WOERNER GMV-C User manual

Operating manual Page 1 of 32 B0825
GMV-C
Piston pump GMV-C
Translation of the
original operation manual
Version EN 12/2018

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GMV-C
Translation
With delivery into member countries of the European Community,
this operating manual has to be translated into the user’s language.
If details of the translated operating manual do no coincide with the
original ones, then the original operating manual (German) is to be
referred to for clarification or the manufacturer to be contacted.
Copyright
This document shall neither be transferred to third parties nor
copied. Its content must neither be commercialized nor
communicated, if not explicitly allowed. Violating the before
mentioned will cause claim for indemnification.
All rights reserved.

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Contents
1. Important information on this operating manual...........................................................5
1.1 User .......................................................................................................................5
1.2 Obligation to read...................................................................................................5
1.3 Questions: What to do?..........................................................................................5
1.4 Operating manual...................................................................................................5
1.4.1 Validity ...................................................................................................................5
1.4.2 Content and purpose..............................................................................................6
1.4.3 Site of operation.....................................................................................................6
1.4.4 Meaning of the safety instructions and safety signs................................................6
2. Identification....................................................................................................................7
2.1 Product mark and type designation ........................................................................7
2.2 Product version ......................................................................................................7
2.3 Product denomination ............................................................................................7
2.4 Manufacturer and address......................................................................................7
2.5 Conformity..............................................................................................................7
3. Product description.........................................................................................................8
3.1 Use.........................................................................................................................8
3.2 Limits of application................................................................................................8
3.3 Environmental conditions .......................................................................................8
3.4 Use according to design.........................................................................................9
3.5 Technical data......................................................................................................10
3.5.1 Components.........................................................................................................10
3.5.2 Dimensions ..........................................................................................................10
3.5.3 Technical data......................................................................................................13
3.5.4 Level monitoring...................................................................................................14
4. Description of function..................................................................................................15
4.1 Drive.....................................................................................................................15
4.2 Working mode GMV-C .........................................................................................15
4.3 Level monitoring...................................................................................................16
4.3.1 For cartridge 04 / 05.............................................................................................16
4.3.2 For cartridge 40....................................................................................................16
4.3.3 For reservoir 07....................................................................................................17
4.4 Function control....................................................................................................17
5. Safety instructions ........................................................................................................17
5.1 Fundamental........................................................................................................17
5.2 Required users‘ skills ...........................................................................................17
5.3 Safety devices......................................................................................................18
5.4 Accident prevention..............................................................................................18
5.5 Residual dangers .................................................................................................18
5.6 Improper use........................................................................................................18
5.7 General safety regulations and duties ..................................................................19
5.8 Exclusion of liability..............................................................................................19
6. Transport, installation, start-up and putting out of operation....................................20
6.1 Transport..............................................................................................................20
6.2 Unpacking............................................................................................................20
6.3 Installation............................................................................................................20
6.4 Power supply and switching-on............................................................................21
6.4.1 Electric drive.........................................................................................................21
6.4.2 Pneumatic drive....................................................................................................21
6.5 Start-up................................................................................................................22

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6.5.1 Filling the unit with lubricant .................................................................................22
6.5.2 Venting of the cartridge reservoir..........................................................................24
6.5.3 Venting of the unit ................................................................................................24
6.5.4 Venting of the line feeding the lubricating point ....................................................25
6.6 Putting out of operation ........................................................................................25
7. Operating manual..........................................................................................................25
7.1 Trouble shooting, fault eradication........................................................................25
7.2 Replacing the lubricant cartridge..........................................................................26
7.3 Switching-off.........................................................................................................26
8. Cleaning, servicing, fault remedy and repair...............................................................26
8.1 Cleaning...............................................................................................................26
8.2 Maintenance.........................................................................................................27
8.3 Inspection chart....................................................................................................27
8.4 Repair ..................................................................................................................27
8.5 Spare parts...........................................................................................................27
8.6 Accessories..........................................................................................................28
9. Return to manufacturer.................................................................................................29
10. Disposal...................................................................................................................31
11. Appendix..................................................................................................................31
11.1 Content of the declaration of harmlessness..........................................................31
11.2 Declaration of Conformity.....................................................................................32

