WOERNER PEK User manual

Operation manual PEK Page 1 of 25 B0053
Single-line pump
PEK
Translation of the
original operation manual
Version EN 03/2017

Operation manual PEK Page 2 of 25 B0053
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 clarifi-
cation 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 in-
volve the obligation to compensate damage.
All rights reserved.

Operation manual PEK Page 3 of 25 B0053
Table of contents
1. Important notes on this operation manual.....................................................................5
1.1 Users........................................................................................................................5
1.2 Obligation to read.....................................................................................................5
1.3 What to do in case of questions................................................................................5
1.4 Operation manual.....................................................................................................5
1.4.1 Applicability ..............................................................................................................5
1.4.2 Content and purpose................................................................................................5
1.4.3 Location....................................................................................................................6
1.4.4 Meanings of safety notes and safety symbols...........................................................6
2. Identification....................................................................................................................7
2.1 Product brand and type designation .........................................................................7
2.2 Product version.........................................................................................................7
2.3 Product marking .......................................................................................................7
2.4 Manufacturer and contact address............................................................................7
2.5 Conformity................................................................................................................7
3. Product description.........................................................................................................8
3.1 Purpose of use .........................................................................................................8
3.2 Limits of Use.............................................................................................................8
3.3 Ambient conditions...................................................................................................8
3.4 Conventional usage..................................................................................................9
3.5 Technical data..........................................................................................................9
3.5.1 Assemblies...............................................................................................................9
3.5.2 Dimensions.............................................................................................................10
3.5.3 Base unit ................................................................................................................10
3.5.4 Level monitoring (option)........................................................................................11
4. Functional description ..................................................................................................12
4.1 Arrangement PEK...................................................................................................12
4.2 Power supply..........................................................................................................12
4.3Functioning.............................................................................................................13
5. Safety notes...................................................................................................................14
5.1 Basic principle ........................................................................................................14
5.2 Requirements on user training................................................................................14
5.3 Safety facilities........................................................................................................15
5.4 Accident prevention................................................................................................15
5.5 Residual risks.........................................................................................................15
5.6 Incorrect applications..............................................................................................15
5.7 General safety regulations and duties.....................................................................16
5.8 Disclaimer...............................................................................................................16
6. Transportation, installation, commissioning and shutdown......................................17
6.1 Transportation ........................................................................................................17
6.2 Unpacking ..............................................................................................................17
6.3 Installation..............................................................................................................17
6.4 Power supply and switch-on...................................................................................18
6.5 Commissioning.......................................................................................................18
6.6 Shutdown ...............................................................................................................19
7. Operation .......................................................................................................................19
7.1 Refilling the reservoir..............................................................................................19
7.2 Switch-off................................................................................................................19
8. Cleaning, servicing, fault remedy, and repair..............................................................20
8.1 Cleaning.................................................................................................................20

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8.2 Servicing.................................................................................................................20
8.3 Inspection schedule................................................................................................21
8.4 Troubleshooting, fault remedy ................................................................................21
8.5 Repair.....................................................................................................................22
8.6 Spare part list .........................................................................................................22
9. Return shipment to factory...........................................................................................22
10. Disposal...................................................................................................................24
11. Appendix..................................................................................................................24
11.1 Content of the declaration of conformity..................................................................24
11.2 Declaration of conformity........................................................................................25

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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 product.
1.2 Obligation to read
As an operator and user of the product, you are obliged to read and understand this opera-
tion 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 PEK. 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 product. 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 per-
sonal 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
Single-line pump manufactured by Eugen Woerner GmbH & Co. KG
Product type: PEK
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 (PEK)
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 single-line pump 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 is designed for the delivery of lube oils as of 10cSt exclu-
sively.
3.2 Limits of use
The application area of the machine’s components is restricted as follows:
Temperature range: -10 …+60 °C
Admissible delivery pressure: max. 32 bar
Medium: Mineral oil
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 machine’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
Machine operation in an aggressive atmosphere (solvent vapours, acids,
lyes, salt water mist, etc.) may cause damage to or corrosion of compo-
nents and, thus, failure of the system and endangerment due to leaking
lubricant!
Ambient temperature range
Lower temperature limit: -10 °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 consul-
tation with the manufacturer only.

