Multi-turn gearboxes
Spur gearboxes
GST 10.1 – 40.1
Operation instructions
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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.1 Transport 6
3.2 Storage 6
3.3 Packaging 6
4.
Fitting the handwheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
5. Mounting multi-turn actuators SA/SAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
6. Mounting to valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
7. Operation of valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
8. Enclosure protection IP 68 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
9. Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
9.1 General references 12
9.2 Change of grease 13
10.
Disposal and recycling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
11. Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
12. Spare parts list Spur gearboxes GST 10.1 – GST 16.1 . . . . . . . . . . . . . . . . . . . . 16
13. Spur gearboxes GST 25.1 – GST 40.1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
14. Declaration of Conformity and Declaration of Incorporation. . . . . . . . . . . . . . . . . 20
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Addresses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2
Spur gearboxes GST 10.1 – GST 40.1 Operation instructions
Scope of these instructions:
These instructions apply to multi-turn gearboxes of the type range:
GST 10.1 – GST 40.1.
1. Safety instructions
1.1 Range of application AUMA spur gearboxes GST 10.1 – GST 40.1 are used for the operation of
valves (e.g. gate valves and globe valves).
They are designed for manual operation as well as motor operation in
conjunction with electric actuators.
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.
Explosion-proof products are specially marked. The service conditions
mentioned in these operation instructions and in the technical data sheet
have to be respected during use. Other service conditions require explicit
and written confirmation by the manufacturer.
1.2 Maintenance The maintenance instructions (refer to page 13) must be observed, otherwise 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 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
Operation instructions Spur gearboxes GST 10.1 – GST 40.1
2. Technical data
Features and functions
Type of duty Short-time duty S2 - 15 min. (open-close duty)
Intermittent duty S4 - 25 % (modulating duty)
Direction of rotation Standard: Clockwise rotation at input shaft results in clockwise rotation at output shaft
Option: GST 10.1 – GST 30.1
Reversal of rotation direction using a reversing gearbox GW 14.1
Stages One stage: GST 10.1 – GST 16.1
Double stage:GST 25.1 – GST 40.1
Input shaft GST 10.1 - GST 40.1:
For standard reduction ratios, the input shaft is made of stainless steel.
Exceptions: GST 16.1 5.6 : 1
GST 40.1 22 : 1 und 16 : 1
Standard: Cylindrical with parallel key according to DIN 6885.1
Option
1)
: Square - tapered (DIN 3233)
- cylindrical
Output torques
Operation
Motor operation With electric multi-turn actuator, directly
flanges for mounting the multi-turn actuator, refer to separate technical data sheets.
Manual operation Standard: Via handwheel, directly
Option: Remote extension shaft (not contained within the AUMA product range)
Valve attachment
Output drive types A, B1, B2, B3, B4 according to EN ISO 5210
A, B, D, E according to DIN 3210
C according to DIN 3338
Special output drives: AF, AK, AG, IB1, IB3, IB4
1) For size, please contact AUMA
2) At max. output torque
3) Conversion factor for output torque to input torque
Spur gearboxes GST 10.1 – GST 40.1 Operation instructions
4
Type Output torque Reduction ratio Input torque
2)
Factor
3)
Nominal
torque
max. Nm
Modulating
torque
max. Nm
Nominal
torque
Nm
Modulating
torque
Nm
GST 10.1
120 60
1 : 1 135 66 0.9
1.4 : 1 95 46 1.3
2 : 1 67 33 1.8
GST 14.1
250 120
1.4 : 1 198 92 1.3
2 : 1 139 66 1.8
2.8 : 1 99 48 2.5
GST 14.5
500 200
2 : 1 278 111 1.8
2.8 : 1 198 80 2.5
4 : 1 139 55 3.6
GST 16.1
1,000 400
2.8 : 1 397 160 2.5
4 : 1 278 111 3.6
5.6 : 1 198 80 5.0
GST 25.1
2,000 800
4 : 1 556 222 3.6
5.6 : 1 397 160 5.0
8 : 1 278 111 7.2
GST 30.1
4,000 1,600
5.6 : 1 794 320 5.0
8 : 1 556 222 7.2
11 : 1 404 162 9.9
GST 35.1
8,000 –
8 : 1 1,111 – 7.2
11 : 1 808 – 9.9
16 : 1 556 – 14.4
GST 40.1
16,000 –
11 : 1 1,616 – 9.9
16 : 1 1,111 – 14.4
22 : 1 808 – 19.8
Type GST 10.1 GST 14.1 GST 14.5 GST 16.1 GST 25.1 GST 30.1 GST 35.1 GST 40.1
Handwheel
mm
200
315
(250)
315 400 500 500 500 500
Service conditions
Mounting position Any position
Enclosure protection according
to EN 60 529
Standard: IP 67
Options: IP 68 (also refer to page 12)
Corrosion protection Standard: KN Suitable for installation in industrial units,
in water or power plants with a low pollutant concentration
Options: KS Suitable for installation in occasionally or permanently aggressive
atmosphere with a moderate pollutant concentration
(e.g. wastewater treatment plants, chemical industry)
KX Suitable for installation in extremely aggressive atmosphere with
high humidity and high pollutant concentration
Finish coating Standard: Two-component iron-mica combination
Colour Standard: AUMA silver-grey (similar to RAL 7037) if finish-painted
Option: Other colours on request
Ambient temperature Standard: –40 °C to +80 °C
Options: –60 °C to + 60 °C (extreme low temperature), version EL
– 0 °C to +120 °C (high temperature), version H
Lifetime Open-close duty: Operations (OPEN - CLOSE - OPEN) with 30 turns per stroke
GST 10.1: 20,000 operations
GST 14.1 – 16.1: 15,000 operations
GST 25.1 – 30.1: 10,000 operations
GST 35.1 – 40.1: 5,000 operations
Modulating duty
4)
:
GST 10.1: 5.0 million modulating steps
GST 14.1 – 16.1: 3.5 million modulating steps
GST 25.1 – 30.1: 2.5 million modulating steps
Accessories
Limit switching Limit switching device WSH for manually operated valves. For the signalling of intermediate
and end positions (refer to separate data sheet).
