lubrication or cycle
time is read from the memory and the operational
sequence is continued from where it has been
interrupted.

Intermediate lubrication
With provided voltage you can any time activate an
intermediate lubrication by actuation of the push
button at the lower motor shell of the pump, for e.g.
checking the function after a change of the
parameters. The pump will immediately start with a
new lubrication cycle then. The expired or stored
lubrication or cycle time is resetted and starts anew.

After remedy of the cause for malfunction, the error

State: 01.16EN

signal can be resetted by triggering an intermediate

lubrication.
09-1-50-04
09 1 50 03

1090200400

Subject to alterations! © BEKA 2016 All rights reserved!

BAIER
BAIER++KÖPPEL
KÖPPELGmbH
GmbH++Co.
Co.KG
KG BEETHOVENSTR.
BEETHOVENSTR.14 14TEL.: +49
POSTFACH
9241 729-0
1320 WEB: TEL.:
www.beka-lube.de
+49 9241 729-0 WEB: www.beka-lube.de
D-91257
D-91257
PEGNITZ
PEGNITZ FAX: +49 D-91253
9241 729-50
PEGNITZ E-MAIL:
FAX:
[email protected]
+49 9241 729-50 E-MAIL: [email protected] Contents
 Control and Monitoring Devices
Control units
EP-tronic

Connections of control unit

bayonet plug, 12 and 24 V DC
Stroke control System pressure monitoring
(proximity switch (pressure limiting valve
Level monitoring Status signal at progressive distributor) w. micro switch)

Control units
Control units

External signal lamp

grün (Nr. 1)

Signal lamp green

rot (Nr. 2)

Signal lamp red

white (Nr. 3)
min.

grey (Nr. 4)
max.
Three step switch green
for adaption and
condition of use blue

orange (Nr. 6) yellow

Intermediate lubrication red

button

black (Nr. 5) Bayonet plug

brown (ge/gr)
State: 01.16EN

Ignition, Ground,
terminal15 terminal 31

(Nr. ...) = Cable-Nr. at unicolored cable

lower motor part of pump

Unused plug type connections have to be closed

09-1-50-05

with a sealing cap.

09-1-50-06

Order-no.: 1000913004
1090200400

© BEKA 2016 All rights reserved! Subject to alterations!

BAIER + KÖPPEL GmbH +BAIER
Co. KG+ KÖPPEL
BEETHOVENSTR.
GmbH + Co.14KG TEL.: +49
BEETHOVENSTR.
9241 729-0 WEB:
14 www.beka-lube.de
POSTFACH 1320 TEL.: +49 9241 729-0 WEB: www.beka-lube.de
D-91257 PEGNITZ FAX: +49
D-91257
9241 729-50
PEGNITZ E-MAIL: [email protected]
D-91253 PEGNITZ FAX: +49 9241 729-50 Contents
E-MAIL: [email protected]
 Control and Monitoring Devices
Control units
EP-tronic

Connections of control unit

Hirschmann plug, 7-poles, 100 to 250 V AC

Stroke control System pressure monitoring

(proximity switch (pressure limiting valve
Level monitoring Status signal at progressive distributor) w. micro switch)
Control units

Control units
green

blue

yellow

red

lower motor part of pump Hirschmann plug,

7-poles, 100 to 250 V AC
(cable not enclosed
in delivery)

1
State: 01.16EN

2
2 1
K1277

ZS 3 3
7
+ 24 V 4 4
5 6
L 5
100 to 250 V AC N 6 (View of contacts)
PE 7

Unused plug type connections have to be closed

09-1-50-06

with a sealing cap.

09-1-50-05

Order-no: 1000913004
1090200400

Subject to alterations! © BEKA 2016 All rights reserved!

BAIER
BAIER++KÖPPEL
KÖPPELGmbH
GmbH++Co.
Co.KG
KG BEETHOVENSTR.
BEETHOVENSTR.14 14TEL.: +49
POSTFACH
9241 729-0
1320 WEB: TEL.:
www.beka-lube.de
+49 9241 729-0 WEB: www.beka-lube.de
D-91257
D-91257
PEGNITZ
PEGNITZ FAX: +49 D-91253
9241 729-50
PEGNITZ E-MAIL:
FAX:
[email protected]
+49 9241 729-50 E-MAIL: [email protected] Contents
 Control and Monitoring Devices
Control units
EP-tronic

Order key for type-no. 2157 2157 9010 3 A 1 00

Type-no. 2157
Code-no. 2157
Plug type bayonet plug Hirschmann connector
12 and 24 V DC 7-poles, 100 to 250 V AC
Code-no. 9010 9020
Additional functions Code-no.
not connected to control unit 0

Control units
connected to control unit:
monitoring of system pressure (DBV* with micro switch) 1
level monitoring 2
monitoring of system pressure and level 3
Parameters Cycle time
Lubrication time 0,5 to 8 h 2 to 32 min 2 to 32 h
I 1 to16 min 1 A J
II 2 to 32 min 2 B K
III 2 to 32 s 3 C L
Strokes
I 1 to 16 strokes 4 D M
II 17 to 32 strokes 5 E N
III 33 to 48 strokes 6 F O
Revolutions of the pump
I 1 to 16 7 G P
II 10 to 160 8 H Q
III 170 to 320 9 I R
Status signal (external) Error signal (standard) OK-signal
Code-no. 1 2
Special models without
Code-no. 00
* DBV = pressure limiting valve

All operational modes or additional functions can be activated, resp. adjusted by means of the BEKA-DiSys diagnosis software!

State: 01.16EN
09-1-50-07
1090200400

© BEKA 2016 All rights reserved! Subject to alterations!

BAIER + KÖPPEL GmbH +BAIER
Co. KG+ KÖPPEL
BEETHOVENSTR.
GmbH + Co.14KG TEL.: +49
BEETHOVENSTR.
9241 729-0 WEB:
14 www.beka-lube.de
POSTFACH 1320 TEL.: +49 9241 729-0 WEB: www.beka-lube.de
D-91257 PEGNITZ FAX: +49
D-91257
9241 729-50
PEGNITZ E-MAIL: [email protected]
D-91253 PEGNITZ FAX: +49 9241 729-50 Contents
E-MAIL: [email protected]
 Control and Monitoring Devices
Control units
EP-tronic
Control units
State: 01.16EN
09-1-50-08

1090200400

Subject to alterations! © BEKA 2016 All rights reserved!

BAIER
BAIER++KÖPPEL
KÖPPELGmbH
GmbH++Co.
Co.KG
KG BEETHOVENSTR.
BEETHOVENSTR.
D-91257
D-91257
PEGNITZ
14 14TEL.: +49
PEGNITZ FAX: +49
POSTFACH
9241 729-0
D-91253
1320 WEB: TEL.:
9241 729-50
www.beka-lube.de
PEGNITZ E-MAIL:
FAX:
+49 9241 729-0
[email protected]
+49 9241 729-50
WEB: www.beka-lube.de
E-MAIL: [email protected] X Contents