AUMA GP 10.1 User manual

Multi-turn gearboxes
GP 10.1 –GP 30.1
Assembly and commissioningOperation instructions

Read 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.
Target group:
This document contains information for assembly, commissioning and maintenance staff.
Table of contents Page
31. Safety instructions................................................................................................................. 31.1. Basic information on safety 41.2. Range of application 41.3. Warnings and notes 41.4. References and symbols
52. Identification........................................................................................................................... 52.1. Name plate 62.2. Short description
73. Transport, storage and packaging........................................................................................ 73.1. Transport 83.2. Storage 83.3. Packaging
94. Assembly................................................................................................................................ 94.1. Mounting position 94.2. Handwheel fitting 94.3. Multi-turn actuators for motor operation 104.3.1. Input mounting flange: mount 114.4. Mount gearbox to valve 114.4.1. Output drive types B 114.4.1.1. Gearbox with output drive types B: mount to valve
135. Commissioning...................................................................................................................... 135.1. Seating via multi-turn actuator
146. Servicing and maintenance................................................................................................... 146.1. Preventive measures for servicing and safe operation 146.2. Maintenance intervals 146.3. Disposal and recycling
167. Technical data......................................................................................................................... 167.1. Technical data Multi-turn gearboxes
198. Spare parts............................................................................................................................. 198.1. Multi-turn gearboxes GP 10.1 –GP 14.1 (2.4:1/3:1/4:1) 218.2. Multi-turn gearboxes GP 14.1 (4:1/8:1) 238.3. Multi-turn gearboxes GP 16.1 (4:1/8:1) 258.4. Multi-turn gearboxes GP 25.1 –30.1(16:1) 278.5. Multi-turn gearboxes GP 25.1 30.1 (4:1/8:1)
31Index........................................................................................................................................
2
GP 10.1 –GP 30.1
Table of contents

1. Safety instructions
1.1. Basic information on safety
Standards/directives Our products are designed and manufactured in compliance with recognised
standards and directives.
The end user or the contractor must ensure that all legal requirements, directives,
guidelines, national regulations and recommendations with respect to assembly,
electrical connection, commissioning and operation are met at the place of installation.
Safetyinstructions/warn-
ings All personnel working with this device must be familiar with the safety and warning
instructions in this manual and observe the instructions given. Safety instructions
and warning signs on the device must be observed to avoid personal injury or property
damage.
Qualification of staff Assembly, electrical connection, commissioning, operation, and maintenance must
be carried out exclusively by suitably qualified personnel having been authorised by
the end user or contractor of the plant only.
Prior to working on this product, the staff must have thoroughly read and understood
these instructions and, furthermore, know and observe officially recognised rules
regarding occupational health and safety.
Work performed in potentially explosive atmospheres is subject to special regulations
which have to be observed.The end user or contractor of the plant are responsible
for respect and control of these regulations, standards, and laws.
Electrostatic charging Das Getriebe muss am Installationsort geerdet werden.
Highly efficient charge generating processes (processes more efficient than manual
friction) on the device surface must be excluded at any time, since they will lead to
propagating brush discharges and therefore to ignition of a potentially explosive
atmosphere.
This also applies to fireproof coatings or covers available as an option.
Ignition hazards Gearboxes were subjected to an ignition hazard assessment in compliance with the
currently applicable standard according to ISO 80079-36/ -37.Hot surfaces,
mechanically generated sparks as well as static electricity and stray electric currents
were identified and assessed as major potential ignition sources.Protective measures
to prevent the likelihood that ignition sources arise were applied to the gearboxes.
This includes in particular lubrication of the gearbox, the IP protection codes and the
warnings and notes contained in these operation instructions.
Commissioning Prior to commissioning, it is important to check that all settings meet the requirements
of the application. Incorrect settings might present a danger to the application, e.g.
cause damage to the valve or the installation.The manufacturer will not be held
liable for any consequential damage. Such risk lies entirely with the user.
Operation Prerequisites for safe and smooth operation:
●Correct transport, proper storage, mounting and installation, as well as careful
commissioning.
●Only operate the device if it is in perfect condition while observing these instruc-
tions.
●Immediately report any faults and damage and allow for corrective measures.
●Observe recognised rules for occupational health and safety.
●Observe the national regulations.
●During operation,the device warms upand increasedsurfacetemperaturemay
occur.To prevent possible burns, we recommend checking the surface temper-
ature using an appropriate thermometer and wearing protective gloves, if re-
quired, prior to working on the device.
Protective measures The end user or the contractor are responsible for implementing required protective
measures on site, such as enclosures, barriers, or personal protective equipment
for the staff.
3
GP 10.1 –GP 30.1 Safety instructions

