AUMA GS 50.3 - 250.3 User Manual
Part-turn gearboxes
Worm gearboxes
GS 50.3 – GS 250.3
for flange types FA
Operation instructions
Worm gearboxes GS 50.3 – GS 250.3 Operation instructions
Scope of these instructions:
These operation instructions are valid for worm gearboxes of the type range
GS 50.3 – GS 125.3 with primary reduction gearings VZ 2.3 – VZ 4.3. and GS
160.3 – GS 250.3 with primary reduction gearings GZ 160.3 – GZ 250.3.
Table of contents Page
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 7
3.1 Transport 7
3.2 Storage 7
3.3 Packaging 7
4. Fitting the handwheel 7
5. Mounting positions of the different versions 8
6. Mounting multi-turn actuators SA/SAR 9
7. Mounting to valve 11
8. Setting the end stops for manual operation 12
8.1 Worm gearboxes on butterfly valves 12
8.2 Worm gearboxes on ball valves 13
9. Setting the end stops with mounted multi-turn electric actuator 13
9.1 Worm gearboxes on butterfly valves 13
9.2 Worm gearboxes on ball valves 14
10. Changing the swing angle 16
10.1 Changing the swing angle for sizes GS 50.3 – GS 125.3 (option)16
10.2 Changing the swing angle for sizes GS 160.3 – GS 250.3 17
11. Enclosure protection IP 68 18
12. Maintenance 19
12.1 General notes 19
12.2 Grease change for worm gearboxes GS 50.3 – GS 125.3 and primary reduction gearing
VZ 2.3 – VZ 4.3 20
12.2.1 Worm gearboxes 20
12.2.2 Primary reduction gearing 20
12.3 Grease change for worm gearboxes GS 160.3 – GS 250.3 and primary reduction gearing
GZ 160.3 – GZ 250.3 21
12.3.1 Worm gearboxes 21
12.3.2 Single-stage reductions gearings GZ 160.3 – GZ 250.3 (reduction ratios 4:1 and 8:1) 21
12.3.3 Double-stage primary reduction gearing GZ 200.3 – GZ 250.3 (reduction ratio 16:1) 22
12.4 After maintenance 22
13. Disposal and recycling 23
14. Service 23
15. Spare parts list worm gearboxes GS 50.3 – GS 125.3 and reduction gearing
VZ 2.3 – VZ 4.3 24
16. Spare parts list worm gearboxes GS 160.3 – GS 250.3 26
17. Spare parts list reduction gearings GZ 160.3 – GZ 250.3 (reduction ratios 4:1, 8:1 and 16:1) 28
Index 31
Addresses of AUMA offices and representatives 32
2
Operation instructions Worm gearboxes GS 50.3 – GS 250.3
1. Safety instructions
1.1 Range of application AUMA worm gearboxes GS 50.3 – GS 250.3 are used for the operation of valves
(e.g. butterfly valves and ball valves).
They are designed for manual operation as well as motor operation in conjunction
with electric actuators.
For other applications, please consult us. 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 gearboxes’
designated use.
1.2 Maintenance The maintenance instructions (refer to page 19) must be observed, otherwise a
safe operation of the worm gearbox is no longer guaranteed.
1.3 Warnings and notes Non-observance of 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 operation.
The following references draw special attention to safety-relevant procedures 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 consequential damage.
This pictograph means: Warning!
“Warning” marks activities or procedures which, if not carried out correctly, can
affect the safety of persons or material.
3
Worm gearboxes GS 50.3 – GS 250.3 Operation instructions
2. Technical data
Features and functions
Version Standard: clockwise rotation RR, counterclockwise rotation LL, option: RL or LR
Housing material Standard: cast iron (GJL-250), Option: spheroidal cast iron (GJS-400-15)
Self-locking The gearboxes are self-locking when at stand-still under normal service conditions; strong
Output torques
End stops Positive for both end positions by traveling nut, sensitive adjustment
Strength of end stop Guaranteed strength of end stop (in ft lbs.) for input side operation
Swing angle
GS 50.3 – GS 125.3
Swing angle
GS 160.3 – GS 250.3
Mechanical position indicator Standard: Pointer cover for continuous position indication
Input shaft Cylindrical with parallel key according to DIN 6885.1
Operation
Motor operation With electric multi-turn actuator, directly or through primary reduction gearing VZ/GZ
Type of duty According to actuator
Manual operation
1) With worm wheel made of spheroidal cast iron
2) Requires worm wheel made of bronze
3) Special sizing is required
4) For gas applications with sealed pointer cover, an air vent in the pointer cover or venting grooves in the valve mounting flange must be provided
5) Handwheel sizes shown reflect general industrial selection criteria. For information on gearbox/handwheel selection in accordance with AWWA Standard C504, please
refer to separate selection list/chart.
