AUMA GSTI Series User manual

Multi-turn gearbox
GSTI 25.1 – GSTI 40.1
qualified for use in nuclear power plants
(Inside and Outside Containment)
Operation instructions Assembly, operation, commissioning

Table of contents
1. Safety instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1. Range of application 3
1.2. Maintenance 3
1.3. Warnings and notes 3
2. Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
3. Transport, storage and packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.1. Transport 5
3.2. Storage 5
3.3. Packaging 5
4. Handwheel fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
5. Mounting multi-turn actuators SAI and SAN . . . . . . . . . . . . . . . . . . . . . . 6
6. Mounting to valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
7. Operation of valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
8. Enclosure protection IP 68-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
9. Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
9.1. General references 13
9.2. Change of grease 14
10. Disposal and recycling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
11. Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
12. Spare parts list spur gearboxes GSTI 25.1 – GSTI 40.1 . . . . . . . . . . . . . . . 16
13. Certificates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
13.1. Certificate of type testing 18
13.2. Declaration of incorporation 19
Index. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Addresses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
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Multi-turn gearbox GSTI 25.1 – GSTI 40.1 qualified for use in nuclear power plants
(Inside and Outside Containment) Operation instructions
Read the operation instructions first
.Observe safety instructions.
.These operation instructions are part of the product.
.Store operation instructions during product life.
.Pass on instructions to any subsequent user or owner of the product.

1. Safety instructions
1.1. Range of application
AUMA spur gearboxes GSTI 25.1 – GSTI 40.1 are used for the operation of
valves (e.g.gate valves and globe valves).
They are qualified for use in nuclear power plants inside and outside
containment. They are designed for manual operation as well as motor oper-
ation in conjunction with electric actuators.
As the case may be, deviations from the qualified versions may exist for
these products.These deviations have been discussed and agreed between
customer and manufacturer (AUMA).
Deviating versions are stipulated in the order acknowledgement and may be
enquired from AUMA stating the commission number (refer to the name
plate). Before using the product, check whether the respective service
conditions match those of the version contractually stipulated in the order
acknowledgement.
For other applications, please consult AUMA.The manufacturer is not liable
for any possible damage resulting from use in other than the designated
applications.Such risk lies entirely with the user.
Observance of these operation instructions is considered as part of the
designated use.
1.2. Maintenance
The maintenance instructions (refer to page 13) must be observed, other-
wise a safe operation of the spur gearbox is no longer guaranteed.
1.3. Warnings and notes
Failure to observe the warnings and notes may lead to serious injuries or
damage.Qualified personnel must be thoroughly familiar with all warnings
and notes in these operation instructions.
Correct transport, proper storage, mounting and installation, as well as
careful commissioning are essential to ensure a trouble-free and safe oper-
ation.
The following references draw special attention to safety-relevant proce-
dures in these operation instructions.Each is marked by the appropriate
pictograph.
This pictograph means: Note!
“Note” marks activities or procedures which have major influence on the
correct operation.Non-observance of these notes may lead to consequen-
tial damage.
This pictograph means: Warning!
“Warning” marks activities or procedures which, if not carried out correctly,
can affect the safety of persons or material.
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Multi-turn gearbox GSTI 25.1 – GSTI 40.1 qualified for use in nuclear power plants
Operation instructions (Inside and Outside Containment)

