WOERNER GMA User manual

GMA Operation manual Page 1 of 27 B0301
PUMP UNIT
Type GMA
Translation of the
original operation manual
Version EN 06/2018

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Translation
When delivery is made into EEC countries, this operation manual
needs to be translated into the user’s country language accordingly.
In case that any inconsistency in the translated text occurs, the
original (German) operation manual should be referred to for
clarification or the manufacturer contacted.
Copyright
Unless permitted explicitly, the dissemination, reproduction, and
utilisation of this document as well as the communication of its
contents are prohibited. Any violation of this stipulation shall involve
the obligation to compensate damage.
All rights reserved.

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Table of contents
1. Important notes on this operation manual.....................................................................5
1.1 Users......................................................................................................................5
1.2 Obligation to read...................................................................................................5
1.3 What to do in case of questions..............................................................................5
1.4 Operation manual...................................................................................................5
1.4.1 Applicability............................................................................................................5
1.4.2 Content and purpose..............................................................................................5
1.4.3 Location .................................................................................................................6
1.4.4 Meanings of safety notes and safety symbols ........................................................6
2. Identification....................................................................................................................7
2.1 Product brand and type designation.......................................................................7
2.2 Product version ......................................................................................................7
2.3 Product marking.....................................................................................................7
2.4 Manufacturer and contact address .........................................................................7
2.5 Conformity..............................................................................................................7
3. Product description.........................................................................................................8
3.1 Purpose of use.......................................................................................................8
3.2 Limits of use...........................................................................................................8
3.3 Ambient conditions.................................................................................................8
3.4 Conventional usage................................................................................................9
3.5 Technical data........................................................................................................9
3.5.1 Assemblies.............................................................................................................9
3.5.2 Dimensions ..........................................................................................................10
3.5.3 Base unit..............................................................................................................10
3.5.4 Level monitoring (option)......................................................................................11
3.5.5 Electrical connection ............................................................................................11
4. Functional description ..................................................................................................12
4.1 Layout..................................................................................................................12
4.2 Drive.....................................................................................................................12
4.3 Function...............................................................................................................12
4.4 Pump elements operation.....................................................................................13
5. Safety notes...................................................................................................................14
5.1 Basic principle......................................................................................................14
5.2 Requirements on user training..............................................................................14
5.3 Safety facilities .....................................................................................................14
5.4 Accident prevention..............................................................................................15
5.5 Residual risks.......................................................................................................15
5.6 Incorrect applications ...........................................................................................15
5.7 General safety regulations and duties ..................................................................16
5.8 Disclaimer ............................................................................................................16
6. Transportation, installation, commissioning and shutdown......................................17
6.1 Transportation......................................................................................................17
6.2 Unpacking............................................................................................................17
6.3 Installation............................................................................................................17
6.4 Power supply and switch-on.................................................................................17
6.5 Commissioning.....................................................................................................18
6.6 Shutdown.............................................................................................................19
6.7 Filling level evaluation via external control unit.....................................................19
7. Operation .......................................................................................................................20
7.1 Troubleshooting, fault remedy..............................................................................20
7.2 Refilling the reservoir............................................................................................21

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7.3 Switch-off .............................................................................................................21
8. Cleaning, servicing, fault remedy, and repair..............................................................22
8.1 Cleaning...........................................................Fehler! Textmarke nicht definiert.
8.2 Servicing ..............................................................................................................22
8.3 Inspection schedule..............................................................................................23
8.4 Repair ..................................................................................................................23
8.5 List of spare parts.................................................................................................24
9. Return shipment to factory...........................................................................................24
10. Disposal...................................................................................................................26
11. Appendix..................................................................................................................26
11.1 Content of the declaration of conformity...............................................................26
11.2 Declaration of conformity......................................................................................27

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1. Important notes on this operation manual
This operation manual forms part of the machine and must be available
to the operation and maintenance personnel at any time.
The safety notes contained herein need to be observed When reselling
the machine, this operation manual must be handed over in any case as
well.
In addition to this operation manual, always be careful to observe the
laws and regulations being applicable in the country of use.
1.1 Users
This operation manual is intended for technically qualified users, who have been instructed
or trained in the operation of the pump unit.
1.2 Obligation to read
As an operator and user of the pump unit, you are obliged to read and understand this
operation manual and, in particular, its section Safety regulations. It is your safety that is at
stake! Should you have any question or uncertainty, contact WOERNER, please.
1.3 What to do in case of questions
In case of questions that you cannot solve by means of this operation manual, WOERNER
will help you. In such situations it is indispensable that you provide us with a precise
description of the problem at stake.
1.4 Operation manual
1.4.1 Applicability
This operation manual is applicable to the series versions of the GMA-B and GMA-C pump
units. Should any part thereof be related to particular versions only, special reference will be
made.
1.4.2 Content and purpose
This operation manual contains the relevant information for the commissioning, operation
and maintenance of the pump unit. It is designed to help you in using the pump unit properly,
efficiently and safely.