5)
vibrations may cancel the self-locking effect. While in motion, safe breaking is not guaranteed. If
this is required, a separate brake must be used.
Type Output torques
100 % 140 % 175 %
max. ft lbs. max. ft lbs. max. ft lbs. max. ft lbs. max. ft lbs.
GS 50.3
GS 63.3
GS 80.3
GS 100.3
GS 125.3
GS 160.3
GS 200.3
GS 250.3
Type
Reduction gearing – – – VZ 2.3 VZ 3.3 VZ 4.3 VZ 2.3 VZ 3.3 VZ 4.3
ft lbs. 185 330 330 370 185 370 185
Type
Reduction gearing GZ 160.3 GZ 200.3 GZ 250.3
Reduction ratio 4:1 8:1 4:1 8:1 16:1 4:1 8:1 16:1
ft lbs. 370 330 370 370
184 258 – 369 92
369 516 – 738 184
738 1,033 – 1,475 369
1,475 2,065 – 2,950 738
2,950 4,130 – 5,900 1,475
5,900 8,298 10,326 – 2,950
11,801 16,595 20,652 – 5,900
23,602 32,822 41,303 – 16,000
GS 50.3 GS 63.3 GS 80.3 GS 100.3 GS 125.3
GS 160.3 GS 200.3 GS 250.3
1)
200 %
1)
Modulating torque
2)
Standard: Fixed swing angle up to max. 100°; set in the factory to 92° unless ordered otherwise.
Options: Adjustable in steps of:
10°– 35°, 35° – 60°, 60° – 80°, 80° – 100°, 100° – 125°, 125° – 150°,
150° – 170°, 170° – 190°
For version with worm wheel made of bronze: swing angle > 190°,
Multi-turn version without end stops, version GSD
3)
Standard: Adjustable 80° – 100°; set in the factory to 92° unless ordered otherwise.
Options: Adjustable in steps of: 20° – 40°, 40° – 60°, 60° – 80°,
‘ Multi-turn version without end stops, version GSD
For version with worm wheel made of bronze: swing angle
3)
Options: Sealed pointer cover for horizontal outdoor installation
> 100°,
4)
Protection cover for buried service instead of pointer cover
Flanges for mounting of actuator, refer also to separate technical data sheets.
Via handwheel, directly or through primary reduction gearing VZ/GZ
Available handwheel diameters, selection according to the max. output torque:
Type
Reduction gearing – – – – VZ 2.3 VZ 3.3 VZ 4.3 – VZ 2.3 VZ 3.3 VZ 4.3
Handwheel Ø
mm
Type
Reduction gearing – GZ 160.3 – GZ 200.3 – GZ 250.3
Handwheel Ø
mm
GS 50.3 GS 63.3 GS 80.3 GS 100.3 GS 125.3
160
200
250
630
800
250
315
GS 160.3 GS 200.3 GS 250.3
400 315 – 500
315
400
400
500
315
315
400
630
250
400
315
400 315 – 800
500
630
800
400
500
400
500
500
630
315
400
400
25.4 mm correspond to 1 inch
4
Operation instructions Worm gearboxes GS 50.3 – GS 250.3
Primary reduction gearing
Primary reduction gearing Planetary gear with various reduction ratios for reducing the input torques
Valve attachment
Valve attachment Dimensions according to SP 101
Standard: GS 50.3 – GS 125.3: without spigot
Options: GS 50.3 – GS 125.3: with spigot
Splined coupling for connection
Standard: without bore or pilot bore from GS 160.3
to the valve shaft
Options: Machined with bore and keyway, square bore or bore with two-flats
Service conditions
Enclosure protection according
to EN 60 529
6)
Standard: IP 68-3, dust and water tight up to max. 3 m head of water
Options
Corrosion protection Standard: KN Suitable for installation in industrial units, in water or power plants
Options: KS Suitable for installation in occasionally or permanently aggressive
Paint Standard: GS 50.3 – GS 125.3: Two-component iron-mica combination
Color Standard: Grey (DB 702, similar to RAL 9007)
Option: Other colors on request
Ambient temperature Standard: – 20 °F to + 175 °F/ – 25 °C to + 80 °C
Options: – 40 °F to + 140 °F/ – 40 °C to + 60 °C (low temperature), version L
Lifetime Open-close duty: The lifetime is based on a load profile typical for part-turn valves
GS 160.3 – GS 250.3: without spigot
GS 160.3 – GS 250.3: with spigot
Worm gearbox can be repositioned 4 x 90° on coupling
7)
: IP 68-6, dust and water tight up to max. 6 m head of water
IP 68-10, dust and water tight up to max. 10 m head of water
IP 68-20, dust and water tight up to max. 20 m head of water
with a low pollutant concentration
atmosphere with a moderate pollutant concentration
(e.g. in wastewater treatment plants, chemical industry)
KX Suitable for installation in extremely aggressive atmosphere
with high humidity and high pollutant concentration
