WOERNER GMG-LEZ User manual

GMG-LEZ Operation manual Page 1 of 37 B0840
PUMP UNIT
GMG-LEZ
Translation of the
original operation manual
Version EN 10/2017

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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 Base unit ..................................................................................................................9
3.5.3 Level monitoring (option)........................................................................................11
3.5.4 Control....................................................................................................................11
3.5.5 Electric connection of the pump unit.......................................................................12
3.5.6 Level monitoring connection...................................................................................13
3.5.7 Electric pressure switch connection........................................................................14
4. Functional description............................................................................................15
4.1 Drive.......................................................................................................................15
4.2 Delivery function.....................................................................................................15
4.3 Stirring without delivery function.............................................................................15
4.4 Pump elements.......................................................................................................16
4.4.1 GMG-LEZ Pump elements......................................................................................16
4.4.2 Relief valve.............................................................................................................16
4.5 Level control (option)..............................................................................................17
5. Safety notes.............................................................................................................18
5.1 Basic principle ........................................................................................................18
5.2 Requirements on user training................................................................................18
5.3 Safety facilities........................................................................................................18
5.4 Accident prevention................................................................................................19
5.5 Residual risks.........................................................................................................19
5.6 Incorrect applications..............................................................................................19
5.7 General safety regulations and duties.....................................................................20
5.8 Disclaimer...............................................................................................................20
6. Transportation, installation, commissioning and shutdown ...............................21
6.1 Transportation ........................................................................................................21
6.2 Unpacking ..............................................................................................................21
6.3 Installation..............................................................................................................21
6.4 Power supply and switch-on...................................................................................22
6.5 Commissioning.......................................................................................................22

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6.6 Shutdown ...............................................................................................................23
7. Operation.................................................................................................................24
7.1 Control (option).......................................................................................................24
7.1.1 Control operation....................................................................................................25
7.1.2 Changing the password..........................................................................................28
7.1.3 Error messages......................................................................................................28
7.1.4 Troubleshooting, fault remedy ................................................................................29
7.2 Refilling the reservoir..............................................................................................30
7.3 Switch-off................................................................................................................30
8. Cleaning, servicing, fault remedy, and repair .......................................................31
8.1 Cleaning.................................................................................................................31
8.2 Servicing.................................................................................................................31
8.3 Inspection schedule................................................................................................32
8.4 Repair.....................................................................................................................32
8.5 Accessories............................................................................................................33
9. Return shipment to factory ....................................................................................33
10. Disposal...................................................................................................................35
11. Appendix .................................................................................................................35
11.1 Content of the declaration of conformity..................................................................35
11.2 Declaration of conformity........................................................................................36
11.3 Control settings parameter sheet............................................................................37

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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 GMG-LEZ 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-LEZ
Pat. No. DE102011087221
European patent has been registered.
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 (e.g. GMG-LEZ)
No.<order number> (e.g. 612345/1)
Model year
2.4 Manufacturer and contact address
Eugen Woerner GmbH & Co. KG
Hafenstrasse 2
D-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/EG).
For the content of the declaration of conformity see the appendix (sub-section 11.1).

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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
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 pump unit GMG-LEZ is based on the standard GMG-L and consists of four main
assemblies:
Pump body with monitoring device and motor
Reservoir
Control
Blocks with connections for Outlets, pressure gauge and pressure switches
3.5.2 Base unit
In its basic version, the GMG-LEZ comprises the pump body with motor and a reservoir
mounted on. The technical data of this unit is as follows:
Number of pump elements max. 2
Delivery volume per stroke
per pump element 11 0.11 cm³
Admissible delivery pressure 250 bar
Temperature range -20 … +60 °C
Motor connection voltage 24 VDC

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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: St / Polyamide / Acryl
Gaskets: NBR
1 Reservoir
2 Pump element
3 Eccentric
4 Pump body
5 Gear motor
Upperpump
element row
Lower pump
element row

