WOERNER GMG-B User manual

GMG-B Operation manual Page 1 of 45 B0743
PUMP UNIT
TYPE GMG-B
Translation of the
original operation manual
Version EN 10/2019

GMG-B Operation manual Page 2 of 45 B0743
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 clari-
fication 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.

GMG-B Operation manual Page 3 of 45 B0743
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..............................................................................................................11
3.5.4 Level monitoring (option)......................................................................................12
3.5.5 Control .................................................................................................................12
3.5.6 Progressive distributor (option).............................................................................13
3.5.7 Electric connection...............................................................................................13
4. Functional description ..................................................................................................15
4.1 Drive.....................................................................................................................15
4.2 Delivery function...................................................................................................15
4.3 Stirring without delivery function...........................................................................16
4.4 Pump elements....................................................................................................16
4.5 Level control (option)............................................................................................17
4.6 Progressive distributors (option)...........................................................................18
5. Safety notes...................................................................................................................19
5.1 Basic principle......................................................................................................19
5.2 Requirements on user training..............................................................................19
5.3 Safety facilities .....................................................................................................20
5.4 Accident prevention..............................................................................................20
5.5 Residual risks.......................................................................................................21
5.6 Incorrect applications ...........................................................................................21
5.7 General safety regulations and duties ..................................................................21
5.8 Disclaimer ............................................................................................................22
6. Transportation, installation, commissioning and shutdown......................................23
6.1 Transportation......................................................................................................23
6.2 Unpacking............................................................................................................23
6.3 Installation............................................................................................................23
6.4 Power supply and switch-on.................................................................................24
6.5 Commissioning.....................................................................................................24
6.6 Shutdown.............................................................................................................26

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7. Operation .......................................................................................................................27
7.1 Control "C" (option) ..............................................................................................27
7.1.1 Control operation..................................................................................................28
7.1.2 Test mode (also see item 7.1.7)...........................................................................29
7.1.3 Time ON / Time OFF variant ................................................................................30
7.1.4 Time ON / Distributor pulses OFF variant.............................................................31
7.1.5 Machine pulses ON / Time OFF variant................................................................32
7.1.6 Machine pulses ON / Distributor pulses OFF........................................................33
7.1.7 Special functions..................................................................................................34
7.1.8 Error messages....................................................................................................35
7.1.9 Connecting an external progressive distributor.....................................................35
7.1.10 Troubleshooting, fault remedy..............................................................................35
7.2 Refilling the reservoir............................................................................................37
7.3 Switch-off .............................................................................................................37
8. Cleaning, servicing, fault remedy, and repair..............................................................38
8.1 Cleaning...............................................................................................................38
8.2 Servicing ..............................................................................................................38
8.3 Inspection schedule..............................................................................................39
8.4 Repair ..................................................................................................................39
8.5 Accessories..........................................................................................................40
8.6 List of spare parts.................................................................................................40
9. Return shipment to factory...........................................................................................41
10. Disposal...................................................................................................................43
11. Appendix..................................................................................................................43
11.1 Content of the declaration of conformity ...............................................................43
11.2 Declaration of conformity......................................................................................44
11.3 Control settings parameter sheet..........................................................................45

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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 des-
cription of the problem at stake.
1.4 Operation manual
1.4.1 Applicability
This operation manual is applicable to the series versions of the GMG-B 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: GMG-B
2.2 Product version
Version as of model year 2018
2.3 Product marking
The type label is located at the side of the pump body and contains information as follows:
Manufacturer
Type (GMG-B)
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: -20 …+60 °C
Adm. delivery pressure: max. 250 bar
Depending on the version, these limits of use may be restricted further. Such further restric-
tions 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 end-
angerment 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 consulta-
tion 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 GMB-B pump unit consists of up to four assemblies the different GMG-B versions of
which may vary:
Pump body with monitoring device and motor
Reservoir
Control
Progressive distributor (option)

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3.5.2 Dimensions
GMG-B dimension sheet
Weight:
with reservoir "2" max. 6,1 kg*
with reservoir "4P" max. 6,3 kg*
with reservoir "7V" max. 7,8 kg*
*without progressive distributor, without lubricant