GS 160.3 – GS 250.3: Two-component iron-mica combination
– 75 °F to + 140 °F/ – 60 °C to + 60 °C (extreme low temperature), version EL
+ 32 °F to + 250 °F/ – 0 °C to + 120 °C (high temperature), version H
Type Operating cycles (OPEN - CLOSE - OPEN)
100 % 140 % 175 %
GS 50.3 15,000 5,000 – 1,000
GS 63.3 15,000 5,000 – 1,000
GS 80.3 15,000 5,000 – 1,000
GS 100.3 15,000 5,000 – 1,000
GS 125.3 15,000 5,000 – 1,000
GS 160.3 15,000 5,000 1,000 –
GS 200.3 15,000 5,000 1,000 –
GS 250.3 10,000 3000 750 –
Modulating duty: min. 2.5 million operations
6) Refer to section enclosure protection IP 68
7) Not available for GS 50.3
8) With worm wheel made of spheroidal cast iron
9) The lifetime for modulating duty depends on the load and the number of starts. A high starting frequency will rarely improve the modulating accuracy. To reach the
longest possible maintenance and fault-free operation time, the number of starts per hour chosen should be as low as permissible for the process
for swivel movements of 90° (max. 100°)
and a maximum output torque of
8)
8)
200 %
9)
5
Worm gearboxes GS 50.3 – GS 250.3 Operation instructions
Accessories
Valve position indicators Valve position indicator WSG for the signalization of intermediate and end positions for precise
Limit switching Limit switching WSH for manually operated valves. For the signalization of intermediate and
Further information
Reference documents Product description Worm gearboxes GS 50.3 – GS 250.3 /GS 315 – GS 500
Lever gearboxes See separate documents
and low-backlash feedback for swing angles ranging from 82° – 98°
(refer to separate data sheet)
Valve position indicator WGD for signalization of intermediate and end positions for swing
angles
> 180° (refer to separate data sheet)
end positions (refer to separate data sheet)
Dimension sheets GS 50.3 – GS 125.3, GS 160.3 – GS 250.3
Technical data GS 50.3 – GS 125.3, GS 160.3 – GS 250.3
Technical data SA, SAR, WSG, WGD, WSH
6
Operation instructions Worm gearboxes GS 50.3 – GS 250.3
3. Transport, storage and packaging
3.1 Transport
3.2 Storage
3.3 Packaging Our products are protected by special packaging for the transport ex works. The
.
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.
.
If eyebolts are supplied with the gearbox, they should be used to lift the gearbox
only and not the valve
.
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 bare surfaces.
In case worm gearboxes are to be stored for a long period
(more than 6 months), the following points must be observed additionally:
.
Prior to storage: Protect bare 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 corrosion
show, apply new corrosion protection.
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
centers.
4. Fitting the handwheel For worm gearboxes designed for manual operation the handwheel may be
supplied separately. Fitting is done on site according to figure A.
Figure A: Handwheel
Ball handle
(option)
Circlip
Worm shaft
gearbox
Spacer
(may be required)
Spacer
(may be required)
Circlip
Handwheel
7
Worm gearboxes GS 50.3 – GS 250.3 Operation instructions
5. Mounting positions of the different versions
RR LL RL LR
Description of the 4 versions (viewed at the pointer cover):
Code Direction of rotation at input shaft Position of worm shaft Direction of rotation at output drive
RR
LL
RL
LR
clockwise
clockwise
clockwise
clockwise
Right side
Left side
Right side
Left side
Mounting positions of AUMA multi-turn actuator with AUMA worm gearbox (please indicate when ordering)
GS versions RR / RL
clockwise
counterclockwise
counterclockwise
clockwise
RR
RL
RR
RL
A
B
RR
RL
C
RR
RL
D
GS versions LL / LR
LL
LR
A
B C
LL
LR
LL
LR
D
LL
LR
Mounting positions can easily be changed at a later date.
Limitation: For SA/SAR 14.1/14.5 with GS 125.3, mounting position “C” in version RR/RL and “A” in version LL/LR is
only possible for a handwheel diameter up to 12.4 ”.
Up to size GS 125.3, the actuator-gearbox combination is delivered in the ordered mounting position. For packing
reasons, actuator and gearbox is delivered separately from size GS 160.3.