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1.4.3 Location
This operation manual must always be available to the users at their places of work.
1.4.4 Meanings of safety notes and safety symbols
Safety notes
In this operation manual, the pictograms and key words for safety instructions, precautions,
and notes have the following meanings:
Danger! Any danger threatening immediately and capable of causing
serious personal injuries.
Warning! Any possibly dangerous situation capable of causing serious
personal injuries.
Caution! Any possibly dangerous situation that might cause minor
personal injuries.
Caution! Warning about property damage.
Note! Any possibly harmful situation in which the product itself or an
object in its close vicinity might be damaged.
Important! Notes on application and other useful information facilitating the
proper usage of the product.
Danger! Any danger threatening immediately due to the presence of
electric current that may cause serious personal injuries.

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2. Identification
2.1 Product brand and type designation
Piston pump unit manufactured by Eugen Woerner GmbH & Co. KG
Product type: GMA
2.2 Product version
Version as of model year 2015
2.3 Product marking
The type label is located at the side of the pump body and contains information as follows:
Manufacturer:
Type: (GMA)
No. <order number> (e.g. 612345/1)
Model year
2.4 Manufacturer and contact address
Eugen Woerner GmbH & Co. KG
Hafenstrasse 2
DE-97877 Wertheim
Phone: [phone]
Fax [phone]
Net www.woerner.de
E-Mail [e-mail]
2.5 Conformity
The pump unit is in conformity with the EC directive on machinery (2006/42/EC).
For the content of the declaration of conformity see the appendix (section 11).

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3. Product description
3.1 Purpose of use
The pump unit is designed for the delivery of lube oils as of 140 cP and
lube greases up to NLGI class 2 exclusively.
3.2 Limits of use
The application area of the pump unit’s components is restricted as follows:
Temperature range:
GMA-B -20 …+ 60 °C
GMA-C -20 …+ 40 °C
Admissible delivery pressure: max. 250 bar
Depending on the version, these limits of use may be restricted further. Such further
restrictions are dealth with in this operation manual later on.
Besides, the pump unit’s area of application is determined by the medium to be delivered.
Hence, when determining the area of application, you also need to refer to the technical data
sheets for the medium to be used.
3.3 Ambient conditions
Pump unit operation in an aggressive atmosphere (solvent vapours,
acids, lyes, salt water mist, etc.) may cause damage to or corrosion of
components and, thus, failure of the system and endangerment due to
leaking lubricant!
Ambient temperature range
Lower temperature limit: -20 °C
Upper temperature limit: +60 °C
Relative humidity: max. 70%
Noise level: <70 dB(A)
Physical environment
In heights as of 1.000 metres above sea level, the system should be operated after
consultation with the manufacturer only.

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3.4 Conventional usage
The pump unit is exclusively designed for the delivery of lubricating oils or lubricating
greases in central lubrication systems. Conventional usage also includes:
the observance of the safety notes and adherence to the safety regulations contained
in this operation manual;
the adherence to the maintenance and servicing instructions given in this operation
manual.
Any usage contrary hereto or going beyond the conventional one may
cause serious personal and property damage.
The delivery of gases, liquefied gases, gases dissolved under pressure,
vapours, and liquids the vapour pressure of which exceeds, at the permissible
maximum temperature, the normal atmospheric pressure (1013 mbar) by
more than 0,5 bar, as well as that of highly inflammable or explosive media
and foodstuff is prohibited!
Important: Please also note the safety data sheets pertaining to the
materials used.
3.5 Technical data
3.5.1 Assemblies
The GMA pump unit consists of two assemblies:
Pump body with monitoring device and motor
Reservoir