Maintenance To ensure safe device operation, the maintenance instructions included in this manual
must be observed.
Any device modification requires prior written consent of the manufacturer.
1.2. Range of application
AUMA multi-turn gearboxes are designed for the operation of industrial valves, e.g.
gate valves and globe valves.
Other applications require explicit (written) confirmation by the manufacturer.
The following applications are not permitted, e.g.:
●Industrial trucks according to EN ISO 3691
●Lifting appliances according to EN 14502
●Passenger lifts according to DIN 15306 and 15309
●Service lifts according to EN 81-1/A1
●Escalators
●Continuous duty
●Radiation exposed areas in nuclear power plants
No liability can be assumed for inappropriate or unintended use.
Observance of these operation instructions is considered as part of the device's
designated use.
1.3. Warnings and notes
The following warnings draw special attention to safety-relevant procedures in these
operation instructions, each marked by the appropriate signal word (DANGER,
WARNING, CAUTION, NOTICE).
Indicates an imminently hazardous situation with a high level of risk. Failure
to observe this warning results in death or serious injury.
Indicates a potentially hazardous situation with a medium level of risk.Failure
to observe this warning could result in death or serious injury.
Indicates a potentially hazardous situation with a low level of risk. Failure to
observe this warning could result in minor or moderate injury. May also be
used with property damage.
Potentially hazardous situation. Failure to observe this warning could result
in property damage. Is not used for personal injury.
Safety alert symbol warns of a potential personal injury hazard.
The signal word (here: DANGER) indicates the level of hazard.
1.4. References and symbols
The following references and symbols are used in these instructions:
Information The term Information preceding the text indicates important notes and information.
Symbol for CLOSED (valve closed)
Symbol for OPEN (valve open)
➥Result of a process step
Describes the result of a preceding process step.
4
GP 10.1 –GP 30.1
Safety instructions

2. Identification
2.1. Name plate
Figure 1: Arrangement of name plates
[1] Gearbox name plate
[2] Additional plate, e.g. KKS plate (Power Plant Classification System)
Description of gearbox name plate
Figure 2: Gearbox name plate (example GP 25.1)
[1] Name of manufacturer
[2] Address of manufacturer
[3] Type designation - valve attachment (flange)
[4] Order number
[5] Serial number
[6] Reduction ratio
[7] Factor
[8] Max. valve torque (output torque)
[9] Type of lubricant
[10] Permissible ambient temperature
[11] Can be assigned as an option upon customer request
[12] Enclosure protection
[13] Data Matrix code
Type designation Figure 3:Type designation (example)
1. Type and size of gearbox
5
GP 10.1 –GP 30.1 Identification

