Tai Lieu Xi Mang
Tai Lieu Xi Mang
DHRV 50-1800/K
High efficiency
centrifugal fan
Type: DHRV 50-1800/K
Job-No.: 12300051 / 10
Item: 04.FN-02
Customer: Loesche GmbH
CONTENTS
13 Appendix
13.1 Declaration of incorporation as defined by EC machinery directive
13.2 Operating instructions for louver damper
13.3 Operating instructions for actuator
13.4 Operating instructions for coupling
13.5 Operating instructions for temperature sensor
13.6 Erection drawing
operation including setting up, troubleshooting in the course of work, evacuation of production waste, care
and disposal of fuels and consumables.
maintenance (servicing, inspection, repair) and/or
transport.
In addition to the operating instructions and to the mandatory rules and regulations for accident prevention and
environmental protection in the country and place of use of the machine/plant, the generally recognized
technical rules for safe and proper working must also be observed.
The machine/plant has been built in accordance with state-of-the-art standards and the recognized safety rules.
Nevertheless, its use may constitute a risk to life and limb of the user or of third parties, or cause damage to the
machine and to other material property.
The machine/plant must only be used in technically perfect condition in accordance with its designated use and
the instructions set out in the operating manual, and only by safety-conscious persons who are fully aware of
the risks involved in operating the machine/plant. Any functional disorders, especially those affecting the safety
of the machine/plant, should therefore be rectified immediately.
Assembly, operation, maintenance and repairs to the equipment must be carried out by specialist personnel
with the appropriate qualifications. In this case the Accident Prevention Regulations must be observed.
Repair, assembly and maintenance work may only be carried out if the equipment or the plant are not in
operation. It must also be impossible to switch on the equipment by a remote switch.
Easily accessible inlet and discharge openings on plant and equipment must be fitted with a wire mesh guard if
they represent a direct or indirect hazard.
The manufacturer is not liable for damage of any kind which results from misuse of the equipment or plant or
through non-observance of the technical documentation.
Our supply is limited by the text of the quotation or order confirmation. If additional protection measures are
necessary, these must be provided and assembled by the operator of the equipment or plant.
When dealing with hazardous material the maintenance and operating personnel must be specially trained.
Independent of the safety hints contained in these instructions, the local safety regulations apply in any case for
the operation of the plant.
The operator is responsible for seeing that they are enforced.
If further information than is available in this documentation, is required on the equipment / plant, please contact
the customer service department of the manufacturer.
1.2 Symbols
General danger warning Warning of danger to persons which you must observe
Transport information
2 General Requirements
The agreed guarantee can only be undertaken by us if following requirements are fulfilled.
correct and expert assembly, commissioning and operation using the documentation provided
proof that the stated maintenance frequency has been maintained
operation of the equipment or of the plant only within the permitted operating range
immediate reporting of damage to the manufacturer
the equipment or plant is only used for the purpose for which it is intended according to the technical
documentation
an alteration of the conditions of use is only permissible after consultation with the manufacturer
the operator is responsible for an environmentally friendly removal and disposal of the residual material and
of exchanged spare parts and wear parts
only original spare parts from the manufacturer are used
the technical documentation must be read, understood and observed by the operating personnel
we reserve the right to make technical alterations which are necessary for the improvement of the
equipment or plants.
The fans may be stored only where they are not subjected to vibrations in dry and frost-free rooms. Large
variations in temperature should be avoided as far as possible during storage.
Ensure that no load or pressure force is applied by the connected ducting to the
connecting flange.
Pay particular attention to possible alterations in duct length as a result of
variations in temperature and settling.
© Ventilatorenfabrik Oelde
Copies, even of parts of this text, may only be made with our approval.
The fan may only be operated when the temperature of the ambient air is at least 5 °C!
Operation in some rotating speed ranges is prohibited or only permitted over a short period of
time so as to avoid damage to the fan.
The centrifugal fan possesses an impeller which deflects the axial-flow air to a
centrifugal flow. In the impeller, which is equipped with backward inclined blades,
the air flow is accelerated and therefore has a higher velocity energy. When it
leaves the impeller, the air flow reaches the scroll with parallel side plates. Here the
velocity energy is transformed to a large part into pressure energy.
Construction "K" With construction type "K", the impeller is mounted on a shaft running in two
bearings. Power transmission from the motor to the shaft is through a flexible
coupling.