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3.5.2 Dimensions
The GMA pump aggregate's dimensions are as follows:
Reservoir
GMA-B
GMA-C
width
max.
mm
depth
max.
mm
height
max.
mm
weight
kg
width
max.
mm
depth
max.
mm
height
max.
mm
weight
kg
2 l transparent
328
264
273
6,0
412
264
332
9,6
4 l sheet steel
328
264
323
7,0
412
264
386
10,7
4 l transparent
328
264
320
6,1
412
264
383
9,7
7 l sheet steel
328
264
422
7,5
412
264
485
12,4
5 l Polyester
328
264
376
7,1
412
264
438
10,7
10 l Polyester
328
264
556
7,7
412
264
618
13,2
3.5.3 Base unit
In its basic version, the GMA consists of the motor and a reservoir mounted on. This unit's
technical data is as follows:
GMA-B and GMA-C
Number of pump elements 1 …4
Delivery volume per stroke
per pump element 6 0,08 cm³
per pump element 8 0,15 cm³
adjustable
Admissible delivery pressure 250 bar
Material Casing Aluminium
Pump element Steel
Motor Steel / Copper
Reservoir Polyamide / Steel / Polyester
Gaskets NBR
Filling connector Flat lubrication nipple ø22 acc. to DIN 3404
Nipple for snap
GMA-B
Motor supply voltage 24 VDC
Maximum power consumption 2,5 A
Speed in case of 24 V approx. 27 min-1
in case of 12 V approx. 18 min-1
Temperature range -20 … +60 °C
GMA-C
Motor supply voltage 230/400 V
Mains frequency 50 Hz
Protection system DIN EN 60529 IP55
Insulating category F
Speed 1 min-1 / 4,5 min-1 / 25 min-1
Temperature range -20 … +40 °C
Rated power in case of n = 1 min-1 45 W
in case of n = 4,5 min-1 45 W
in case of n = 25 min-1 90 W


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Rated current (230/400 V)
in case of n = 1 min-1 0,38/0,22 A
in case of n = 4,5 min-1 0,38/0,22 A
in case of n = 25 min-1 0,74/0,43 A
3.5.4 Level monitoring (option)
The technical data of the (optional) level monitoring unit is as follows:
Level monitoring "F"
Switching current max. 0,5 A
Switching power max. 40 W / 60 VA
Switching voltage max. 230 VUC
System of protection DIN EN 60529 IP65
Cable gland M16x1,5
Level monitoring "C1" and "C2"
Operating voltage 10 … 30 VDC
Residual ripple ≤10%
Load current max. 200 mA
Inherent power consumption approx. 7,5 mA
Potential drop ~0,8 V
"empty" signal intermittently
Type of connection C1 GMA-B: Terminal strip
GMA-C: Cable 3 m
C2 GMA-C: Unit plug M12x1, 4 pins
When connecting inductive or capacitive loads, the relevant sup-
pressor circuits (diode, RC element, varistor) need to be provided for!
3.5.5 Electrical connection
The electric connection of the pump unit is made directly through the terminal box of the
motor (GMA-C) or a terminal strip in the pump casing (GMA-B).
The electric wiring in accordance with DIN VDE1000-10 may be done
by qualified electricians only!

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4. Functional description
4.1 Layout
A: Pump casing
B: Pump element
C: Three-phase current A.C. motor
(GMA-C)
Direct current D.C. motor (GMA-B)
D: Reservoir
E: Eccentric shaft
F: Eccentric
G: Pump piston
4.2 Drive
The GMG-B pump unit is driven by a direct current gear motor (C) that is flanged to the pump
casing (A) from below.
4.3 Function
At the piston pump there are up to four pump elements arranged radially around an
eccentric, which is surrounded by a rolling bearing. On rotation of the actuator or the
eccentric shaft respectively the pump piston of each pump element designs a suction or a
delivery stroke per revolution and thus delivers the lubricant out of the reservoir to the
lubricating points. Depending on the pump element, the delivery volume can be adjusted
individually. Depending on the version, the reservoir is additionally fitted with an agitator that
facilitates the medium's flowing in.
A
B
C
D
E
F
G