2. Flange size for valve attachment
Type and size
These instructions apply to the following devices types and sizes:
Part-turn gearboxes type GP, sizes 10.1 –30.1
Order number The product can be identified using this number and the technical data as well as
order-related data pertaining to the device can be requested.
Please always state this number for any product inquiries.
On the Internet at http://www.auma.com > Service & Support >myAUMA, we offer
a service allowing authorised users to download order-related documents such as
wiring diagramsandtechnical data (bothin German and English),inspection certificate
and the operation instructions when entering the order number.
Serial number Table 1:
Description of the serial number (with the example of 0515MK12345)
MK123451505
Positions 1+2: Assembly in week = week 0505
Positions 3+4:Year of manufacture = 201515
Internal number for unambiguous product identificationMK12345
Reduction ratio The reduction ratio within gearing reduces the required input torques and increases
the operating time.
Factor Mechanical conversion factor for actuator size determination:
Input torque = required valve torque (output torque)/factor
Data Matrix code Whenregistered as authorised user, youmayuse ourAUMA Assistant App to scan
the Data Matrix code and directly access the order-related product documents without
having to enter order number or serial number.
Figure 4: Link to AUMA Assistant App:
For further Service & Support, Software/Apps/... refer to www.auma.com
2.2. Short description
AUMA GP multi-turn gearboxes are coaxial planetary gearings transmitting a rotary
movement to a valve.They are driven either via electric motor (by means of a
multi-turn actuator) or manually (via a handwheel).
They are typically used with stem gates, wedge gate valves, and ball valves.Due to
their compact design –the input shaft is in the extended valve shaft –this gearbox
can also be used in confined spaces, e.g. pit applications.
6
GP 10.1 –GP 30.1
Identification

3. Transport, storage and packaging
3.1. Transport
For transport to place of installation, use sturdy packaging.
Transport gearbox and actuator separately.
Hovering load!
Risk of death or serious injury!
→Do NOT stand below hovering load.
→Do NOT attach hoist with ropes or hooks to handwheel.
→Fix hoist with ropes or hooks as well as eyebolt to gearbox or wrap around the
gearbox and actuator housings.
→Respect total weight of combination.
→Lifting via eyebolt is only permissible for the net weight of the gearbox.
Figure 5: Example: Lifting the gearbox
Information Eyebolt and hoist with lifting accessories are not included in the AUMA scope of
delivery.
Table 2:
Weights
[kg]Type
6.0GP 10.1
6.0GP 14.1
19.5GP 16.1
55GP 25.1
63.5GP 30.1 (4:1/8:1)
75.5GP 30.1 (16:1)
7
GP 10.1 –GP 30.1 Transport, storage and packaging

3.2. Storage
Danger of corrosion due to inappropriate storage!
→Store in a well-ventilated, dry room (maximum humidity 70 %).
→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.
Long-term storage For long-term storage (more than 6 months), observe the following points:
1. Prior to storage:
Protect uncoated surfaces, in particular the output drive parts and mounting
surface, with long-term corrosion protection agent.
2. At an interval of approx. 6 months:
Check for corrosion.If first signs of corrosion show, apply new corrosion protec-
tion.
3.3. Packaging
Our products are protected by special packaging for transport when leaving the
factory.The packaging consists of environmentally friendly materials which can easily
be separated and recycled.We use the following packaging materials: wood,
cardboard, paper, and PE foil. For the disposal of the packaging material, we
recommend recycling and collection centres.
8
GP 10.1 –GP 30.1
Transport, storage and packaging

4. Assembly
4.1. Mounting position
The gearboxes described here can be operated without restriction in any mounting
position.
4.2. Handwheel fitting
Gearboxes designed for manual operation are supplied with a separate handwheel.
Fitting is performed on site according to the description below.
Figure 6: Handwheel
[1] Retaining ring for input shaft (partly required)
[2] Gear input shaft
[3] Spacer (partly required)
[4] Handwheel
[5] Spacer (partly required)
[6] Retaining ring
[7] Ball handle
1. For input shafts with keyway: Place retaining ring [1] onto input shaft [2].
2. If required, fit spacer [3].
3. Slip handwheel [4] onto input shaft.
4. If required, fit spacer [5].
5. Secure handwheel [4] using the retaining ring [6] supplied.
6. Fit ball handle [7] to handwheel.
4.3. Multi-turn actuators for motor operation
Refer to the operation instructions pertaining to the multi-turn actuator for indications
on how to mount multi-turn actuators to gearboxes.
This chapter supplies basic information and instructions which should be considered
in addition to the operation instructions of the multi-turn actuator.
9
GP 10.1 –GP 30.1 Assembly