Impeller The impeller of the fan is made from steel plate. It is electrodynamically balanced in
two planes. The balancing quality shall be to G 2,5, according to DIN ISO 1940.
Casing
The gas flows to the impeller from two sides. This necessitates two inlet spigots
and one outlet spigot.
The split casing simplifies the assembly of large impellers and shafts and the
transport of large fans.
An inlet box deflects the air by 90° into the shaped inlet.
Shaft/Bearing The pedestal bearing equipped with roller bearings permits a compact support of
the shaft. The bearing is fitted with circulating oil lubrication. A conveying ring lifts
the oil out of the lower part of the housing and inject it into two collecting pans.
From here the oil flows downwards through the roller bearings. Combined with a
large housing surface this effects a good removal of warmth.
Shaft Seal Sealing between casing and shaft is with a "Novapress-Multi" seal. The disc in
plastic material encloses the shaft and is held onto the casing wall with a steel
pressure ring.
Drive Motor
A thermoelectric element incorporated into the motor winding, protects against
overheating.
Power Transmission The fan is driven by the motor through a flexible shaft coupling. The coupling has a
vibration- and shock-absorbing effect and compensates for slight disalignment of
the shaft.
Regulating Damper Adjustable flaps, arranged in a fan-like shape, diagonally to the flow direction,
directly in front of the inlet opening, modify the initial torque with which the handled
medium flows towards the impeller. By means of this type of regulation the energy
consumption adapts to alterations in performance with only small losses.
5 Transport
The fan must be fastened only to designated crane lugs.
Please observe the accident prevention regulations!
5.1 Storage
Use only hoists with adequate lifting capacity!
The slings used must comply with the safety regulations.
Eyebolts (for example, in bearing housings and motors) must be tightened up firmly before use.
You can see from the drawing and the shipping papers the amount of space required for the machine parts.
Protect the items that have been delivered against vandalism and theft.
Covers or tarpaulins for protection against the weather must not touch the surfaces of the items in storage.
Ensure an adequate circulation of air by putting wooden spacers between the items.
Plastics and painted parts must be protected against mechanical damage, direct sunlight, ozone and
aggressive media.
Avoid mechanical vibration.
The substrate must be level so that no tensions or deformations arise.
Do not stack the components.
Unpainted parts are treated at the factory with protection against corrosion. The protection against corrosion
must be renewed and applied again twice a year.
Under certain circumstances information regarding storage is given on the packed items with requirements
going beyond the ones stated above. These are to complied with accordingly.
If packing, packaging or cartons need to be opened during transport, then the desiccant is to be replaced as
necessary and the packing and packaging then closed up again properly.
The period of warranty is neither interrupted nor postponed as a result of the time in storage.
Inlet and discharge nozzles are protected at the factory to prevent the entry of foreign bodies. This covering
must remain intact until immediately before connection of the pipe and may only be removed for a short
time.
Provide a certificate or log of correct storage.
Caution! The bearing housing is delivered without a filling of oil!
Do not put it into operation before filling it with oil.
Once the protective packaging has been removed and the fan has been
set up. It must be filled with oil, even if the initial commissioning will not
follow immediately.
In order to avoid bearing damages by corrosion the impeller has to be turned
manually once a week until commissioning. This guarantees a continuous
wetting of the antifriction bearing parts with lubricant.
6 Installation
Danger of injury!
During assembly do not reach between the components. You are
assembling/dismantling heavy components (baseframe and casing bottom
half).
The result can be squashed and broken fingers.
Concrete foundations must be dry and set. They must be in a position to take up the static and dynamic
forces. Comply also with the assembly drawing when doing this.
During assembly the usual machine-building principles must be observed. The work may only be carried out by
persons with the necessary training.
Depending on the form of transportation, the fan components are pre-assembled as far as possible. You do not
need to heed the assembly description of ready-assembled components.
The milled contact areas for bearings and the motor are protected
against damage and corrosion while being transported through a
metal covering metal plate. This plate must be removed before the
bearings or the motor are put on!
Ensure that the work-place and all parts to be assembled are clean. Dirt or damage on the bearings impair
the bearing properties and lead to premature wear.
Place the shims for the pillow block housings in the correct position on the bearing pedestals. 10 mm
corresponds to the theoretical alignment height.
Push the inlet cone and shaped inlet over the bearing housings onto the shaft from the inlet side.
The rotor may only be moved with carrying belts or similar lifting gear. Lifting gear must not be attached to
the pillow block housings. The impeller and shaft must be protected against damage.