Reversing gearboxes Reversing gearbox GW for reversing the rotation direction for manual and motor operation
Special features for use in potentially explosive atmospheres
Explosion protection II2G c IIC T4 in compliance with ATEX 94/9/EC
Type of duty
5)
During open-close duty:
Short-time duty S2 - 15 min. at 50 % of maximum nominal output torque up to GST 14.5
and at 35 % of maximum nominal output torque from GST 16.1
During modulating duty:
Intermittent duty S4 - 25 % at maximum modulating torque
Ambient temperature
Standard: –40 °C to +60 °C
Options: –60 °C to +60 °C (extreme low temperature)
Combinations with actuators SAExC at ambient temperatures > 40 °C with special sizing.
Further information
Reference documents Product description Spur gearboxes GST 10.1 – GST 40.1
Dimension sheet GST 10.1 – GST 40.1
Technical data GST 10.1 – GST 40.1
Technical data SA/SAR
Technical data GW
Technical data WSH
4) 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
5) The type of duty must not be exceeded.
Operation instructions Spur gearboxes GST 10.1 – GST 40.1
5
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 f
ollowing 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 corrosion show, apply new corrosion protection.
3.3 Packaging Our products are protected b
y 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. Fitting the handwheel For gearboxes designed for manual operation, the handwheel is supplied
separately. Fitting is done on site according to figure 1.
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Spur gearboxes GST 10.1 – GST 40.1 Operation instructions
Figure 1: Handwheel
Ball handle
(option)
Spacer
(partly required)
Circlip
Handwheel
Gearbox input shaft
Circlip
Spacer
(partly required)
5. Mounting multi-turn actuators SA/SAR
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 (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 b
y 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.
7
Operation instructions Spur gearboxes GST 10.1 – GST 40.1
Figure 2: Mounting multi-turn actuators onto spur gearboxes
Input flange
Bearing flange
Gearbox SA(R) 07.5-F10/G0 SA(R) 10.1-F10/G0 SA(R) 14.1-F14/G1/2
Screw Pcs. Screw Pcs. Screw Pcs.
GST 10.1
M 10 x 25 4 M 10 x 25 4 M 16 x 40 4
GST 14.1
M 10 x 25 4 M 16 x 40 4
GST 14.5
M 10 x 25 4 M 16 x 40 4
GST 16.1
M 16 x 40 4
GST 25.1
M 16 x 40 4
Gearbox SA(R) 14.5-F14/G1/2 SA(R) 16.1-F16/G3 SA(R) 25.1-F25/G4
Screw Pcs. Screw Pcs. Screw Pcs.
GST 14.5
M 16 x 40 4
GST 16.1
M 16 x 40 4
GST 25.1
M 16 x 40 4 M 20 x 50 4
GST 30.1
M 16 x 40 4 M 20 x 50 4
GST 35.1
M 16 x 40 4 M 20 x 50 4 M 16 x 50 8
GST 40.1
M 20 x 50 4 M 16 x 50 8
Table 1: screws for mounting AUMA multi-turn actuators on spur gearbox
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 unif
ormly 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: W
e recommend applying liquid thread sealing material to
the screws to avoid contact corrosion.
.
Fasten screws crosswise to a torque according to table 2.
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Spur gearboxes GST 10.1 – GST 40.1 Operation instructions
Figure 3
Output drive type B1/B2
Plug sleeve
Output drive type B3/B4
Bore with keyway
Thread
Fastening torque T
A
[Nm]
Strength class
8.8 A2-70/A4-70 A2-80/A4-80
M 8251824
M10 50 36 48
M12 87 61 82
M16 214 150 200
M20 431 294 392
M30 1,489 564 –
M36 2,594 – –
Table 2: Fastening torques for screws
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