4.3.1. Input mounting flange: mount
An input mounting flange is required for mounting a multi-turn actuator. Depending
on the version, the flange for mounting the multi-turn actuator is already fitted in the
factory.
Table 3:
Suitable input mounting flanges
Input mounting flange for mounting multi-turn actuatorInput shaftReduction ratioGearboxes
DIN 3210EN ISO 5210[mm]
G0F10202.4 : 1
GP 10.1 G0F10203 : 1
G0F10204 : 1
G1/2F14302.4 : 1
GP 14.1 G1/2F1420/303 : 1
G0F10204 : 1
G1/2F14304 : 1
GP 16.1 G0F10208 : 1
G1/2F14304 : 1
GP 25.1 G1/2F14308 : 1
G0F102016 : 1
G3F16404 : 1
GP 30.1 G1/2F14308 : 1
G1/2F143016 : 1
Assembly steps 1. Clean mounting faces, thoroughly degrease uncoated mounting surfaces.
Figure 7:Mounting example, input mounting flange with AUMA multi-turn actuator
[1] Gearboxes
[2] Parallel pin
[3] Input mounting flange
[4] AUMA multi-turn actuator
2. Mount parallel pin [2].
3. Place input mounting flange [3] and fasten with screws.
10
GP 10.1 –GP 30.1
Assembly

4. Fasten screws crosswise to a torque according to table.
Table 4:
Tightening torques for screws (for mounting multi-turn actuator and input mounting flange)
Tightening torque [Nm]Threads
Strength class A2-80
48M10
82M12
200M16
392M20
5. Mount AUMA actuator in compliance with the operation instructions pertaining
to the multi-turn actuator.
4.4. Mount gearbox to valve
4.4.1. Output drive types B
Figure 8: Output drive type B
[1] Gearing flange
[2] Hollow shaft with keyway
[3] Valve shaft with parallel key
Short description Output drive type B with bore and keyway
Information Spigot at valve flanges should be loose fit.
4.4.1.1. Gearbox with output drive types B: mount to valve
Figure 9: Mounting output drive types B
[1] GP gearbox
[2] Valve
[3] Valve shaft
11
GP 10.1 –GP 30.1 Assembly

1. Check if mounting flanges fit together.
2. Check, if output drive of gearbox [2] matches the output drive of valve/valve
shaft [2/3].
3. Apply a small quantity of grease to the valve shaft [3].
4. Fit gearbox [1].
Information: Ensure that the spigot fits uniformly in the recess and that the
mounting faces are in complete contact.
5. Fasten gearbox with screws.
Information: We recommend applying liquid thread sealing material to the
screws to avoid contact corrosion.
6. Fasten screws crosswise to a torque according to table.
Table 5:
Tightening torques for screws
Tightening torque Nm]Threads
Strength class A2-80
48M10
82M12
200M16
392M20
12
GP 10.1 –GP 30.1
Assembly

5. Commissioning
5.1. Seating via multi-turn actuator
This chapter supplies basic information and instructions which should be considered
in addition to the operation instructions of the multi-turn actuator.
●The valve manufacturer has to determine whether the valve is limit or torque
seated.
●End position seating must be set in compliance with the operating instructions
pertaining to the multi-turn actuator.
●For limit seating, determine overrun, i.e. how much does the valve move after
the motor has been switched off?
●When setting the torque switching within the multi-turn actuator, make sure that
the tripping torque for both directions does not exceed the max. gearbox input
torque (refer to technical data or name plate).
●Set the torque switching within the multi-turn actuator to the following value to
prevent damage to the valve:
Tripping torque = valve torque/factor (refer to name plate)
13
GP 10.1 –GP 30.1 Commissioning