Place the rotor in the prescribed position on the bearing pedestals.
Check the horizontal position by means of a shaft level or other suitable aligning or measuring instrument.
If the shaft is in a slanted position, this must be corrected by removing or adding shims.
Align the shaft assembly concentrically to the inlet opening:
horizontal displacement:
The shaft can be finely centered by means of the setscrews next to the pillow block housings.
vertical displacement:
Beneath the two pillow block housings through even removal or addition of shims.
When aligning the fan and the motor ensure that the rotary axes are placed exactly in line. Every
misalignment will lead to increased bearing stress, thereby resulting in a shortening of the design bearing
lifetime.
Align locating and non-locating bearings alternately. Begin with the locating bearing.
The permissible difference in height between both bearings is 0.5 mm
Once again check the bearing position.
Tighten the fixing bolts and secure with counter nuts.
Bolt set-screws to the bearings and secure with counter nuts.
Place the seal on the casing flange. Sealing cord on inside and outside.
Place on the upper section of the housing carefully.
Tighten the fixing screws evenly and alternately.
Align the inlet cone and tighten evenly and on alternate sides with fixing bolts in the area of the inlet box.
The arrangement of the inlet zone is decisive for the efficiency of the fan.
The inlet ring can be moved radially and axially within a certain range.
If this is insufficient for the adjustment, the shaft must be moved.
Horizontal movement:
Fine adjustment of the shaft centre can be made with the set screws next to the pillow block housings.
Vertical movement:
Even removal or insertion of packing plates under both pillow block housings.
When the shaped inlet has been adjusted in relation to the impeller with a continuous weld a = 3 mm,.
material SG-2.
Coupling
For erection and connection please observe the operating instructions of the coupling manufacturer.
Before starting assembly, the shaft extensions and coupling halves must be carefully cleaned.
Fit the coupling, if possible, only with special fitting tools.
To simplify mounting the hubs can be warmed. Plastic parts must be removed beforehand at temperatures
higher than 80°C.
The coupling is fixed axially by means of a holding screw.
While aligning the shafts, the radial and angular offset must be kept as small as possible (refer to
"Maintenance").
Finally check all threaded connections or holding screws.
When connecting the direct current motor, the instructions of the motor manufacturer must be observed.
Mains Current!
Connection may only be carried out when there is not current passing through.
In the first place, the wiring diagrammes in the motor connection box and the additional information from
the motor manufacturer are applicable.
The supply of cooling air must not be hindered. The distance of the ventilator hood to adjacent objects must
be at least 1/4 of the diameter of the ventilator hood collar.
When connecting the direct current motor, the instructions of the motor manufacturer must be observed.
7 Commissioning
Before the test run all rotating parts must be guarded against accidental contact in accordance
with the Accident Prevention Regulations.
We recommend that one of our specialists carry out an assembly inspection and the initial start-
up. Please contact our service department.
Please check:
assembly dimensions of impeller and shaft.
drive tension of belts or alignment of coupling
that all fixing screws are well tightened
Are following threaded connections tightened?
- Motor fixing
- Bearing fixing
- Impeller fixing
- Anchor bolts
that the fan casing and connecting pipework are airtight
Are all access doors closed and locked?
the direction of rotation of the fan. For this purpose, switch on the motor for a moment. You can check
the correct direction of rotation against the arrow on the volute casing of the fan. Repeat this
procedure each time the fan is re-connected (change of position).
that the lubrication supply is ensured. You will find information about the lubricant amounts in the
section „Maintenance“.
Make sure that no loose parts, such as dust, tools or assembly material have been left in the fan
casing.
All guards and safety devices must have been installed and be functional.
Protect the motor and the bearings from any radiated heat (scroll casing, direct sunshine, furnaces, etc.).
The supply of cooling air to the drive motors must not be interrupted. In order to ensure sufficient cooling of
the motor, the ambient temperature must not exceed 40 °C.
Attention!
Do not operate the fan above the rotating speed specified in the chapter „Technical Data“. You
will thus avoid inadmissable operating conditions which could damage and destroy the fan.
Check the earth connection of the casing. Flexible joints which are not electrically conductive must be
jumpered with earthing cables.
During the acceptance test, you should carry out a vibration check of the bearing points. Criterion for this
will be DIN ISO 10816.
For further information see Section "Servicing".
The bearings shall not be commissioned in a non-lubricated state.
