WOERNER GMZ-E User manual

Operating manual GMZ-E Page 1 of 31 B0668
PUMP UNIT
GMZ-E
Translation of the
original operation manual
Version EN 12/2018

GMZ-E Operating manual Page 2 of 31 B0668
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........................................................................................................10
3.5.1 Group of components.............................................................................................10
3.5.2 Dimensions.............................................................................................................10
3.5.3 Pump unit...............................................................................................................11
3.5.4 Level control optical/electrical.................................................................................12
4. Functional description ..................................................................................................13
4.1 Components...........................................................................................................13
4.2 Power supply..........................................................................................................13
4.3 Functioning.............................................................................................................14
4.4 Pump elements.......................................................................................................15
4.5 Level monitoring (Ultrasonic sensor).......................................................................15
4.5.1 Ultrasonic with one analogue output (A) .................................................................16
4.5.2 Ultrasonic with two switched outputs (2).................................................................17
4.6 Level control optical/electrical.................................................................................18
4.7 Level control optical................................................................................................18
5. Safety notes...................................................................................................................19
5.1 Basic principle ........................................................................................................19
5.2 Requirements on user training................................................................................19
5.3 Safety facilities........................................................................................................19
5.4 Accident prevention................................................................................................19
5.5 Residual risks.........................................................................................................20
5.6 Incorrect applications..............................................................................................20
5.7 General safety regulations and duties.....................................................................20
5.8 Disclaimer...............................................................................................................21
6. Transportation, installation, commissioning and shutdown......................................21
6.1 Transportation ........................................................................................................21
6.2 Unpacking ..............................................................................................................21
6.3 Setting-up...............................................................................................................21
6.4 Power supply and switch-on...................................................................................22
6.5 Commissioning.......................................................................................................22
6.6 Shutdown ...............................................................................................................23

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7. Operation .......................................................................................................................24
7.1 Troubleshooting, fault remedy ................................................................................24
7.2 Exchange of barrel .................................................................................................25
7.3 Switch-off................................................................................................................25
8. Cleaning, servicing, fault remedy, and repair..............................................................26
8.1 Cleaning.................................................................................................................26
8.2 Servicing.................................................................................................................26
8.3 Inspection schedule................................................................................................27
8.4 Repair.....................................................................................................................27
8.4.1 Changing the pump element...................................................................................27
8.4.2 Gear motor replacement:........................................................................................27
8.5 Spare part list .........................................................................................................28
9. Return shipment to factory...........................................................................................28
10. Disposal...................................................................................................................30
11. Appendix..................................................................................................................30
11.1 Content of the declaration of conformity..................................................................30
11.2 Declaration of conformity........................................................................................31

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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 GMZ-E pump unit. 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 multi-line pump. 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: GMZ-E
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 (GMZ-E)
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 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 180 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: -10 °C …+40 °C
Admissible delivery pressure: max. 350 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: -10 °C
Upper temperature limit: +40 °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!

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3.5 Technical data
3.5.1 Group of components
The pump unit GMZ-E consists of up to 3 groups of components which may vary, depending
on the specification of the pump:
Pump body with motor
Barrel lid (optional)
Grease follow-up plate (optional)
3.5.2 Dimensions
Pump unit for 200 l barrel Pump unit for 50 l barrel
Dimensions:
with option of barrel lid ø700 mm ø438 mm
Weight: approx. 45 kg approx. 33 kg
Inclusive of barrel lid
and follow-up plate

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3.5.3 Pump unit
The GMZ-E pump consists of the pump body with motor and optionally with a barrel lid and a
grease follow-up plate. This device has the following technical data:
Number of pump elements 1 … 15
Delivery volume per stroke 0,08 cm³
Permitted delivery pressure 350 bar
Pipe connection 6 mm, 8 mm, 10 mm
Temperature range -10 … +40 °C
Number of strokes (Standard motor and 50 Hz) 23,9 min-1
Material Housing: Aluminium
Pump element: Steel
Motor: Aluminium/Steel/Copper
Barrel lid / grease follow-up plate: Aluminium cast
Sealings: NBR
Lubricant Mineral oil >180 cP
grease NLGI-class 000 … 2
Motor:
Connection voltage with 50 Hz D/Y 220-240/380-415 V
with 60 Hz Y 440-460 V
Electric current with 50 Hz D/Y 1,21/0,7 A
with 60 Hz D/Y 1,07/0,62 A
Nominal rotation speed 1500 min-1
Performance 180 W
Protection class DIN EN 60529 IP55
(dustproof, protection against jets of water
from all sides)
Insulation class F
Pressure control (pressure switch)
Switching voltage AC max. 230 VAC
max. 5 A
induktive max. 3 A
Switching voltage DC max. 125 VDC
max. 0,4 A
induktive max. 0,05 A
Plug connection DIN EN 175301-803, shape A
Protection class DIN EN 60529 IP65
Circuit diagram:
The pressure control can’t be used as a level control. It only serves to verify, that sufficient
lubricant is conveyed to the pump elements by the delivery pump.