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1. Important information on this operating manual
This operating manual forms part of the machine and has to be made
available to the operating and maintenance staff at any time.
The safety instructions specified herein have to be obeyed.
If the machine is traded, the operating manual is to be included in the
shipment.
In addition to this operating manual, the current laws and regulations of
the user’s country have to be considered as well, in any case.
1.1 User
This operating manual has been written for technically qualified users, who have been
instructed or trained for the operation of this product.
1.2 Obligation to read
As owner and user of this unit, you are obliged reading and understanding this operating
manual, in particular the chapter “Safety instructions”. It is your safety that is dealt with.
In case of question and doubt, please get in contact with WOERNER.
1.3 Questions: What to do?
If questions arise, which you cannot solve with this operating manual, do not hesitate to ask
WOERNER for support. In such case, describe the problem as precisely as possible.
1.4 Operating manual
1.4.1 Validity
This operating manual fits to the series design of the unit of type GMV-C. If some sections of
the operating manual refer to some special versions, then it will be especially pointed to.

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1.4.2 Content and purpose
This operating manual delivers all the relevant information for start-up, operation and
maintenance of the unit to assist you to use the unit efficiently as well safely according to
its design and intended purpose of use.
1.4.3 Site of operation
Make the operating manual available to the users at their workplace at any time.
1.4.4 Meaning of the safety instructions and safety signs
Safety instructions
The pictograms and warning words used in safety instructions, safety rules and references
of this operating manual do mean:
Danger! Immediately threatening danger that may lead to heavy body
injuries.
Warning! Possibly dangerous situation that may lead to heavy body
injuries.
Caution! Possibly dangerous situation that may lead to slight body
injuries.
Caution! Warning of material damage.
Note! Possibly dangerous situation that may lead to possible damage
to the product or objects in its environment.
Important! Instructions for use and other useful information that facilitate
usage of the product according to its design.
Danger! Immediately threatening danger by electric current that may
lead to heavy body injuries.

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GMV-C
2. Identification
2.1 Product mark and type designation
Product of the manufacturer Eugen Woerner GmbH & Co. KG
Product type: GMV-C
2.2 Product version
Version from the year of production 2015
2.3 Product denomination
The identification plate has been attached to the side of the pump case and informs on:
Manufacturer
Type (GMV-C)
No. <order number> (for example 612345/1)
Year of production
2.4 Manufacturer and address
Eugen Woerner GmbH & Co. KG
Hafenstrasse 2
D-97877 Wertheim
Tel. [phone]
Fax [phone]
Net www.woerner.de
E-Mail [e-mail]
2.5 Conformity
The unit meets the provisions as specified in the EC-directive for machines (2006/42/EC)
Declaration of conformity, see annex (chapter 11)

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3. Product description
3.1 Use
The unit GMV-C has been exclusively designed for the supply of oil and
lubricating grease up to the NLGI-class 2.
3.2 Limits of application
The range of application of the components has been limited as follows:
Temperature range: +10 …+50 °C
According to real version, the application limits can be further restricted. The further
restrictions are pointed to later in details in this instruction manual.
In addition, the range of application of the unit is determined by the medium to be supplied.
Therefore, to finally define the range of application, consult also the technical data sheets of
the medium to be used.
3.3 Environmental conditions
Operating this unit in aggressive atmosphere (vapour of solvents, acids,
bases, salt water mist, etc.) may cause damage, respectively corrosion
of components and consequently, failure of the equipment and hazards
due to emerging lubricant!
Ambient temperature range
lower limit temperature: +10 °C
upper limit temperature: +50 °C
Relative air humidity: max. 70%
Noise level: <70 dB(A)
Physical environment
If the equipment is planned to be operated more than 1,000 m above sea level, consult the
manufacturer, in every case.