2. Technical data
Qualification
According to IEEE 382-1996.
Application
For motor operation or manual operation of valves (e.g. gate valves and globe valves) in nuclear power plants for inside and
outside containment in compliance with IEEE 381-1996
Features and functions
Type of duty Open-close duty: Short-time duty S2 - 15 min.
Restriction for GSTI 40.1 max. input speed ≤90 rpm
Direction of rotation Clockwise rotation at input shaft results in clockwise rotation at output shaft
Stages Double stage
Input shaft GSTI 25.1 – GSTI 40.1: For standard reduction ratios, the input shaft is made of stainless steel.
Exception: GSTI 40.1 22 : 1 and 16 : 1
Standard: Cylindrical with parallel key according to DIN 6885.1
Output torques
Operation
Motor operation Directly via electric multi-turn actuator
Flanges for mounting the multi-turn actuator, also refer to separate Technical data sheets.
Manual operation Directly via handwheel (not qualified)
Valve attachment
Mounting position Any position
Output drive types A, B1, B2, B3, B4 according to EN ISO 5210
A, B, E according to DIN 3210
Special output drive: AF
Service conditions
Enclosure protection EN 60529 IP 68-6 dust and water tight up to max. 6 m head of water.
Type-tested with 5.0 bar overpressure (with air) (also refer to page 12)
Corrosion protection KI, aluminium-free version in combination with multi-turn actuator SAI (Inside Containment)
and in combination with multi-turn actuator SAN (Outside Containment)
Finish coating Decontaminable
Colour Standard: Silver-grey (RAL 7001)
Option: Other colours are possible on request
Ambient temperature Standard: –25 °C to +80 °C,
DBE conditions for a short time up to +185 °C
Lifetime Open-close duty: 5,000 operating cycles with load profile accroding to KTA 3504-9/88
Further information
Reference documents Product description Spur gearboxes GSTI 25.1 – GSTI 40.1
Dimensions GSTI 25.1 – GSTI 40.1
Technical data GSTI 25.1 – GSTI 40.1
Technical data SAI/SAN
Drawings indicating centre of gravity GSTI3)
1) At max. output torque
2) Conversion factor for output torque to input torque
3) Note the permissible actuator weight and the centre of gravity of the actuator-gearbox combination.
For actuators by other manufacturers, please contact AUMA.
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Multi-turn gearbox GSTI 25.1 – GSTI 40.1 qualified for use in nuclear power plants
(Inside and Outside Containment) Operation instructions
Type Output torque Reduction ratio Input torque1) Factor2)
max. Nm Nm
GSTI 25.1 2,000 4 : 1 556 3.6
5.6 : 1 397 5.0
8 : 1 278 7.2
GSTI 30.1 4,000 5.6 : 1 794 5.0
8 : 1 556 7.2
11 : 1 404 9.9
GSTI 35.1 8,000 8 : 1 1,111 7.2
11 : 1 808 9.9
16 : 1 556 14.4
GSTI 40.1 16,000 11 : 1 1,616 9.9
16 : 1 1,111 14.4
22 : 1 808 19.8
Type GSTI 25.1 GSTI 30.1 GSTI 35.1 GSTI 40.1
Handwheelmm 500 500 500 500

3. Transport, storage and packaging
3.1. Transport .Transport to place of installation in sturdy packing.
.If mounted together with actuator:
Attach ropes or hooks for the purpose of lifting by hoist only to the
gearbox and not to the actuator.
3.2. Storage .Store in well-ventilated, dry room.
.Protect against floor dampness by storage on a shelf or on a
wooden pallet.
.Cover to protect against dust and dirt.
.Apply suitable corrosion protection agent to uncoated surfaces.
In case gearboxes are to be stored for a long period (more than 6 months),
the following points must be observed additionally:
.Prior to storage: Protect uncoated surfaces, in particular the output drive
parts and mounting surface, with long-term corrosion protection agent.
.Check for corrosion approximately every 6 months. If first signs of corro-
sion show, apply new corrosion protection.
3.3. Packaging
Our products are protected by special packaging for the transport ex works.
The packaging consists of environmentally friendly materials which can
easily be separated and recycled.
For the disposal of the packaging material, we recommend recycling and
collection centres.
We use the following packaging materials:
Wooden material boards (OSB)/cardboard/paper/PE film
4. Handwheel fitting
For gearboxes designed for manual operation, the handwheel is supplied
separately.Fitting is done on site according to figure 1.
The handwheel has not been submitted to any seismic test and is therefore
not qualified according to IEEE.
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Multi-turn gearbox GSTI 25.1 – GSTI 40.1 qualified for use in nuclear power plants
Operation instructions (Inside and Outside Containment)
Figure 1: Handwheel Ball handle
(option)
Spacer
(partly required)
Circlip
Handwheel
Gearbox worm shaft
Circlip
Spacer
(partly required)

