Control and Monitoring Devices

Control units
GIGA-tronic

Description
The control device GIGA-tronic is an integrated unit
for grease lubrication pumps of the series GIGA and
GIGA PLUS.
motor cover
of the central
One lubrication cycle for this type of control consists lubrication pumps
of the cycle time and the lubrication time. Cycle time GIGA or
GIGA PLUS
means the phase from the beginning of a lubrication

Control units
to the beginning of the next one.
push button for
intermediate
lubrication

inspection window

connection of the
Lubrication time system diagnosis
Cycle time
rotary switch for adjustment of the cycle time

There are two rotary switches in the inspection rotary switch for adjustment of the lubrication time

window of the integrated EP-tronic ZX control. The

right one is for adjusting the cycle time and the left Technical data
one for adjusting the lubrication time.
Supply voltage: 10 to 60 V DC
Max. current load: I = 6,0 A
Cycle time Lubrication time Fuse (not enclosed): F 6,3 A
controlled by: controlled by: (5x20) semi time-lag
· time · time Output for signal lamp: I = 0,4 A
· clock cycles · strokes Temperature range: -30°C to +70°C
· revolutions Protection class: IP 65

The following additional functions can be connected, The control device is equipped with an operational
respectively evaluated:
database which records the following values with
Additonal functions: date and time (RTC Real-Time-Clock, also
· overpressure monitoring (Pmax.) or adjustable to other time zones):
· line-break monitoring · Control data (e.g. type, control unit version, serial
(both only possible for cycle time mode)
number, among others)
· external status signal
· 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 level errors, number of
stroke monitoring errors, number of revolution
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
09-1-70-01

· Event log of the last 100 changes of the settings

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
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 Control and Monitoring Devices
Control units
GIGA-tronic

Cycle time Lubrication time

The cycle time can be controlled time or stroke- There are three different operational modes
dependent with the integrated GIGA-tronic control available for the lubrication time, namely time
unit. control, stroke control at the distributor and
revolution control!

Cycle time control

The cycle time can be adjusted in hours and minutes Time control
for this type of control (see diagram). The lubrication time can be set in minutes for the
Control units

time-dependent control of the lubrication time.

Diagram of a lubrication cycle:

Diagram of a lubrication cycle:

Lubrication time
Cycle time Lubr.time 1 to 16 min (16 notches à 1 min)
2 to 32 min (16 notches à 2 min) 2 to 32 min (16 notches à 2 min)
0,5 to 8 h (16 notches à 0,5 h)
2 to 32 h (16 notches à 2 h) Cycle time

Clock cycle control
The cycle time can also be defined by clock pulses
for the integrated electronic GIGA-tronic control unit.
To this purpose is a proximity switch attached to e.g.
a lubrication pinion. It sends an impulse to the control
with each revolution. The incoming pulses are
counted by the control and lubrication is triggered,
depending on the adjusted number of clock pulses.
If the pulses are missing for a longer period than the
adjusted monitoring time (7 days as a standard), the
control will indicate malfunction. The green and the
red LED in the inspection window at the lower motor
shell of the pump or the possibly installed green and
red signal lamps start flashing.
Diagram of a lubrication cycle:
State: 01.16EN
Stroke control
With the integrated electronic control device GIGA-
tronic, the lubrication time can also be defined by the
number of lubrication pulses at the progressive
distributor. Lubricant supply is also monitored
thereby.
It is necessary to count the number of piston strokes
to that purpose. When lubricant is supplied into the
progressive distributor, the piston is moved
permanently and progressively. A proximity switch is
mounted to one of these pistons which sends a
signal to the control with each piston stroke. These
signals are counted by the control.
If these signals are missing for a longer period than
the set monitoring time (12 min. as a standard), the
control will indicate malfunction. The green and the
red LED in the inspection window of the control at the
motor cover or the possibly installed green and red
signal lamps start flashing.