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3.5.3 Base unit
In its basic version, the GMG-B comprises the pump body with motor and a reservoir
mounted on. The technical data of this unit is as follows:
Number of pump elements 1 or 2
Delivery volume per stroke
per pump element 04 0,04 cm³
per pump element 08 0,08 cm³
per pump element 16 0,16 cm³
Admissible delivery pressure 250 bar
Temperature range -20 … +60 °C
Motor connection voltage 24 VDC
Pump drive power input 2,5 A
Overall power input, incl. control 3 A
Output speed approx. 30 min-1
Protection type DIN EN 60529 IP55
Material Casing: Aluminium
Pump element: Steel
Motor: Aluminium / Steel / Copper
Reservoir types "2" and "4P": Polyamide
(Lid polypropylene)
Reservoir type "7V": galvanised Steel
(Lid galvanised Steel)
Gaskets: NBR
GMG-B Basic elements
Reservoir
Control (option)
Pump body with motor

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Filling connection Cone lubricator nipple DIN 71412
Flat lubricator nipple DIN 3404
Closing nipple
Filling connection variants:
This part is located beneath the left-side pump element.
1) not for oil suitably
3.5.4 Level monitoring (option)
The technical data of the (optional) level monitoring unit is as follows:
Switching voltage max. 30 VDC
Switching current max. 0,25 A
Switching power max. 3 W
Temperature range 0 … +60 °C
Contact function NC contact
When connecting inductive or capacitive loads, the relevant sup-
pressor circuits need to be provided for!
(Diode, RC element, varistor)
3.5.5 Control
The technical data of the (optional) control is as follows:
Control "C"
Power input 2 W
Input resistance 4,5 kΩ
Temperature range -20 … +60 °C
Data buffer 10 years
Filling connector "G"
Closing nipple
Filling connector "W"
Closing nipple
Accessory for filling connector
"G" and "W":
Quick release
coupling 954.002-09
(pmax = 35 bar)
Filling connector "A" 1)
Cone lubricator nipple
DIN 71412 - AG1/4
Filling connector "C" 1)
Flat lubricator nipple
DIN 3404 - M22

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3.5.6 Progressive distributor (option)
The technical data of the progressive distributor that can be flanged on optionally is
as follows:
Metering volume per cycle and outlet 0,09 cm³, 0,14 cm³, 0,20 cm³
Number of outlets 2 … 20
Operating pressure max. 150 bar
Useable medium Oil viscosity >140 cP
Grease up to NLGI class 2
Material Outer body Aluminium
Internal parts Steel
Gaskets FPM
If the progressive distributor is fitted with a "RK" (Reed contact) monitoring
device, its technical data is as follows:
Switching voltage 10 … 36 VUC
Switching current max. 25 mA
Switching power max. 0,9 VA
Temperature range -5 … +60 °C
Outer material PA / 1.4305
3.5.7 Electric connection
The pump unit’s electric connection data is as follows:
Type of connection: Connector socket M12x1, 5-pin (8)
8
9

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Version with control:
Pin 1 +24 V
2 +24 V (external release,
external impulses)
3 0 V
4 Alarm output
Connection scheme for the version with control:
For pump operation, the voltage supply must be available.
In order to release the pump in the "Time"-mode, the pin 2 is to be supplied with 24 V.
In "Pulse"-mode, the machine pulses have to be supplied to pin 2.
Version without control:
Pin
1 +24 V (Delivery function: 24 V to Pin 1)
2 +24 V (Stirring function: 24 V to Pin 1 and 2)
3 0 V
4 Level control
For equipotential bonding installation, the pump casing is fitted with a threaded M4 (9)
connector.
The electric wiring in accordance with DIN VDE 1000-10 may be done
by qualified electricians only!

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4. Functional description
4.1 Drive
The GMG-B pump unit is driven by a direct current gear motor 5that is flanged to the pump
casing 4from below.
4.2 Delivery function
When the eccentric shaft 3is rotating, the delivery piston 2.1 of every pump element per-
forms a suction and delivery stroke per rotation each whilst delivering lubricant from the
reservoir 1to the lube points.
Depending on the case of application (lubricant, lubricant need, etc.), the pump unit can be
fitted with different pump elements and monitoring elements.