5. Mounting multi-turn actuators SAI and SAN
Mounting multi-turn actuators to gearboxes is described in the operation
instructions pertaining to the multi-turn actuator.
Mounting the multi-turn actuator:
.Thoroughly degrease the faces of the bearing flange at actuator and of the
input flange at spur gearbox.
.Place the multi-turn actuator on the spur gearbox.
.Ensure that the spigot mates uniformly in the recess and that the mounting
faces are in complete contact.
.Fasten actuator with screws and lock washers (see table 1) at the flange
of the spur gearbox.
.Fasten screws crosswise with a torque according to table 2.
Do not attach ropes or hooks for the purpose of lifting the
actuator by hoist to the handwheel. If multi-turn actuator is
mounted on gearbox, attach ropes or hooks for the purpose
of lifting by hoist to gearbox and not to multi-turn actuator.
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Multi-turn gearbox GSTI 25.1 – GSTI 40.1 qualified for use in nuclear power plants
(Inside and Outside Containment) Operation instructions
Figure 2: Mounting multi-turn actuators onto spur gearboxes
Input flange
Bearing flange
Gearboxes SAI 50-F14/G1/2
SAN 14.5-F14/G1/2
SAI 100-F16/G3
SAN 16.1-F16/G3
SAN 25.1-F25/G4
Screw Pcs. Screw Pcs. Screw Pcs.
GSTI 25.1 M16 x 40 4 – –
GSTI 30.1 M16 x 40 4 M20 x 50 4 –
GSTI 35.1 M16 x 40 4 M20 x 50 4 –
GSTI 40.1 – M20 x 50 4 M 16 x 50 8
Table 1: Screws for mounting AUMA multi-turn actuators onto spur gearboxes

Screws for actuator
For mounting AUMA devices, screws are supplied together with the gear-
boxes. When mounting other devices, the screws might be either too long or
too short (insufficient reach of screw).
Danger of falling devices due to fracturing when using inap-
propriate screws.
Death or serious injury possible!
Check length of screws.
The depth of screws must be sufficient for the internal threads to ensure the
supporting strength of the device and to adopt the lateral forces due to the
applied torque.
Screws which are too long could make contact with the housing parts.This
causes a risk that the device could shift radially with respect to the gearbox.
This can lead to shearing off the screws.
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Multi-turn gearbox GSTI 25.1 – GSTI 40.1 qualified for use in nuclear power plants
Operation instructions (Inside and Outside Containment)

6. Mounting to valve
The gearboxes can be operated in any mounting position.
.Prior to mounting, the gearbox must be checked for dam-
age. Damaged parts must be replaced by original spare
parts.
.After mounting to valve, touch up any possible damage to
paint finish.
Mount gearbox to valve (with output drive types B1 – B4 or E)
.Check whether mounting flanges match.
.Check whether bore and keyway match the input shaft of the valve.
.Apply a small quantity of grease to input shaft of valve..
.Fit gearbox.
Information: Ensure that the spigot fits uniformly in the recess and
that the mounting faces are in complete contact
.Fasten with screws of minimum quality 8.8 according to table 2.
Information: We recommend applying liquid thread sealing material to
the screws to avoid contact corrosion.
.Fasten screws crosswise to a torque according to table 2.
Anschlussform A
Anwendung:
.Anschlussform für steigende, nicht drehende Spindel
.Zur Aufnahme von Schubkräften geeignet
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Multi-turn gearbox GSTI 25.1 – GSTI 40.1 qualified for use in nuclear power plants
(Inside and Outside Containment) Operation instructions
Figure 3
Output drive type B1/B2
Plug sleeve Output drive type B3/B4
Bore with keyway
Screws Fastening torque TA[Nm]
Thread Strength class
8.8 A2-80/A4-80 10.9
M16 214 200 314
M20 431 392 615
M30 1,489 – 2,121
M36 2,594 – 3,695
Table 2: Fastening torques for screws