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4.4 Pump elements operation
4
3
R
7
Fördervolumen
1
2
6
The suction stroke is carried out by delivery piston 1and control piston 2. During such
operation, suction piston 1is actuated by means of the eccentric shaft, whilst the spring
actuates control piston 2. The control piston closes pressure hole 3up and stops, depending
on the preset delivery volume, at a certain position. The delivery piston continues the
movement, thus causing a vacuum to build up in the proportioning space. Then, after
opening by the delivery piston of suction hole 4, lubricant is drawn from the reservoir.
In case of pressure stroke, delivery piston 1moves to the left. By such move, intake hole 4is
closed up, whilst control piston 2is shifted by the lubricant being available in between
delivery piston and control piston until pressure hole 3is released and lubricant delivered
through the delivery piston to the outlet.
The pump element with piston diameter 8 mm = 0,15 cm³/stroke is marked with a red ring R.
Adjustment of the delivery volume:
The delivery volume can be reduced to a minimum of about 25% of the rated one. For that
purpose, take the following actions:
Turn out the plug screw 7.
Set the required delivery volume at the adjusting nipple 7with the wrench included in
the delivery.
Clockwise turn: Reducing the delivery volume.
Anticlockwise turn: Increasing the delivery volume.
The adjusting nipple features a hexagon, against which a spring-loaded piston exerts
pressure in radial direction. In this way, the delivery volume is prevented from
automatically changing. At the same time, this type of locking serves as a measure
for the adjustment of the delivery volume. Six notches correspond to one turn of the
adjusting nipple and reduction by approximately 33% of the rated volumetric
displacement. As for precise adjustment to a defined delivery volume per stroke, a
volumetric prove-measurement has to be taken. The pump elements are delivered
adjusted to maximum volumetric displacement.
Turn in the plug screw 7.
Delivery volume

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5. Safety notes
5.1 Basic principle
The pump unit leaves the factory in flawless condition and ensures high technical safety.
The pump unit is in conformity with the rules of technology and the applicable safety and
health regulations. Nevertheless, in case of incorrect operation or misuse, risks are
threatening to the:
lives and bodies of the users or third parties,
pump unit or other operator assets,
efficient use of the pump unit.
5.2 Requirements on user training
Any person getting to work on the pump unit must be authorised and trained for that purpose
by the operator. They must be able to recognise and avoid potential risks. This also includes
knowledge in the accident prevention regulations, first-aid measures, and local rescue
facilities.
The unit may be inspected, maintained and repaired by technically skilled
personnel with product-specific training only.
Work on electric facilities may be performed by skilled electricians in
conformity with DIN VDE 1000-10 only.
5.3 Safety facilities
Mechanically, the pump unit is built intrinsically safe.
The pump unit may not be operated unless the reservoir lid is closed.

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5.4 Accident prevention
For accident prevention, take these measures:
Prevent unauthorised persons from accessing the pump unit.
Keep foreign persons away from the areas and places of risk.
Inform present foreign persons about residual risks repeatedly. Inform yourself about
such risks in the "Residual risks" section.
5.5 Residual risks
When using the pump unit properly and adhering to the maintenance and repair cycles and
measures prescribed, there are no residual risks to persons and objects within the pump
unit’s area.
If the pump unit is delivered in pre-filled condition, the product and safety data sheets related
to the medium filled in need to be observed in addition to this operation manual.
5.6 Incorrect applications
Any usage contrary hereto or going beyond the conventional one may cause
serious personal and property damage.
As experience shows, possible incorrect applications include, for instance, the following:
the delivery of highly inflammable or explosive media;
the delivery of media being capable of reacting with the materials used for the pump
unit;
the delivery of foodstuff.

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5.7 General safety regulations and duties
Basically, the following safety regulations and duties are applicable to the use
of the pump unit:
The generally accepted rules for work safety need to be
observed. Besides, the basic regulations and rules on work
safety and accident prevention being applicable to the place of
use have to be followed.
When using the pump unit inside vehicles, the generally
accepted traffic law-related rules need to be observed.
The user is obliged to observe the regulations pertaining to the
use of working appliances.
The pump unit must be operated in flawless and clean condition
only.
It is prohibited to remove, modify, bridge or bypass any and all
protection, safety or monitoring facilities.
It is prohibited to reconstruct or modify the pump unit.
The operator should be notified of any fault or damage
immediately.
For repair, no others than original spare parts may be used.
The operator is required to regularly check and maintain all
protection, safety, and monitoring facilities.
After every repair, the flawless condition of the pump unit must
be ensured by means of a test run.
5.8 Disclaimer
Should any damage be caused to persons, objects, the environment and/or property due to
the non-observance of this Operation Manual, no matter whether intentionally or
unintentionally, WOERNER shall be held harmless thereof. Besides, all warranty claims will
be rejected. The same also applies to any and all consequential damage.