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3.4 Use according to design
The unit must be exclusively used for the supply of oil and lubricating greases in central
lubricating installations, which the following conditions have to be considered for:
Observance of the safety instructions and safety rules in this operating manual.
Compliance with the maintenance and service instructions in this operating manual.
Any other usage or any usage beyond the designed one may lead to
heavy personal and material damages.
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 hPa) 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!

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3.5 Technical data
3.5.1 Components
The unit consists of maximum 3 components, which may vary according to the real
executions:
Pump case
Drivey
Reservoir and level monitoring
3.5.2 Dimensions
1 - Outlets
2 - 3/2-way valve
3 - Compressed-air connection
4 - Function control

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Reservoir
Reservoir 04: Equipment for cartridges 400 g System Lube Shuttle
Reservoir 05: Equipment for cartridges 500 g System Reiner
Reservoir 0, connection G 1/4:

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Reservoir 40 for grease cartridges 400 g acc. to DIN 1284:
Reservoir 07 for mineral oil:

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3.5.3 Technical data
The basic design of the unit consists of the pump case with operating device and reservoir.
The device has the following technical data:
Delivery volume
per stroke and outlet
70 mm³
Number of strokes max.
40 min-1
Number of outlets
2 / 4
Control time min.
0,5 s
Break time min.
1 s
Medium
Grease up to NLGI-class 2
Mineral oil
Temperature range
+10 …+50 °C
Reservoir
Cartridge 400 g acc. to DIN 1284
Cartridge 400 g System Lube Shuttle
Cartridge 500 g System Reiner
Oil reservoir 0,7 l
Air pressure
2 …10 bar
Material
Pump case
Aluminium
Material
Seals
NBR/FPM
Acceleration max.
2 x g
Pneumatic drive:
Air pressure of the drive 2 …10 bar
Compressed air quality Grade 4
acc. to DIN ISO 8573-1
3/2-way valve:
Power rate 5 W
Relative duty factor 100% ED
Protection class DIN EN 60529 IP65
Plug connector DIN EN 175301-803, shape BI
Voltage 24 VDC

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When connecting inductive or capacitative loads, install proper
protection circuits! (Diode, RC-circuit, varistor)
Connection scheme of the individual connections
Electrical connecting diagrams
Level monitoring
Drive
3/2-way valve
Function
control
Reservoir 04/05
Reservoir 40
Reservoir 07
21
3.5.4 Level monitoring
Reservoir 04 / 05:
Voltage 10 … 30 VUC
Amperage max. 0,5 A
Protection class DIN EN 60529 IP67
Plug M8x1, 3-pin
Switching function NO contact at min
Reservoir 40:
Voltage 10 … 30 VUC
Amperage max. 0,25 A
Protection class DIN EN 60529 IP67
Plug M8x1, 3-pin
Switching function NC contact at min
Reservoir 07:
Voltage 10 … 30 VUC
Amperage max. 0,5 A
Protection class DIN EN 60529 IP65
Plug M12x1, 4-pin
Switching function NC contact at min

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4. Description of function
4.1 Drive
The unit is driven by a pneumatic piston screwed to the pump case. The piston is actuated
via a flange-mounted 3/2-directional control valve. This 3/2-directional control valve, in turn,
is energised from an external voltage supply. For that purpose, an external control is
required.
4.2 Working mode GMV-C
The piston pump consists of the pump case with supply piston, pneumatic drive unit including
3/2-directional control valve and tank.
Suction phase:
The supply and pneumatic pistons are reset by spring force. During the return stroke, the
lubricant is sucked from the tank by the generated vacuum.
Pressure phase:
When the pneumatic piston is actuated, the supply one delivers the lubricant to the outlets
through check valves.