Output drive type A
Application:
.Output drive for rising, non-rotating valve stem
.Suitable for accepting thrust
Finish machining of stem nut
This working stop is only required if stem nut is supplied unbored or with pilot bore.
The output drive flange does not have to be removed from the gearbox.
.Remove spigot ring (80.2, figure ) from output drive.
.Remove stem nut (80.3) together with bearings (80.01 and 80.02).
.Remove bearing races (80.02) and bearing rims (80.01) from stem nut (80.3).
.Bore and drill stem nut (80.03) and cut thread.
Information: When fixing in the chuck, make sure stem nut runs true!
.Clean the machined stem nut (80.3).
.Apply sufficient Lithium soap EP multi-purpose grease to bearing rims
(80.01) and bearing races (80.02) ensuring that all hollow spaces are
filled with grease.
.Place greased bearing rims (80.1) and bearing races (80.02) on stem nut (80.3).
.Re-insert stem nut (80.3) with bearings (80.01 and 80.02) into output drive.
Information: Ensure that dogs or splines are placed correctly in the
keyway of the hollow shaft.
.Screw in spigot ring (80.2) until it is firm against the shoulder.
Mount gearbox (with output drive type A) to valve
[1] Valve stem
[2] Output drive type A
[3] Screws to actuator
[4] Valve flange
[5] Screws to output drive
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Multi-turn gearbox GSTI 25.1 – GSTI 40.1 qualified for use in nuclear power plants
Operation instructions (Inside and Outside Containment)
Figure 4
80.3
80.2
Output drive type A
Stem nut
80.01/80.02
Figure 5

.If the output drive type A is already mounted to the gearbox: Loosen
screws [3] and remove output drive type A [2].
.Check if the flange of output drive type A matches the valve flange [4].
.Apply a small quantity of grease to the valve stem [1].
.Place output drive type A on the valve stem and turn until it is flush on the
valve flange.
.Turn output drive type A until alignment of the fixing holes.
.Screw in fastening screws [5], however do not completely tighten.
.Fit gearbox on the valve stem so that the stem nut dogs engage into the
output socket.
The flanges are flush with each other if properly engaged.
.Adjust gearbox until alignment of the fixing holes.
.Fasten gearbox with screws [3].
.Fasten screws [3] crosswise with a torque according to table 2.
.Turn gearbox and actuator with handwheel in direction OPEN until valve
flange and output drive type A are firmly placed together.
.Tighten fastening screws [5] between valve and output drive type A
crosswise applying a torque according to table 2.
Protection tube for rising valve stem
.Seal thread of protection tube with hemp, Teflon tape, or thread sealing
material.
.Screw protection tube (1) into thread (figure 6) and tighten it firmly.
.Push down the sealing (2) to the housing.
.Check whether cap (3) is available and without damage.
.
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Multi-turn gearbox GSTI 25.1 – GSTI 40.1 qualified for use in nuclear power plants
(Inside and Outside Containment) Operation instructions
3
1
2
Figure 6: Protection tube for rising valve stem

7. Operation of valves
The max. output torque (refer to technical data, page 4 or name plate) refers
to the peak values and should not be applied over the whole travel.
Clockwise rotation at input shaft results in clockwise rotation at output drive
For motor operation:
.Observe operation instructions pertaining to multi-turn actuator.
.The setting of the torque switching within the multi-turn actuator may not
exceed the max. permissible input torque for both directions (refer to tech-
nical data, page 4, or name plate).
.Set the torque switching within the multi-turn actuator to the following
value to prevent any damage to the valve:
TValve
TTorque switch =Factor
Factor = Conversion factor from output torque to input torque.
Refer to values in technical data, page 4.
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Multi-turn gearbox GSTI 25.1 – GSTI 40.1 qualified for use in nuclear power plants
Operation instructions (Inside and Outside Containment)