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3.5.4 Level control optical/electrical
Switching voltage AC max. 400 VAC
max. 6 A
Switching voltage DC max. 400 VDC
max. 3 A
Electrical connection screw connection 2x (M20x1,5)
Protection class DIN EN 60529 IP66
Switching function positively driven NC contact
When connecting inductive or capacitive loads, the relevant suppressor
circuits (diode, RC element, varistor) need to be provided for!

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4. Functional description
4.1 Components
1 Gear motor
2 Pump casing
3 Barrel lid
4 Delivery pump
5 Grease follow up plate
6 Pressure monitor (pressure switch)
7 Pump elements
8 Ring screws (for 200 l only)
9 Level control (ultrassonic sensor)
4.2 Power supply
The pump unit is driven by an electric motor. The power supply is effected by connecting the
electric motor to the voltage supply.
When connecting the motor, observe the right rotating direction: Rotating
direction of the drive shaft to the left side when looking at the fan.
Work on electric facilities may be performed by skilled electricians in
conformity with DIN VDE 1000-10 only.

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4.3 Functioning
1 Pump element
2 Vent screw G 1/4
3 Gear motor
4 Pressure monitor
5 Eccentric shaft
6 Pump casing
7 Pressure ring
8 Threaded connection G2
9 Control piston
10 Check valve
11 Delivery piston
12 Intermediate chamber
13 Pressure spring
14 Check valve
15 Delivery pump
The barrel pump consists of the
following components:
Feed pump (15), pump housing
(6), pump elements (1) and drive
motor (3). The feed pump (15) is
powered by the drive motor (3)
via the vertical eccentric shaft (5).
Phase 1
During the suction stroke the delivery piston (11) forced downward by the control piston (9) is
pressed upward again by the compression spring (13). The vacuum resulting in the
intermediate chamber (12) causes the lubricant to be drawn in via the non-return valve (14).
Phase 2
During the next half revolution of the control piston (9), the delivery piston (11) is forced
downward again and the lubricant contained in the intermediate chamber (12) is delivered in
upward direction via the nonreturn valve (10).
Phase 3
Further rotation of the control spool (9) through 180° results in a new suction stroke and the
non-return valve (10) closing at the same time enables the spring-loaded delivery piston (11)
to force the lubricant above it into the upper pump housing (6).
The pressure monitor (4) signals "barrel empty" when no more lubricant is delivered by the
feed pump (15), however there is still lubricant left in the pump housing.
The vertical eccentric shaft (5) drives a pressure ring (7) to which the pump elements (1) are
attached. Due to the eccentricity of the pressure ring (7) each delivery piston performs one
constant delivery and suction stroke per pump shaft revolution.
The pump elements (1) draw accurately metered quantities of lubricant (dependent on element
adjustment) from the lubricant reservoir in the pump housing (6).

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4.4 Pump elements
4
3
R
7
Delivery volumen
1
2
6
The suction stroke is performed by delivery piston 1and control piston 2. In this action,
delivery piston 1is actuated by the eccentric shaft, and control piston 2is actuated by the
spring. The control piston closes delivery hole 3and is retained in a certain position depending
on the delivery volume set. The delivery piston continues to move. As a result, a vacuum is
built up in the metering chamber. After opening of suction hole 4by the delivery piston,
lubricant will be drawn from the reservoir.
In delivery stroke, delivery piston 1moves to the left. In this motion, suction hole 4will be
closed and control piston 2displaced by the lubricant being available in between the delivery
piston and the control piston until it releases delivery hole 3and the lubricant is delivered by
the delivery piston to the outlet.
Pump element 8is marked by a red ring R.
Adjusting the delivery volume:
The delivery volume can be reduced to minimum of appr. 25% of the rated one.
Adjustment is to be done as follows:
Remove lock screw 7.
Adjust on adjusting nipple 7the delivery volume required by using the wrench
contained in the scope of delivery.
Turning to the right will decrease the delivery volume, whereas
turning to the left will increase it.
The adjusting nipple will latch. Here, one latch equals 1/6 rotation of the adjusting
nipple.
When leaving the factory, the pump elements are set to maximum delivery volume.
Screw down lock screw 7again.
4.5 Level monitoring (Ultrasonic sensor)
Technical data:
Operating voltage: 9 V ... 30 VDC
reverse polarity protected
No-load supply current: ≤80 mA
Class of protection: DIN EN 60529 IP67
Type of connection: M12x1, 5-pin,
Circular connector
Transducer frequency: 200 kHz
Operation
Ultrasonic sensors work maintenance free. Small amounts of dirt on the surface do not
influence function. Thick layers of dirt and cakedon dirt affect sensor function and therefore
must be removed.
Touch control