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4.3 Level monitoring
4.3.1 For cartridge 04 / 05
A filling level control is fixed on the mounting bar of the cartridge bracket, which indicates an
"empty" message (NO contact) in case of empty supply from the tank. The filling level control
is connected by a plug M8x1, 3-pin.
The distance between filling level control and base plate has to amount to minimum 20 mm.
Increasing the distance, the residual quantity between "empty" message and final empty
supply can be varied.
4.3.2 For cartridge 40
Inside the cartridge tank, there is a filling level control built-in, which indicates an "empty"
message (NC contact). The filling level control is connected by a plug M8x1, 3-pin.
Level monitoring

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4.3.3 For reservoir 07
Inside the tank, there is a filling level switch with float, which indicates an "empty" message
(NC contact), when the minimum quantity is exceeded. Reaching the residual volume of
appr. 0,2 l, the "empty" message is released.
4.4 Function control
As a function control, an inductive proximity switch is mounted on the back side. This
proximity switch controls the piston movement continuously and reports a function failure.
Actuation of the driving piston: NO contact.
The connection is made by means of a plug connection M8x1, 3-pin.
5. Safety instructions
5.1 Fundamental
The unit is shipped from the works in faultless condition and guarantees high technical
safety.
The unit complies with the rules of technology as well as current labour safety and health
protection regulations. There is, however, danger in case of maloperation and abuse for the:
Body and life of both users and third parties,
unit or other material values of the users, and
efficient usage of the unit.
5.2 Required users‘ skills
Persons, who work with and on the unit, have to be authorised and instructed by the user
accordingly. They must be able detecting and eliminating possible danger. For that purpose,
knowledge on accident prevention rules, first-aid measures and local rescue equipment is
imperative.

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Technically skilled staff properly instructed on the product is allowed to carry-
out inspection, service and maintenance only.
Skilled electricians are the only ones allowed to intervene in electrical
installations according to DIN VDE 1000-10.
5.3 Safety devices
The unit is inherently safe due to its design.
For cartridges 04 and 05:
The unit must be operated only with the cover of the cartridge closed.
5.4 Accident prevention
Stick to these measured to prevent accidents:
Hinder unauthorised persons from access to the unit
Keep foreign persons away from dangerous areas and dangerous sites
Inform repeatedly present foreign persons on residual dangers. As for residual dangers, see
section "Residual dangers".
5.5 Residual dangers
As regards the unit itself, there are no residual dangers for persons and equipment if that unit
is used according to its design as well as intended purpose, and the specified cycles as well
as measures for maintenance and service are kept.
5.6 Improper use
If the unit is used for purposes other than specified and agreed upon, there is
danger for heavy damage to both persons and equipment.
Referring to experience, improper use may include, for example:
Supply of highly flammable or explosive media.

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Supply of media, which are able reacting with materials the unit has been made of.
Supply of foodstuff.
5.7 General safety regulations and duties
In general, using the unit the following safety regulations and duties are to be
complied with:
Consider the generally accepted rules for labour safety. This is also true,
in addition, for the current basic rules on labour safety and accident
prevention on the site of operation.
When used in vehicles, obey to the generally accepted rules and regula-
tions of the Road Code.
As user comply with the regulations for the usage of working equipment.
Operate the unit in clean and faultless state only.
Never remove, modify, bridge or neglect any protection, safety and
monitoring equipment, in no case.
Do not reconstruct or change the unit.
Report faults or damage to the owner.
Assemble original spare parts only for repair.
The user has to inspect and maintain in good condition all the protection,
safety and monitoring equipment on a regular basis.
After each repair, make sure that the unit is in faultless state and take a
test run.
5.8 Exclusion of liability
If damage to persons, equipment, environment and assets occurs due to ignoring this
operating manual regardless if intentionally or unintentionally, WOERNER shall not be held
responsible. No claim for warranty will be accepted. This is also true for any consequential
damage.

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6. Transport, installation, start-up and putting out of operation
6.1 Transport
Transport the unit cautiously to its destination. For that purpose, make use of proper
equipment.
6.2 Unpacking
Lift the unit carefully from the packaging and place the unit on a stable as well as plane
support.
Note! Consider that inside the unit and attached components according to
the bill of delivery there might be residues of blue-coloured test oil.
6.3 Installation
The unit is prepared for being mounted on wall by means of two screws M6. The mounting
area has to be that stable to absorb the weight of the unit including the filled cartridge. In
addition, make sure that the mounting surface is vertical and plane.
Drilling pattern for wall mounting:
Fixing for screws M8 or
wall mounting screws M6