Lubrication time
Clock cycles
1 to 16 pulses (16 notches à 1 pulse)
10 to 160 pulses (16 notches à 10 pulses) Diagram of a lubrication cycle:
20 to 320 pulses (16 notches à 20 pulses)
100 to 1600 pulses (16 notches à 100 pulses)
500 to 8000 pulses (16 notches à 500 pulses)

proximity switch Lubrication time by

09-1-70-02

at the lubrication pinion strokes at the distributor

1 to 16 strokes (16 notches à
17 to 32 strokes 1 stroke)
33 to 48 strokes
proximity switch
1090200400

Cycle time for stroke

control
Subject to alterations! © BEKA 2016 All rights reserved!
BAIER
BAIER++KÖPPEL
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 Control and Monitoring Devices
Control units
GIGA-tronic

Revolution control Additional functions

With the integrated electronic GIGA-tronic control,
the lubrication time can also be defined by the
number of revolutions of the pump motor, e.g. in the
case of fluctuations in rotary speed due to very low
temperatures or high torques.
The revolutions are detected by an integrated
The following additional functions can be evaluated:
- system pressure or line-break monitoring
- external status signal
Overpressure monitoring (Pmax.)
(pressure limiting valve with micro switch)
The maximum operating pressure in the system can

Control units
sensor. A signal is sent to the control with each motor
be monitored with the integrated electronic GIGA-
revolution and these incoming signals are counted.
tronic control. A micro switch is attached to the
pressure limiting valve of the pump element to this
If these signals of the pump motor are missing for a
purpose (see documentation on pump elements).
longer period than the adjustable monitoring time (30
sec. as standard) after start of a lubrication process,
If there is an error in the system, e.g. a blocked lube
the control will indicate malfunction.
point, the pressure in the system will build up too
The red LED in the inspection window at the motor
high. The pressure limiting valve actuates a micro
cover of the pump or an externally installed signal
switch and a signal is sent to the control. The pump is
lamp (optional) start flashing.
switched off and the malfunction is indicated by
flashing of the red LED and constant light of the
green LED or by possibly installed external signal
Diagram of a lubrication cycle: lamps.

Attention:
Overpressure monitoring is always active,
Lubrication time by
pump revolutions unless clock cycle control or line-break
1 to 16 min-¹ (16 notches à 1 revolution) monitoring have been selected, as those are
10 to 160 min-¹ (16 notches à 10 revolutions)
170 to 320 min-¹ (16 notches à 10 revolutions) connected to the same bushing (see scheme
Cycle time „connections of the control“).

Underlubrication - error
If the lubrication time cannot be completed within the
cycle time, this will cause underlubrication.
This might happen e.g. due to very low temperatures
when the pump needs more time for processing the
lubrication time as available by the cycle time.
The green and the red LED in the inspection window
pressure limiting valve
of the control at the motor housing or the possibly with micro switch
installed green and red signal lamps start flashing. (at the pump element)
State: 01.16EN

The error memory of the pump records

„underlubrication“. However, the pump is not
switched off as underlubrication is still better than no
lubrication at all.
The error is reset, i.e. the control stops the flashing
automatically as soon as one lubrication can be
09-1-70-03

finished properly.
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
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 Control and Monitoring Devices
Control units
GIGA-tronic

Line-break monitoring (at the distributor) External status signal

A line-break monitoring which is mounted to the
progressive distributor can be electronically
evaluated by means of the integrated GIGA-tronic
control unit.
The line-break monitoring monitors the pressure in
the lubrication line, from the distributor to the lube
Control units
A status signal can optionally be evaluated as error
signal (standard) or OK-signal by the integrated
electronic GIGA-tronic control.
Error signal means that a permanent signal is
displayed in the case of an error, like e.g.:
a level error,

point. There are sensors integrated into the line- a stroke error,
break monitoring. They send a signal as long as the a revolution error,
pressure in the line is maintained. If pressure falls, an over-pressure error (in the line system) or
the signal will stop. At the end of the adjusted number a line breakage.
of starting cycles (2 as a standard) and after the
adjusted monitoring time (1 min. as a standard), the OK-signal means that the permanent signal is
control indicates malfunction. interrupted in the case of an error.

The starting cycles (=the first cycles after the supply Assignment of the M12x1 bushing at the control
voltage has been applied) serve for safety purposes. housing:
Should the pressure in the system drop, e.g. if it has PIN wire function
been switched off during night, the system will need 1 brown +Ub
one or two lubrication cycles to build up pressure 2 - -
again and the sensors will start sending a signal as 3 blue OV
soon as they detect it. This especially goes for longer 4 black ®
lubrication lines. If pressure is not built up within the
starting cycles and the monitoring time which starts Evaluation can be realized e.g. by a relay or a lamp.
after them, the control will indicate malfunction. It has to be wired between PIN 3 (-) and PIN 4.
However, lubrication is continued in this case, as the
other lube points are still lubricated.