Check, before starting up, whether the oil level is between the min./max. marks. The oil level generally
decreases a little after starting up. We recommend making a further mark: "Oil level during operation", so
that oil losses can be easily determined.
The dip-ring may fail at temperatures below 10 °C, depending on the viscosity of the oil. At ambient
temperatures of below 10 °C, the oil must be set during start-up to its maximum level so as to ensure that
the lowest rolling element is completely coated with oil.
Monitor the behaviour of the bearing during the run-in period.
After removing the closing screw a thermometer can be fitted. Malfunction in the bearing can be recognized
by the quick rise in temperature and the rough running noises.
The first oil change must be made after 300 to 500 hours of operation. During this oil change the, despite
thorough cleaning, inevitable impurities are flushed away.
Hot gas fans, should be started up in a throttled state. They require a considerably
higher input with a cold medium than when handling hot gas.
After all reparations of bearing, box and axle and all transport of the whole ventilator, the position of the
rotor and the joint fissure are to be checked.
Enter the dimensions here at the
inflow ring
Nominal Value Actual
Value
a = 60 mm
h = 7,5 mm
A-237284-4
Remarks:
___________ ____________________________
Date Signature
8 Operation
Notes for operation under partial load - operation with louvre damper or vane control
Δp
Continuous operation with very strong throttling
(damper opening angles of more than 60°) lead to
increased machine vibration and must be avoided.
V
If the fan is started up with the damper closed, the amount of current drawn and the loading on the drive motor
can be reduced.
After the startup phase the damper (vane control) must be opened at once. Continuous operation is not
permitted over the damper setting range from 60° to 90° (0° = open, 90° = closed).
If the draft in the ducting system drives the fan when it is switched off, this can cause problems.
Problem Solution
The backwards flowing gas drives the fan in the
Use of a frequency-controlled
opposite direction. When it is switched on again it can
drive motor with speed buffer.
cause overloading of the drive motor.
If the draft is very strong, the fan can possibly be
accelerated above the rated speed when in no-load
operation.
Forwards flowing gas drives the rotor and increases Installation of a brake or an air-tight shut-off valve.
the slowing down time when the fan is switched off.
Oil-lubricated bearings are not being sufficiently
supplied with lubricant and may be damaged.
The shaft can become deformed by uneven warming The idling provides for an even temperature
or cooling. distribution.
Mechanical vibrations
Fans with a fast rotating mass form a relatively complex vibration system and are classified as machines which
tend to vibrate. Although they are dynamically balanced during fabrication, these machines can change their
vibration properties during operation, depending on their application.
Resonances
There is a resonance if the frequency of the operated fan system itself is identical with the excitation
frequency of an interference force from the fan itself or being a periodical interference force effective from
outside.
Aerodynamic effects
Changing operation conditions are often generated within a process plant (temperature alterations,
switching over to different volume flows, inlet vane or damper adjustment, etc.). These produce additional
changing forces in the gas stream (pulsation) which can cause parts of the fan assembly to mechanically
vibrate.
min. balance quality grade for rigid rotors/impeller, tested at manufacturer G 2,5
maximum permissible value of vibration velocity veff [mm/s] rigid installation flexible installation
Delivery status / balancing at the manufacturer 2,3 3,5
Status at commissioning 4,5 7,1
9 Servicing
Re-fix guards
Check that the guards are correctly functioning
Ensure that plant is in an operational state
Remove personnel from hazardous area
Impeller
During the yearly inspection of the impeller, it must be cleaned and checked for tension cracks. Fine cracks can
be found by the dye penetration process.
If material erosion or damage to the impeller are noticed, please report back to the manufacturer.
The impeller can be cleaned by washing or by careful scraping. You may not knock off deposits (possible
damage to impeller).
If necessary, the rotor can be re-balanced in situ by our service technician.
Shaft Seal
During inspection of the fan the sealing must be checked.
Shaft seal
The disc seal does not require maintenance.
Assembly / Dismantling
Drive motor
Observe the motor manufacturer’s instructions for maintenance and care of the motor.
If it becomes necessary to replace the motor, then the replacement motor must be at least equivalent to the
original one. This applies particularly to explosion protection.
Bearing arrangement
All work on the bearings, such as assembly, dismantling, cleaning, setting and
aligning must be carried out by an appropriately trained and instructed expert!
Many lubricants can cause skin irritations and inflammation of the eyes. Follow the
manufacturer’s safety instructions.
General
Assembly
If the bearing is provided with too little lubricant the bearing temperature will
increase and can result in a damage of bearing.