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4.3 Stirring without delivery function
With the version "Stirring without and with supply" only.
In some modes of operation, improvement of lubricant quality and delivery behaviour require
additional stirring of the lubricant.
In the GMG-B pump unit, such stirring is enabled by means of a specially designed eccentric
drive.
When the eccentric shaft 3rotates into the one direction of rotation, the pump elements are
working whilst the stirrer supplies them with lubricant.
As soon as the eccentric shaft 3rotates in counter direction, the lubricant will be stirred while
the pump elements do not deliver.
The integrated control can be used to programme the operation and off-duty times for the
delivery with stirring and the stirring without delivery independently from each other.
Attention! If the pump has not been equipped with the function "Stirring without
and with supply", the medium is supplied every time the pump is
switched on!
Attention! The motor must not continuously run!
4.4 Pump elements
During suction stroke, the pressure spring 2.2 moves the delivery piston 2.1against the
eccentric shaft 3. In such motion, the lubricant being available in the reservoir 1is drawn
through the suction hole 2.3 into the metering chamber 2.4.
During delivery stroke, the eccentric shaft 3displaces the delivery piston 2.1. Thereby,
the suction hole 2.3 is closed and the lubricant volume being available in the metering
chamber 2.4 delivered through the check valve 2.5 to the outlet 2.6.
The 0.04 cm³ delivery volume pump element is marked by a white ring R, whereas the
0,16 cm³ delivery volume pump element is marked by a black ring R.
Suction stroke:
Delivery stroke:

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4.5 Level control (option)
Level control "C":
Minimum level monitoring for grease
When the reservoir is empty and the pump drive shaft rotating, the contact will be switched.
The empty signal is intermitting.
The switching mechanism may change itself, e.g. during reservoir filling.
Therefore, in case of an external control, evaluation of the signal available during pump
switch-on must be delayed (by approx. 5 s).
Version without control:
In the "Stirring without delivery" function, signal evaluation has to be suppressed.
Level control "C"
Level control "F":
Minimum level monitoring for oil
Level control "F" consists of a PUR float that is raised up in the oil. If the oil level falls below
minimum, the contact will open.
Level control "F"
Lubricant avaible
(permanent signal)
No lubricant avaible
(intermittend signal)

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The PUR float is suited for mineral oils without synthetic additives only.
When using other media, their compatibility with the float material
needs to be checked.
The PUR float is not resistent to:
Emulsions
Phosphoric esters
Organic esters
Triglycerides (rape oil)
Synthetic esters
Polyglycols
4.6 Progressive distributors (option)
Progressive distributors VPB can be directly
flange-mounted on the pump elements, but
limited to 2 units with up to 20 outlets each and
various feeding volumes.
The following progressive distributors can be
flanged directly:
VPB-B Data sheet P0378
VPB-G Data sheet P0177
In case of attached progressive distributors,
the 0,16 cm³ delivery volume pump element
is marked with a grey plastic nap N.
Functioning:
In the distributor, the lubricant supplied by the pump element is delivered to the outlets
progressively.
For more information about the functioning of the distributors see data sheets P0378 and
P0177, respectively.
Functional control:
In conjunction with the monitoring of the movement of a distributor piston, the lubricant
supply to all outlets is monitored. When evaluation is to be made via pump control, pro-
gressive distributors with electric functional control need to be selected.
When, however, using the pump controller, one distributor each can be
monitored only.

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Option "Pressure control valve at progressive distributor":
To limit the maximum operating pressure, pressure control valves 7instead of the venting
screw 6can be screwed in.
Opening pressure: Order no.:
70 bar 110.566-65
150 bar 110.564-65
adjusted according to customer‘s specification:
max. 160 bar 110.568-65
For more information about VPB-G progressive distributors see data sheets P0378 and
P0177. For spare parts see data sheet E9904, column "VPB-B".
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 conform-
ity with DIN VDE 1000-10 only.

GMG-B Operation manual Page 20 of 45 B0743
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.
The strainer (see figure "Strainer in the reservoir") fitted into the reservoir
bottom serves as an additional protection against reaching into the reservoir
and for the avoidance of shear spots at the stirring wing. It may be removed
for maintenance and repair purposes only.
Check the presence of the strainer every time when lubricant is refilled!
Strainer in the reservoir
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.