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4.5.1 Ultrasonic with one analogue output (A)
Product description:
The Ultrasonic Sensors with one analogue output measurers the distance to an object, within
the detection zone contactless. A signal proportional to distance is created according to the
adjusted window margings of the analogue characteristic curve. The sensors automatically
detects the load put to the analogue output and switches to current output or voltage output
respectively. Light emitting diodes (three-colour LEDs) indicate all operation conditions. The
Ultrasonic Sensors indicate a blind zone, in which the distance cannot be measured.
Technical data:
Current output: 4 ... 20 mA
RL ≤100 Ω at 9 V ≤UB ≤20 V
RL ≤500 Ω at UB ≥20 V
Voltage output: 0 ... 10 V
RL ≥100 kΩ at UB ≥15 V
short-circuit-proof
Measuring range from bottom edge of drum lid:
200 mm ≙20 mA
810 mm ≙4 mA
Connection diagram: Colour
1 brown
2 white
4 black
5 grey
3 blue
Pin assignment with view onto sensor plug and colour coding of the connection cable
Assembly instructions
Assemble the sensor at the installation location.
Plug in the connector cable to the M12x1 connector.
Start-up
Ultrasonic sensors are delivered factory made with the following settings:
Falling analogue characteristic
Window margins for the analogue output set to 200/810 mm
Note
The Ultrasonic sensor has internal temperature compensation. Because the sensor heat up on
their own, the temperature compensation reaches its optimum working point after approx. 30
minutes of operation.
If an object is within the set window margins of the analogue output, then LED D1 lights up
green, if the object is outside the window margins, then LED D1 lights up red.
The load put to the analogue output is detected automatically when turning supply voltage on.

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During normal mode operation, the measured distance value is displayed on the LED-indicator
in %. Scale switches automatically and is indicated by a point on top of the digits.
If no objects are placed within the detection zone the LED-indicator shows »- - -«.
4.5.2 Ultrasonic with two switched outputs (2)
Product description:
The Ultrasonic Sensors with two switched outputs measurers the distance to an objekt, within
the detection zone contactless. Depending on the adjusted detect distance the switched
outputs are set. Light emitting diodes (three-colour LEDs) indicate the switching status. The
Ultrasonic Sensors indicate a blind zone, in which the distance cannot be measured.
Technical data:
Switched output: 2 x PNP
UB -2 V
Imax = 2x200 mA
short-circuit-proof
Measuring range from bottom edge of drum lid:
Preliminary warning 750 mm
Min. 810 mm
Connection diagram: Colour
1 brown
2 white
4 black
5 grey
3 blue
Pin assignment with view onto sensor plug and colour coding of the connection cable.
Assembly instructions
Assemble the sensor at the installation location.
Plug in the connector cable to the M12x1 connector.
Start-up
Ultrasonic sensors are delivered factory made with the following settings:
Switched outputs on NC contact
Detecting distances on 750/810 mm
Note
The Ultrasonic sensor has internal temperature compensation. Because the sensor heat up on
their own, the temperature compensation reaches its optimum working point after approx. 30
minutes of operation.
During normal mode operation, a yellow LED signals that the corresponding switched output
has connected.

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4.6 Level control optical/electrical
Product description:
This version is only used for the pump unit for 200 l barrel with
grease follow-up plate The dipstick follows the level of the follow-up
plate. When the lowest level of the barrel is reached, the dipstick is
retracted completely. He actuates the position switch and breaks the
circuit.
4.7 Level control optical
Product description:
This version is only used for the pump unit for 200 l barrel with grease
follow-up plate. The dipstick follows the level of the follow-up plate.
When the lowest level of the barrel is reached, the dipstick is retracted
completely.

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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.
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.

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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.
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
uni,
the delivery of foodstuff.
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 it 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.