8
Operation instructions Worm gearboxes GS 50.3 – GS 250.3
6. Mounting multi-turn actuators SA/SAR
When gearboxes and multi-turn actuators are supplied together, the mounting has
been done in the factory up to gearbox size GS 125.3. For sizes GS 160.3 and
larger, the mounting of gearboxes is performed as follows.
In case flange for actuator is not attached to gearbox or
reduction gearing:
.
Thoroughly degrease the mounting faces of the gearbox or reduction gearing as
well as the flange for actuator.
.
For GS 100.3 – GS 250.3:
Insert pin in the corresponding groove of the bearing cover.
.
Fit flange for actuator and fasten with bolts and lock washers.
.
Fasten bolts crosswise with a torque according to table 2.
Figure B: Mounting multi-turn actuator to worm gearbox
Flange for actuator
Bearing flange
Flange for actuator
Primary
reduction
gearing
Bearing flange
Mounting the multi-turn actuator:
.
Thoroughly degrease the faces of the flange for actuator at the gearbox or
reduction gearing as well as the actuator’s bearing flange.
.
Place the multi-turn actuator on the worm gearbox or reduction gearing. The
multi-turn actuator can be mounted on the valve at every 90°
(see page 8, mounting positions).
.
Ensure that the spigot mates uniformly in the recess and that the mounting faces
are in complete contact.
.
Fasten actuator with bolts and lock washers (see table 1) at the flange of the
worm gearbox.
.
Fasten bolts 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.
9
Worm gearboxes GS 50.3 – GS 250.3 Operation instructions
Table 1: Bolts for mounting AUMA actuators to worm gearboxes/ primary reduction gearing
(strength class min. 8.8)
Worm gearbox/
primary
reduction gearing
GS 50.3
GS 63.3
GS 80.3
GS 100.3
GS 100.3/VZ
GS 125.3
GS 125.3/VZ
GS 160.3
GS 160.3/GZ
GS 200.3
GS 200.3/GZ
SA(R) 07.1-FA10 SA(R) 07.5-FA10
Bolt
(UNC)
Lock
washer
Qty.
Bolt
(UNC)
washer
3/8-16x1 3/8 4
3/8-16x1 3/8 4
3/8-16x1 3/8 4
3/8-16x1 3/8 4
3/8-16x1 3/8 4
3/8-16x1 3/8 4
3/8-16x1 3/8 4
3/8-16x1 3/8 4
3/8-16x1 3/8 4
3/8-16x1 3/8 4
3/8-16x1 3/8 4
Lock
Qty.
Worm gearbox/
primary
reduction gearing
GS 63.3
GS 80.3
GS 100.3
GS 100.3/VZ
GS 125.3
GS 125.3/VZ
GS 160.3
GS 160.3/GZ
GS 200.3
GS 200.3/GZ
GS 250.3
GS 250.3/GZ
Worm gearbox/
primary
reduction gearing
GS 160.3
GS 160.3/GZ
GS 200.3
GS 200.3/GZ
GS 250.3
GS 250.3/GZ
SA(R) 10.1-FA10 SA(R) 14.1-FA14 SA(R) 14.5-FA14 SA(R) 16.1-FA16
Bolt
(UNC)
Lock
washer
Qty.
Bolt
(UNC)
Lock
washer
Qty.
Bolt
(UNC)
Lock
washer
Qty.
Bolt
(UNC)
washer
3/8-16x1 3/8 4
3/8-16x1 3/8 4
3/8-16x1 3/8 4
5/8-11x1
1
2
5/8 4
3/8-16x1 3/8 4
3/8-16x1 3/8 4
3/8-16x1 3/8 4
3/8-16x1 3/8 4
3/8-16x1 3/8 4
5/8-11x1
5/8-11x1
5/8-11x1
5/8-11x1
5/8-11x1
1
2
1
2
1
2
1
2
1
2
5/8 4
5/8 4
5/8 4
5/8 4
5/8 4
5/8-11x1
5/8-11x1
5/8-11x1
5/8-11x1
1
2
1
2
1
2
1
2
5/8 4
5/8 4
5/8 4
5/8 4
3
-10x2
4
3
-10x2
4
3
-10x2
4
SA(R) 25.1-FA25 SA(R) 30.1-FA30
Bolt
(UNC)
Lock
washer
Qty.
Bolt
(UNC)
Lock
washer
Qty.
5/8-11x2 5/8 8
3
5/8-11x2 5/8 8
-10x2
4
3/4 8
Lock
3/4 4
3/4 4
3/4 4
Qty.
10
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