Auma Gp 14.1 User manual

Multi-turn gearboxes

GP 10.1 –GP 30.1

Assembly, commissioningOperation instructions

Read operation instructions first.

●Observe safety instructions.

●These operation instructions are part of the product.

●Retain operation instructions during product life.

●Pass on instructions to any subsequent user or owner of the product.

Purpose of the document:

This document contains information for installation, commissioning, operation and maintenance staff.It is intended

to support device installation and commissioning.

Table of contents Page

41. Safety instructions................................................................................................................. 41.1. Basic information on safety 41.2. Range of application 51.3. Warnings and notes 51.4. References and symbols

72. Identification........................................................................................................................... 72.1. Name plate 82.2. Short description

93. Transport, storage and packaging........................................................................................ 93.1. Transport 93.2. Storage 93.3. Packaging

104. Assembly................................................................................................................................ 104.1. Mounting position 104.2. Handwheel fitting 104.3. Multi-turn actuators for motor operation 114.3.1. Input mounting flange: mount 124.4. Gearbox to valve:mount 124.4.1. Output drive type B 124.4.1.1. Gearbox with output drive types B: mount to valve

145. Commissioning...................................................................................................................... 145.1. Seating via multi-turn actuator

156. Servicing and maintenance................................................................................................... 156.1. Preventive measures for servicing and safe operation 156.2. Maintenance intervals 156.3. Disposal and recycling

167. Technical data......................................................................................................................... 167.1. Technical data Multi-turn gearboxes

188. Spare parts............................................................................................................................. 188.1. Multi-turn gearboxes GP 10.1 (4:1/8:1) 208.2. Multi-turn gearboxes GP 14.1 (4:1/8:1) 228.3. Multi-turn gearboxes GP 16.1 (4:1/8:1) 248.4. Drehgetriebe GP 25.1 (4:1/8:1/16:1) 268.5. Drehgetriebe GP 30.1 (4:1/8:1/16:1)

GP 10.1 –GP 30.1

Table of contents

289. Certificates.............................................................................................................................. 289.1. Declaration of Incorporation and EU Declaration of Conformity

29Index........................................................................................................................................

30Addresses...............................................................................................................................

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.This is certified in a Declaration of Incorporation and an

EU Declaration of Conformity.

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.

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 devicewarms up andincreased surface temperaturemay

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.

Maintenance To ensure safe device operation, the maintenance instructions included in this manual

must be observed.

Any device modification requires prior 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

GP 10.1 –GP 30.1

Safety instructions

●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

●Potentially explosive atmospheres

●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 could result 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 may result in minor or moderate injury. May also be used

with property damage.

Potentially hazardous situation. Failure to observe this warning may result in

property damage. Is not used for personal injury.

Arrangement and typographic structure of the warnings

Type of hazard and respective source!

Potential consequence(s) in case of non-observance (option)

→Measures to avoid the danger

→Further measure(s)

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)

Important information before the next step.This symbol indicates what is required

for the next step or what has to be prepared or observed.

GP 10.1 –GP 30.1 Safety instructions

< > Reference to other sections

Terms in brackets shown above refer to other sections of the document which provide

further information on this topic.These terms are either listed in the index, a heading

or in the table of contents and may easily be located.

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

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, we offer a service allowing authorised

users to download order-related documents such as wiring diagrams and technical

data (both in German and English), inspection certificates 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 When registered as authorised user, you may use the AUMA Support 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 the App store:

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.

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.

→Attach ropes or hooks for the purpose of lifting by hoist only to housing and NOT

to handwheel.

→Check available eyebolt for tight seat in housing (verify reach of the screw).

→Fix ropes or hooks to gearbox using available eyebolts only.

→Respect total weight of combination (gearbox, primary reduction gearing, actu-

ator).

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)

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 If the device must be stored for a long period (more than 6 months), the following

points must be observed in addition:

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.

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 5: 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.

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 3210

EN 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 6: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.

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. Gearbox to valve: mount

4.4.1. Output drive type B

Application ●For rotating, non-rising valve stem

●Not capable of withstanding thrust

Design Output drive type B with bore and keyway

[1] Gearing flange

[2] Hollow shaft with keyway

[3] Valve shaft with spring

Information Spigot at valve flanges should be loose fit.

4.4.1.1. Gearbox with output drive types B: mount to valve

Figure 7: Mounting output drive types B

[1] GP gearbox

[2] Valve

[3] Valve shaft

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

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)

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 offer extensive service such as servicing and maintenance as well as customer

product training.For the relevant contact addresses, please refer to <Addresses>

in this document or to the Internet (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.

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.

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.:

●electronic scrap

●various metals

●plastics

●greases and oils

The following generally applies:

●Greases and oils are hazardous to water and must not be released into the

environment.

●Arrange for controlled waste disposal of the disassembled material or for sep-

arate recycling according to materials.

●Observe the national regulations for waste disposal.

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

GearboxesValve WeightInput shaftMax. input

torques

Factor1)

ReductionratioGear-

boxes

Valve 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 25.140F16700 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 for actuator size definition1) Bore with keyway according to DIN 6885-12)

Possible combinations with multi-turn actuators Input mounting flange for mounting multi-

turn actuator

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)

GP 10.1 –GP 30.1

Technical data

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

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

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

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

Further information Machinery Directive: (2006/42/EC)EU Directives

GP 10.1 –GP 30.1 Technical data

8. Spare parts

8.1. Multi-turn gearboxes GP 10.1 (4:1/8:1)

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 cover002.0 Sub-assemblyHousing cover with drive shaft003.0 Sub-assemblyPlanetary gearing006.0 Sub-assemblyInput mounting flange512.0 Sub-assemblyDrive shaft534.0 Blanking plug588.1 Sub-assemblyScrew kit for manual gearbox595.0 Sub-assemblyOutput drive housing617.0 Sub-assemblyOutput drive sleeve618.0 SetSeal kitS1

GP 10.1 –GP 30.1 Spare parts