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6. Transportation, installation, commissioning and shutdown
6.1 Transportation
Transport the pump unit to its destination carefully and by using suitable aids (e.g. hand-carts
or the like).
6.2 Unpacking
Lift the pump unit out of its packaging carefully and put it on a stable and plane base.
Note: The pump unit and the components attached in accordance with
the scope of delivery may still contain residues of blue-dyed test oil.
6.3 Installation
The pump unit is ready for wall-mounting. It is to be secured by means of two M10 screws.
The mounting surface must be sufficiently stable in order to be capable of carrying the pump
unit’s weight including the filled reservoir. Besides, it needs to be ensured that the
mounting surface is vertical and plane.
Drill Scheme:
6.4 Power supply and switch-on
Important: Be careful to compare the data of the local voltage supply with
that given under "Technical data".
Important: Lay the power supply cable such that it cannot be torn off
inadvertently.
Important: Work on electric facilities may only be performed by skilled
electricians in conformity with DIN VDE 1000-10.
Connect the pump unit to the voltage supply.
Ground the pump unit through the potential connection by means of a threaded M4 screw.
Check the electric connections for correct installation prior to commissioning.

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Caution!
Work on electric facilities implies danger to life!
6.5 Commissioning
The pump unit‘s functionality has been checked in the factory. Hence, it is ready for
operation and can be connected to a local voltage supply.
Important: Note the safety instructions contained in the "Power supply and
switch-on" section.
First fill lubricant and then start the pump unit, in every case
(Minimum filling level, see chapter 7.2)
Commissioning procedure:
a) Filling the pump with lubricant
The pump units may be operated with clean oil or grease from original
packages only!
The initial filling with grease must be done through the filler nipple in order to
fill the pump’s suction chamber safely.
Hint: For the pump’s initial filling with grease, we recommend to fill it with
transmission oil up to the stirring wing in order to ensure a speedy and
better bleeding.
When selecting the transmission oil, however, proper compatibility
with the lubricant used needs to be ensured.
b) Bleeding the pump unit
The pump needs to be switched on until the lubricant leaves the pump elements‘ outlets free
of air.
c) Connecting lube lines
The lube point lines must be clean and free of any obstruction.
Connect the outlets of the pump elements with the lube lines. These lines must be clean
and free of any obstruction. You may not connect the lube lines to the lube points unless
the lubricant comes out free of air. Check all connections of the lube lines for tightness and
the lube points for air-free lubricant release.

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Note that the pump unit, depending on the ambient conditions, is capable of building up
maximum pressures of far more than 500 bar!
Warning! If the pump unit is not already fitted with pressure control valves
on delivery, the lube lines need to be retrofitted with suitable
protective elements in order to prevent the pump unit and lube
lines from overloading.
Warning! Any pump pressure above the admissible operating pressure
of 250 bar may result in the destruction of the system and
situations endangering health!
6.6 Shutdown
The unit is shut down when switched off and disconnected from the external power supply.
Work on electric facilities may only be performed by skilled electricians
in conformity with DIN VDE 1000-10.
6.7 Filling level evaluation via external control unit
When the pump aggregate is a level monitoring unit instead, such monitoring unit needs
to be evaluated externally.
The "Empty" message will be released for level check "C" (for grease) intermittently during
the delivery period and for level check "F" (for oil) and “F/K” (for grease) statically.

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7. Operation
7.1 Troubleshooting, fault remedy
No.
Fault
Root cause
Remedy
1
No lubricant
delivery
Drive motor not
running
Check electric connenctions.
Check electric voltage at the motor.
Check the fuse.
Check the motor.
Reservoir is empty.
Refill lubricant.
Air included in lubricant
lines
Fill the lines with lubricant.
Lubricant not suited for
the application
Exchange the lubricant of the
whole system.
Leaking line system
Seal the leaking spot.
Pump unit blockade
Have the pump unit repaired.
Pump element failed
Exchange the pump element.
2
Lubricant
pressure too high
Obstruction in pipeline
system
Check the line system for free
throughput. Remove obstructed
components and clean or replace
them.
Lubricant not suited for
the application
Exchange the lubricant of the
whole system.
Pipeline cross-section
too small
Replace the pipelines by lines
having a bigger cross-section.
3
No response
from "Monitoring
empty"
Lubricant does not
match monitoring
Check whether the monitoring is
suited for the lubricant (level
control "C1", "C2", "F/K" for
grease, level control "F" for oil).
Electric connection
interrupted
Check the electric connection to
the monitoring device.
Should the above mentioned troubleshooting and the corresponding remedies not lead to a
flawless operation of the pump unit, turn to WOERNER, please.