6. Servicing and maintenance
Damage caused by inappropriate maintenance!
→Servicing and maintenance must be carried out exclusively by suitably qualified
personnel having been authorised by the end user or the contractor of the plant.
Therefore, we recommend contacting our service.
→Only perform servicing and maintenance tasks when the device is switched off.
AUMA
Service & Support AUMA offers extensive service such as servicing and maintenance as well as
customer product training.For the contact addresses, refer to our website
(www.auma.com).
6.1. Preventive measures for servicing and safe operation
●Before commissioning, perform visual inspection for grease leakage and paint
damage (corrosion).
●Thoroughly touch up any possible damage to paint. Original paint in small
quantities can be supplied by AUMA.
After six months and then once a year: Check gearbox for damage as well as for
grease and oil leakage.
6.2. Maintenance intervals
Recommendation for plants subject to strong vibration
●For plants subject to strong vibration, 6 months after commissioning and then
once a year: Check fastening screws between actuator and gearbox/valve for
tightness.If required, fasten screws while applying the tightening torques as
indicated in chapter <Assembly>.For screws sealed and secured with e.g.
thread sealing material, this action is not required.
Recommendation for grease change and seal replacement:
●If rarely operated (typically in buried service), the gearboxes are maintenance-
free.Grease change or re-lubrication is not necessary.
●If operated frequently (typically in modulating duty), we recommend changing
both grease and seals after 4 –6 years.
Gearing damage due to using inappropriate grease!
→Only use original lubricants supplied by AUMA.
→Do not mix lubricants.
When deployed in areas where dust formation represents a potential explosion
hazard, perform visual inspection for deposit of dirt or dust on a regular basis.Clean
devices if required.
Check gearbox for unusual running or grinding noise or vibration which might be an
indication of bearing or gear damage.
6.3. Disposal and recycling
Our devices have a long lifetime. However, they have to be replaced at one point in
time.The devices have a modular design and may, therefore, easily be separated
and sorted according to materials used, i.e.:
●Various metals
●Plastic materials
●Greases and oils
The following generally applies:
●Greases and oils are hazardous to water and must not be released into the
environment.
14
GP 10.1 –GP 30.1
Servicing and maintenance

●Arrange for controlled waste disposal of the disassembled material or for sep-
arate recycling according to materials.
●Observe the national regulations for waste disposal.
15
GP 10.1 –GP 30.1 Servicing and maintenance

7. Technical data
Information The following tables include standard and optional features.For detailed information
on the customer-specific version, refer to the order-related data sheet.The technical
data sheet can be downloaded from the Internet in both German and English at ht-
tp://www.auma.com (please state the order number).
7.1. Technical data Multi-turn gearboxes
General information
Coaxial planetary gearing for motor or manual operation of valves (e.g. gate valves and globe valves).
GearboxesValve WeightInput shaftMax. input
torques
Factor1) ReductionratioGearboxesValve attachmentMax. valve
torque
[kg][mm][Nm]
Shaft diamet-
er2)
[mm]
Flange accord-
ing to
EN ISO 5210
up to
[Nm] 6.020462.22.4 : 1
GP 10.120F10100 6.020372.73 : 1 6.020283.64 : 1 6.0301852.22.4 : 1
GP 14.130F14400 6.020/301482.73 : 1 6.0201113.64 : 1 19.5301943.64 : 1
GP 26.140F16700 19.520977.28 : 1 55303333.64 : 1
GP 25.150F251,200 55301677.28 : 1 65208314.416 : 1 63.5406943.64 : 1
GP 30.160F302,500 63.5303477.28 : 1 75.53017414.416 : 1
Conversion factor from output torque to input torque to determine the actuator size1) Bore with keyway according to DIN 6885-1.2)
Possible combinations with multi-turn actuatorsInput mounting flange for mounting multi-turn actu-
ator
Suitable AUMA multi-turn actuator1) Reduction ratioGearboxes
DIN 3210
EN ISO 5210 G0F10SA 07.62.4 : 1
GP 10.1 G0F10SA 07.63 : 1 G0F10SA 07.24 : 1 G1/2F14SA 14.22.4 : 1
GP 14.1 G1/2F14SA 14.23 : 1 G0F10SA 10.24 : 1 G1/2F14SA 14.24 : 1
GP 16.1 G0F10SA 10.28 : 1 G1/2F14SA 14.64 : 1
GP 25.1 G1/2F14SA 14.28 : 1 G0F10SA 10.216 : 1 G3F16SA 16.24 : 1
GP 30.1 G1/2F14SA 14.68 : 1 G1/2F14SA 14.616 : 1
Standard flange according to EN ISO 52101)
Features and functions
●Short-time duty S2 - 15 min (open-close duty)
●Intermittent duty S4 - 25 % (modulating duty)
Type of duty
Clockwise rotation at input shaft results in clockwise rotation at output driveDirection of rotation
Input shaft with metallic surface protection, cylindrical with parallel key according to DIN 6885-1Input shaft
●Directly via electric multi-turn actuator
●Input mounting flanges for mounting multi-turn actuators
Motor operation
16
GP 10.1 –GP 30.1
Technical data