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3.4 Conventional usage
The single-line pump is exclusively designed for the delivery of lubricating oils 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, va-
pours, 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 PEK single-line pump consists of two assemblies the different PEK versions of which
may vary:
- Pump body
- Reservoir with monitoring

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3.5.2 Dimensions
The dimensions and weights of the PEK are as follows:
Wide: max. 158 mm
Depht: max. 140 mm
Hight without reservoir 109 mm
1,5 l-reservoir max. 379 mm
3,0 l-reservoir max. 519 mm
Weight: 2,8 kg
3.5.3 Base unit
In its basic version, the PEK comprises the pump body and a reservoir mounted on. The
technical data of this unit is as follows:
Delivery volume per stroke
not adjustable 10 cm³
adjustable 1 …10 cm³
Actuating pressure p23 … 10 bar
Delivery pressure p1ca. 10 x p2–8 bar
Maximum delivery pressure 32 bar
Residual pressure after pressure reduction 0,8 bar
Temperature range -10 … +60 °C
Compressed air quality acc. to ISO 554, class 5
Viscosity range 10 … 3000 cSt
Usable reservoir capacity 1,5 or 3,0 l
Material Casing Aluminium
Reservoir PVC
Gaskets FPM
Filling connection (option) Filling connection "B"

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3.5.4 Level monitoring (option)
The technical data of the (optional) level monitoring is as follows:
Switching current max. 0,5 A
Switching power max. 10/30 W/VA
Switching voltage max. 230 VUC
Type of protection DIN EN 60529 IP65
Connection diagram:
When connecting inductive or capacitive loads, the relevant suppres-
sor circuits need to be provided for! (Diode, RC element, varistor)
Minimum-control
(NC contact) 8
KFH-F-A-O
Minimum-control
(NO contact) 6
KFH-F-A-S
Minimum-maximum-control
(NO contact) 7
KFH-F-A-SS

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4. Functional description
4.1 Arrangement PEK
1 Filling connection B
2 Actuating pressure connection G 1/8
3 Reservoir PVC transparent
4 Plastic cover
5 Level switch
6 Fill strainer
7 Protective shell
8 Infinitely variable delivery control
9 Outlet G 1/8
4.2 Power supply
The PEK needs compressed air that has ISO 554 class 5 quality. This air is supplied by
means of a fixed piping. Such piping may be laid by qualified professional personnel only.
The compressed air is to be connected via compressed air connection (G 1/8).

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4.3 Functioning
A pneumatically unilaterally operated
piston delivers the oil into the delivery
pipe. Due to the spring power the piston
is reset in order to suck the oil from the
reservoir in. During the suction process
the delivery pipe’s pressure will be de-
creased down to approx. 0,8 bar. The
integrated pressure control valve opens
at 32 bar.
Attention! When air pressure is impinged suddenly, the pressure control
valve’s start-to-leak pressure may be exceeded and that pressure
will not build up in the outlet then. As a result, the delivery capac-
ity will decrease.
Adjustment of the volume flow:
The volume flow can be variably adjusted (option). To do this, turn the adjustment screw to
the right, until the desired volume flow is reached. Each revolution of the adjustment screw
reduces the volume flow rate by 0,4 cm³.
The PEK is preset to the max. volume flow when delivered.

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5. Safety notes
5.1 Basic principle
The PEK 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 PEK 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 per-
sonnel with product-specific training only.
Work on electric facilities may be performed by skilled electricians in conform-
ity with DIN VDE 1000-10 only.

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5.3 Safety facilities
Mechanically, the PEK is built intrinsically safe.
The PEK may not be operated unless the reservoir lid is closed.
5.4 Accident prevention
For accident prevention, take these measures:
Prevent unauthorised persons from accessing the pump
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 PEK properly, there are no residual risks to persons and objects in its
vicinity.
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.
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 protect-
tion, 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 en-
sured 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 unintention-
ally, WOERNER shall be held harmless thereof. Besides, all warranty claims will be rejected.
The same also applies to any and all consequential damage.