8. Enclosure protection IP 68-6
Definition
According to DIN EN 60529, the conditions for meeting the requirements of
enclosure protection IP 68 are to be agreed between manufacturer and
user.
AUMA gearboxes in enclosure protection IP 68-6 fulfil the following require-
ments in compliance with AUMA definitions:
.Head of water max.6 m
Inspection
AUMA gearboxes in enclosure protection IP 68-6 undergo a routine testing
for tightness in the factory.
After submersion
.Check gearbox.
.In case of ingress of water, dry gearbox correctly and check for proper
function.
Notes
When using output drive types A and AF (stem nut), it cannot be prevented
that water enters the hollow shaft along the valve stem during submersion.
This leads to corrosion. The water also enters the thrust bearings of output
drive type A, causing corrosion and damage to the bearings. The output
drive types A and AF should therefore not be used during submersion.
Use suitable sealing material between valve flange and gearbox.
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Multi-turn gearbox GSTI 25.1 – GSTI 40.1 qualified for use in nuclear power plants
(Inside and Outside Containment) Operation instructions

9. Maintenance
9.1. General references
After commissioning, check gearbox for damage to paint finish.
Do a thorough touch-up to prevent corrosion.
Original paint in small quantities can be supplied by AUMA.
AUMA gearboxes require only very little maintenance.
To ensure that the gearbox is always ready to operate, we recommend -
provided that on an average not more than 10 operations are performed per
year - the following measures:
.Approximately six months after commissioning and then every year check
screws between multi-turn actuator, gearbox, and valve for tightness.If
required, tighten applying the torques given in table 2 (page 8).
.Perform a test run as well as a visual inspection for grease leakage every
six months.
.Carry out a detailed functional test for each gearbox every 5 years.
Record the results for future reference.
.For gearboxes permanently exposed to ambient temperatures above
40 °C, maintenance must be performed at shorter intervals.
.For gearboxes with output drive type A: at intervals of approx. 6 months
from commissioning, press in Lithium soap EP multi-purpose grease on
mineral oil base at the grease nipple with grease gun.
Seals:
The seals must be changed when changing the grease.
Seal kits may be obtained from AUMA.
Grease:
A grease and seal change is recommended after the following operation
times:
.if operated seldom, after 10 – 12 years
.if operated frequently, after 6 – 8 years
.Only original AUMA grease must be used.
.For the grease type, refer to the name plate: Standard F4
.Lubricants should not be mixed.
The removed lubricant and the cleaning agent used must be
disposed of according to the relevant regulations.
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Multi-turn gearbox GSTI 25.1 – GSTI 40.1 qualified for use in nuclear power plants
Operation instructions (Inside and Outside Containment)
GSTI 25.1 30.1 35.1 40.1
Qty dm³ 6.3 12.1 22.0 27.0
Weight1) kg 5.7 11.0 20.0 24.3
1) for ρ= approx. 0.9 kg/dm3
Table 3: Grease quantities for spur gearboxes

9.2. Change of grease .For gearboxes with multi-turn actuator: Remove multi-turn actuator.
.Remove gearbox from the valve:
During this time, the valve/pipeline must not be under pres-
sure!
.Mark position of the gearbox on the valve, loosen connecting screws to
the valve and remove the gearbox.
Remove old grease:
Grease type, see name plate; grease quantities, see page 13, table 3.
The numbers used in the following text refer to the spare parts list(s) of
these operation instructions.
.Remove screws at mounting flange (002.0).
.Remove mounting flange assembly with hollow shaft (003.0) from the
housing.
.Remove old grease completely from the housing and the individual parts
and clean gear housing. For this purpose, kerosene or a similar cleaning
agent may be used.
.Replace seals S1 (005, 008, 009) by new ones.
.Clean mounting faces at housing and bearing flange and apply a small
quantity of grease.
.Mount bearing flange (002.0) with hollow shaft (003.0) into housing, whilst
paying attention to the O-ring S1 (008) at the bearing flange.
Screw in screws and fasten them evenly crosswise to the appropriate
torque according to table 2, page 8.
Fill with new grease:
.Remove screws at bearing flange of the input shaft (010.0-1 or 010.0-2).
.Remove bearing flange.
.Fill with new grease.
.Clean mounting faces at housing and bearing flange and apply a small
quantity of grease.
.Fit bearing flange (010.0-1 or 010.0-2) with new O-ring S1 (006). Screw in
screws and fasten them evenly crosswise to the appropriate torque
according to table 2, page 8.
After maintenance:
.Fasten again gearbox to valve.
.If applicable, mount multi-turn actuator.
.For gearboxes with multi-turn actuator, check the setting of the limit
switching according to the operation instructions for multi-turn actuators; if
required, re-set.
.Perform test run to ensure the proper function.
.Check the gearbox for damage to paint finish. Do a thorough touch-up to
prevent corrosion.Original paint in small quantities can be supplied by
AUMA.
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Multi-turn gearbox GSTI 25.1 – GSTI 40.1 qualified for use in nuclear power plants
(Inside and Outside Containment) Operation instructions