Attention:
When line-break monitoring is used, neither
clock cycle control nor overpressure monitoring
is possible, as those are connected to the same Level monitoring
connections (see scheme „connections of the On customer request, the pumps can also be
control“). equipped with an electronic level monitoring function
for minimum level.

Ensure that the corresponding sensor is available

State: 01.16EN

when ordering the GIGA-tronic with level monitoring.

Otherwise the control will signal malfunction due to
the missing level sensor.

line-break
monitoring
09-1-70-04

progressive distributor MX-F

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
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 Control and Monitoring Devices
Control units
GIGA-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
changed. The same goes for changes of the setting
range or cycle or lubrication time.

The sticker in the inspection window should also be

changed in the case of alterations of the lubrication
mode, e.g. from time-dependent to stroke-
dependent or if the setting range has been changed.

The corresponding stickers can be ordered at BEKA.

Function
The integrated electronic GIGA-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 remaininig 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 above the inspection window of the control at
the motor cover, for e.g. checking the function after a
State: 01.16EN

change of the parameters. The pump will

immediately start with a new lubrication cycle then.
The expired or stored lubrication or cycle time is
reset and starts anew.

After remedy of the cause for malfunction, the error

signal can be reset by triggering an intermediate
09-1-70-05

lubrication.
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
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 Control and Monitoring Devices
Control units
GIGA-tronic

Connections of the control

Stroke control Clock cycle control Overpressure monitoring (Pmax.) Line-break monitoring Status signals
(proximity switch at the (proximity switch at e.g. (pressure limiting valve with (at the progressive distributor)
progressive distributor) the lubrication pinion) micro switch at the pump element)
Control uits

only for clock cycle- only for cycle time-

dependent control dependent control

optional

GIGA / GIGA PLUS

blue
green
yellow

push button for intermediate lubrication

remove this screw plug for replacement of Information on scope of supply

the battery for the Real-Time-Clock (RTC)
State: 01.16EN

Voltage feed of the pump is realized by a bayonet

plug with 7 poles or optionally by a cubic plug (see
order key).
Plug-type connections which are not used have to be Pumps with bayonet plug are delivered with a
closed with a blanking cover connecting cable. Pumps with cubic plug are only
Order-no.: 1000913004 delivered with connector. The connecting cables with
M 12 plug-type connection are not included (see
09-1-70-06

parts catalogue, „3. pump accessories“).

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
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 Control and Monitoring Devices
Control units
GIGA-tronic

Order key for type-no. 2172P 2172P F 21 S S S S S 3 0

Type-no. 2172P
Code-no. 2172P
Voltage 24 V DC
Electr. connection plugs bayonet plug, cubic plug,
DIN 72585, 7-poles DIN 43650, 4-poles
Code letter F H
Control GIGA-tronic*

Control units
Parameters Cycle time Clock cycles

100 to 1600

500 to 8000
2 to 32 min
Additional

0,5 to 8 h

10 to 160

20 to 320
2 to 32 h
3x M12

3x M12

3x M12

3x M12

3x M12

3x M12

3x M12

3x M12
without

without

without

1 to 16
plug

Lubr. time
1 to 16 min 20 21 22 23 24 25 26 27 28 2K 2L
2 to 32 min 29 2A 2B 2C 2D 2E 2F 2G 2H 2M 2N
Strokes at the distributor
1 to 16 strokes - 30 - 31 - 32 33 34 35 3K 3L
17 to 32 strokes - 36 - 37 - 38 39 3A 3B 3M 3N
33 to 48 strokes - 3C - 3D - 3E 3F 3G 3H 3P 3R
Revolutions of the pump
1 to 16 50 51 52 53 54 55 56 57 58 5J 5V
10 to 160 59 5A 5B 5C 5D 5E 5F 5G 5H 5W 5X
170 to 320 5K 5L 5M 5N 5P 5R 5S 5T 5U 5Y 5Z
Additional functions - GIGA-tronic evaluation
no 0
overpressure monitoring** 1
level monitoring 2
overpressure and level monitoring** 3
line-break monitoring** 4
line-break and level monitoring** 5
Special models without
Code-no. 0
* standard setting = error signal (output under voltage in case of malfunction),
see section on external status signal
** not for clock cycles State: 01.16EN
09-1-70-07
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
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 Control and Monitoring Devices
Control units
GIGA-tronic
Control units
State: 01.16EN
09-1-70-08

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
beka@beka-lube.de
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E-MAIL: beka@beka-lube.de X Contents