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6. Transportation, installation, commissioning and shutdown
6.1 Transportation
Transport the PEK to its destination carefully and by using suitable aids (e.g. hand-carts or
the like).
6.2 Unpacking
Lift the PEK out of its packaging carefully and put it on a stable and plane base.
Note! The PEK and the components attached in accordance with the
scope of delivery may still contain residues of blue-dyed test oil.
6.3 Installation
The pump unit is ready for wall mounting and is mounted with two M8 screws. The mounting
surface must be sufficiently stable in order to be capable of carrying the PEK´s weight inclu-
ding the filled reservoir.
The PEK must not be exposed to any atmosphere that could be capable of reacting with the
materials used for the pump.
Drill scheme:
Mount the PEK such that it cannot be exposed to unintentional impacts.
50

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6.4 Power supply and switch-on
Important! Be careful to compare the pressure of the compressed air supply
with that given under technical data.
Important! Lay all lines such that they cannot be torn off inadvertently.
Important! Connecting work may only be performed by skilled professionals.
Connect the PEK to the compressed air supply.
For driving the PEK, it is pressurised with compressed air in intervals. The delivery pressure
achievable during operation depends on the amount of the driving air pressure. The max.
operating pressure is restricted by the pressure relief valve.
For instance, the pressurisation with compressed air and the cycling of the PEK can be done
by using an external directional control valve. When relieving the compressed air connector,
be careful to bleed it completely.
Prior to commissioning, check the connections for correct fit.
6.5 Commissioning
The PEK‘s functionality has been checked in the factory. Hence, it is ready for operation.
Important! Note the safety instructions contained in the "Power supply and
switch-on" section.
First fill lubricant and then start the pump unit, in every case
(minimum filling level, see chapter 7.1).
Commissioning Procedure:
a) Filling the pump with lubricant
The PEK may be operated with clean oil!
Venting
Let the pump pulse as many times as it has to, until lubricant exits the outlet air free.
b) Connecting lube lines
The lube lines must be clean and free of any obstruction!

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Connect the outlets of the pump elements with the lube lines. Deliver into the lube lines. You
may not connect the lube lines to the lube points unless the lubricant comes out free of air.
Check all connections of the lube lines for tightness.
Warning! The applied pipelines have to be designed for an operating
pressure of 32 bar
6.6 Shutdown
The unit is shut down by switching the compressed air supply off.
7. Operation
7.1 Refilling the reservoir
The lid of the reservoir is to be used for refilling the pump.
Important! Versions without filling level monitoring require the checking of
the reservoir's filling level in regular intervals (intervals depend-
ing on consumption).
To ensure flawless functioning, the filling level must not be
lower than 10-15 mm above the reservoir’s bottom edge.
7.2 Switch-off
The PEK is switched off by disconnecting it from the compressed air supply.

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8. Cleaning, servicing, fault remedy, and repair
Note! Servicing and repair work may only be performed by technically
skilled personnel with product-specific training, basic mechani-
cal training, and professional experience.
Important! For cleaning, servicing or repair, always disconnect the unit
from the power supply and secure it against restarting.
Important! When working on the PEK, and during your absence, secure
the PEK such that no changes can be caused by other persons
or situations.
All maintenance and repair work on the electric facilities may only be
done by skilled electricians in accordance with DIN VDE 1000-10.
8.1 Cleaning
Important! The PEK must not be cleaned by means of high-pressure
cleaners or compressed air.
Important! The use of solvent containing cleaning agents may incur
damage to the reservoir.
The PEK can be cleaned with commercially available cleaning agents. Before using the
cleaning agents, be sure that they will not attack the materials used for the PEK.
8.2 Servicing
Warning! There is risk of injury, if the safety and protection elements
have to be removed, modified, bridged or bypassed for main-
tenance or servicing. Please note, in particular, the special
hazardous spots described in the "Safety regulations" section
and take effective measures to avoid injuries.
Important! Also note the maintenance instructions in the operation guide-
lines for the various components.