10. Disposal and recycling
AUMA gearboxes have an extremely long lifetime.However, they have to be
replaced at one point in time.
Our gearboxes have a modular design and may therefore easily be disas-
sembled, separated and sorted according to materials, i.e.:
.various metals
.plastics
.greases and oils
The following generally applies:
.Collect greases and oils during disassembly.As a rule, these substances
are hazardous to water and must not be released into the environment.
.Arrange for controlled waste disposal of the disassembled material or for
separate recycling according to materials.
.Observe the national regulations for waste disposal.
11. Service
AUMA offers extensive services such as maintenance and inspection for
gearboxes. Addresses of AUMA offices and representatives can be found on
page and on the Internet (www.auma.com).
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Multi-turn gearbox GSTI 25.1 – GSTI 40.1 qualified for use in nuclear power plants
Operation instructions (Inside and Outside Containment)

12. Spare parts list spur gearboxes GSTI 25.1 – GSTI 40.1
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Multi-turn gearbox GSTI 25.1 – GSTI 40.1 qualified for use in nuclear power plants
(Inside and Outside Containment) Operation instructions

001.0 Housing Sub-assembly
002.0 Ring nut Sub-assembly
003.0 Hollow shaft Sub-assembly
004.0 Intermediate stage Sub-assembly
004.1 Intermediate wheel
005.0 Input shaft Sub-assembly
010.0-1 Input shaft bearing flange Sub-assembly
010.0-2 Input shaft bearing flange with protection cover Sub-assembly
511.0 Screw plug Sub-assembly
512.0 Flange for actuator Sub-assembly
513.1 Grub screw
514.0 Output drive form A (without stem nut) Sub-assembly
514.1 Axial needle roller bearing, from GSTI 30.1 as a single part, axial cylinder roller bearing Sub-assembly
535.1 Snap ring
549.1 Output socket B3/B4/E
551.1 Parallel key
568.1 Stem protection tube
568.2 Cap for stem protection tube
568.3 V-seal
574.1 Radial seal output drive A for ISO flange
575.1 Stem nut type A
S1 Seal kit Set
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Multi-turn gearbox GSTI 25.1 – GSTI 40.1 qualified for use in nuclear power plants
Operation instructions (Inside and Outside Containment)
Note:
Please state type and commission no. of the device (see name plate) when ordering spare parts. Only original AUMA
spare parts should be used. Failure to use original spare parts voids the warranty and exempts AUMA from any
liability. Delivered spare parts may slightly vary from the representation.
No. Designation Type

13. Certificates
13.1. Certificate of type testing
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Multi-turn gearbox GSTI 25.1 – GSTI 40.1 qualified for use in nuclear power plants
(Inside and Outside Containment) Operation instructions

13.2. Declaration of incorporation
19
Multi-turn gearbox GSTI 25.1 – GSTI 40.1 qualified for use in nuclear power plants
Operation instructions (Inside and Outside Containment)

Notes
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Multi-turn gearbox GSTI 25.1 – GSTI 40.1 qualified for use in nuclear power plants
(Inside and Outside Containment) Operation instructions