Features and functions
Available handwheel diameters according to EN 12570, selection according to output torque:
GP 16.1GP 14.1GP 10.1Type
8:14:14:13:12.4:14:13:12.4:1Reduction ratio
20302020/303020Input shaft
250
315
500
630
800
250
315
400
315
400
500
500
630
800
250
315
400
Handwheel Ø[mm]
GP 30.1GP 25.1Type
16:18:14:116:18:14:1Reduction ratio
2020/3030203030Input shaft
250
315
400
315
400
500
500
630
800
250
315
400
500
630
800
630
800
Handwheel Ø[mm]
Manual operation
●Handwheel made of aluminium
●Handwheel with ball handle
Standard:
●Handwheel made of GJL-200
●Handwheel lockable
Option:
B3 according to EN ISO 5210 (bore with parallel keyway)Valve attachment
Service conditions
Any positionMounting position
–60 °C to +80 °CStandard:Ambient temperature
0 °C to +140 °C (up to +150 °C for a short time with reduced lifetime)Options:
IP68-8, dust and water tight up to max.8 m head of waterStandard:Enclosure protection according to
EN 60529 IP68-20, dust-tight and water-tight up to max.20 m head of waterOption:
KN:Suitable for installation in industrial units, in water or power plants with a low pollutant
concentration
Standard:Corrosion protection
KS:Suitable for use in areas with high salinity, almost permanent condensation, and high
pollution.
Options:
KX: Suitable for use in areas with extremely high salinity, permanent condensation, and
high pollution.
Two-component iron-mica combinationPaint
AUMA silver-grey (similar to RAL 7037)Standard:Colour
Available colours on requestOption:
AUMA multi-turn gearboxes meet or even exceed the lifetime requirements of EN 15714-2. Detailed in-
formation can be provided on request.
Lifetime
Cast ironHousing
Special features for use in potentially explosive atmospheres in accordance with ATEX 2014/34/EU
II 2G Ex h IIC T4 GbStandard:Explosion protection in accordance
with ATEX 2014/34/EU
EN ISO 80079-36:2016-12
EN ISO 80079-37:2016-12
Applied standards
Restricted to manual operation, no motor operation permissible.Standard:Type of duty
–30 °C to +70 °CStandard:Ambient temperature
GP 10.1 –GP 16.1: 500 cycles
GP 25.1 –GP 30.1: 250 cycles
according to EN ISO 22109: 2020
Lifetime
17
GP 10.1 –GP 30.1 Technical data

Further information
ATEX Directive: (2014/34/EU)
Machinery Directive: (2006/42/EC)
EU Directives
18
GP 10.1 –GP 30.1
Technical data

8. Spare parts
8.1. Multi-turn gearboxes GP 10.1 –GP 14.1 (2.4:1/3:1/4:1)
19
GP 10.1 –GP 30.1 Spare parts

Please state device type and our order number (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. Representation of spare parts may slightly vary
from actual delivery.
TypeDesignationRef. no. Sub-assemblyHousing cover with drive shaft003.0 Sub-assemblyPlanet carrier022.0 Internal geared wheel045.0 Sub-assemblyInput mounting flange512.0 Sub-assemblyScrew kit for manual gearbox595.0 Sub-assemblyOutput drive housing617.0 SetSeal kitS1
20
GP 10.1 –GP 30.1
Spare parts