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Filling connector "G"
Closing nippl
Filling connector "C" 1)
Button head lubricating nipple
DIN 3404 - M22
Auxiliary for filling connector "G":
Coupling 954.002-09
(pmax = 35 bar)
Filling connector "A" 1)
Hydraulic-type lubricating nipple
DIN 71412 - AG1/4
Filling connector "G"
Closing nippl
Filling connection Hydraulic-type lubricating nipple DIN 71412
Button head lubricating nipple DIN 3404
Lock nipple
A
G1/4
C
G
1) not suitable for oil
3.5.3 Level monitoring (option)
The technical data of the (optional) level monitoring unit is as follows:
Supply voltage 24 VDC
Switching current max. 80 mA
Switching power max. 1.5 W
Temperature range -20 … +60 °C
Contact function PNP opener
When connecting inductive or capacitive loads, the relevant sup-
pressor circuits (diode, RC element, varistor) need to be provided for!
3.5.4 Control
The technical data of the (optional) control is as follows:
Power input 1.7 W
Supply voltage / target 24 VDC
Supply voltage 18 …30 VDC
Voltage at inputs 24 VDC
Response time of inputs 200 ms
Input resistance 4 kΩ
Temperature range -20 … +60 °C
Alarm output 100 mA / 24 VDC / 2 W
Filling connector:
Filling connector:

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3.5.5 Electric connection of the pump unit
The pump unit’s electric connection data is as follows:
Type of connection: Connector socket M12x1, 5-pin (8)
Version with control:
Pin 1 +24 V
2 +24 V (external release)
3 0 V
4 Alarm output / done massage
For attachment of the equipotential bonding, there is a threaded M6 (9) connector available
at the pump casing.

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Connection scheme for a version with "C" control for two rows:
For pump operation, the voltage supply must be applied. Furthermore, it is necessary to
assign Pin 2 to +24 V in "Time ON" mode. It is only then that time will elapse. In case of pulse
mode, the machine pulses have to be assigned to Pin 2.
Version without control:
Pin 1 +24 VDC (0 VDC1))
2 -
3 0 VDC (24 VDC1))
4 -
1) depending on direction of rotation
3.5.6 Level monitoring connection
Level connection:
Type of connection: Socket box M12x1, 4-pin (8.3)
Pin 1 +24 VDC
2 -
3 0 VDC
4 Level (opener)

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The electric wiring in accordance with DIN VDE 1000-10 may be done
by qualified electricians only!
3.5.7 Electric pressure switch connection
The control can be connected with up to two pressure switches.
Connection socket 8.1:
This is the connection for the monitoring of a pressure switch left adapter unit
Connection socket 8.2:
This is the connection for the monitoring of a pressure switch right adapter unit
For appropriate connecting cables please refer to "Accessories" (sub-section 8.5).
Only use connecting cables approved by WOERNER.

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4. Functional description
4.1 Drive
The GMG-LEZ pump unit is driven by a direct current gear motor (5) that is flanged to the
pump casing (4) from below.
4.2 Delivery function
When the eccentric shaft is rotating, the delivery piston of every pump element of the
respectively delivering pump element row performs a suction and delivery stroke per rotation
each whilst delivering lubricant from the reservoir to the lube points.
If the direction of rotation is changed, the relief valve opens. Because of this, the pressure of
the lubricating points is going down.
4.3 Stirring without delivery function
This function can only be used for the GMG-LEZ pump units as single conductor!
In some modes of operation, improvement of lubricant quality and delivery behaviour require
additional stirring of the lubricant.
In the GMG-LEZ pump unit, such stirring is enabled by means of a specially designed
eccentric drive.
When the eccentric shaft (3) rotates into the one direction of rotation, the pump elements are
working whilst the stirrer supplies them with lubricant.
As soon as the eccentric shaft (3) rotates in counter direction, the lubricant will be stirred
while the pump elements do not deliver. But the relief valve is triggered
The integrated control unit 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.

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4.4 Pump elements
4.4.1 GMG-LEZ Pump elements
The pump elements of the GMG-LEZ unit are hooked into the eccentric shaft.
During suction stroke, the delivery piston (2.1) is moved into the direction of the eccentric
shaft (3). In such motion, the lubricant being available in the reservoir (1) is drawn through
the suction hole (2.3) into the metering chamber (2.4).
During delivery stroke, the eccentric shaft (3) displaces 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 0.11 cm³ delivery volume pump element is marked by a green ring R, whereas the
0.04 cm³ delivery volume pump element is marked by a white ring R.
4.4.2 Relief valve
The relief valves of the GMG-LEZ unit are hooked into the eccentric shaft.
The check valve (2.5) is getting pushed by the relief piston (similar 2.1). Thereby the
pressure of the pressure line drops
Delivery stroke:
Suction stroke:
2.1
2.3
2.4 2.5
2.6

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4.5 Level control (option)
Level control "C": Minimum level monitoring for liquid grease NLGI-class 000 up to
grease NLGI-class 2
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 seconds).
Lubricant available No lubricant available
(permanent signal) (intermittent signal)
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. When the oil level falls below minimum,
the contact will open.
Level control "F"
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

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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.