If the bearing is provided with too much lubricant the bearing will be overfilled
and there will be leakages.
Bearing lubrication
In fan building following sorts of oil have proved successful for lubrication:
For normal temperatures up to 80 °C For higher temperatures
80 - 110 °C
ISO Viscosity classification
VG 46 VG 68 VG 100
1. ARAL Aral Motanol HK 46 Aral Motanol HK 68 Aral Motanol HK 100
2. FUCHS Renolin DTA 15 Renolin 207, Renolin DTA 20 Renolin 208, Renolin 104
3. BP BP Energol CS 46 BP Energol CS 68 BP Energol CS 100
4. MOBIL Mobil DTE Oil Medium Mobil DTE Oil Heavy Medium Mobil Vactra Oil Heavy
5. FINA Fina Cirkan 46 Fina Cirkan 68 Fina Cirkan 100
6. SHELL Shell Tellus Oil C46 Shell Tellus Oil C68 Shell Tellus Oil C100
7. ESSO Teresso 46, Nuto H 46 Teresso 68, Nuto H 68 Nuray 100, Nuto H 100
8. TEXACO Rando Oil 46 Rando Oil 68 Rando Oil 100
Plummer block
Non-locating
bearing Locating bearing
Filling volume max.: 5,7 8 Liter
Oil level max.: 110 100 mm
Oil level min.: 75 75 mm
With oil bath lubrication it is generally sufficient to renew the oil once a year as long as the bearing temperature
does not exceed +80° C. Higher temperatures or excessive contamination of the oil mean that the oil must be
replaced more frequently. A bearing temperature which is 10° C higher will halve the useful life, so that when
the bearing temperature is +100° C a useful life of only 3 months may be expected.
The frequency with which the oil should be changed cannot be determined in advance. It must be adapted to
the operating conditions. The best method of control is to monitor the appearance of the oil and to check it
occasionally for impurities and to ensure that it is not excessively oxidised.
The neutralization number of the oil must not exceed 1 mg KOH/g (milligrammes potassium hydroxide per
gramme).
Coupling
Regularly check the wear on the synthetic buffers.
They can be replaced without moving the motor and fan
axially.The insertion of new synthetic buffers is made easier by
painting them with glycerine.
If the fan is not running smoothly, this can be caused by a
disalignment of the shaft.
Casing
The threaded connections on the casing (flanged threaded connections must be checked regularly. Please
observe the Inspection and Maintenance List.
The casing can be cleaned with high-pressure cleaning equipment.
Electrical connection boxes must not be directly subjected to the cleaning jet.
Condensation Drain
During cleaning of the impeller and as a result of condensation, water collects in the lower part of the fan casing.
This water can be run off through the condensation drain.
Louver Damper
Please adhere to the instruction manual in annexe.
before commissioning
every 3 month
every 6 month
after 1 month
after 24 h
monthly
weekly
yearly
daily
check airtightness X X
coupling X X X X
check supply of cooling air X X X
retighten screws X X X
check bearing temperature X X
check smooth running X X
inspect casing for tension cracks X
inspect impeller for signs of wear X
clean fan X
remove rust X
Fan is not running true Coupling has too much play. Replace the plastic washers in the
claw coupling.
Coupling has not been correctly Align coupling. (See section
aligned. maintenance)
Temperature increase in the roller The type of oil is unsuitable for the Select the correct lubrication as
bearings, running noises or operating conditions recommended by the manufacturer.
increased vibrations.
Oil level too low. Fill the oil up to the “max” mark.
Oil level is too high. This results in Reduce the oil level to the “max”
increased friction losses through mark.
splashing movements.
The bearing clearance is too small Check whether the clearance of the
when the bearing is subject to hot bearing corresponds to the
additional warmth from the shaft. original specification. If so, mount a
The inner ring expands too far. bearing with a larger bearing
clearance.
Oil return bore-holes are blocked. Clear out the bore-holes. Drain off
the old oil and refill with the correct
amount of fresh oil.
Machine vibrations Check the balance of the rotating
parts. Re-balance the fan.
Flattening of the roll bodies as a Sight check the roll bodies and
result of sliding movements replace the bearings.
(caused by fast start-up)
Ingress of impurities, such as dirt, Clean the bearing housings. Drain off
sand, etc. into the bearing housing the old oil and refill with the correct
amount of fresh oil.
Chips, dirt, etc. were not removed Clean the parts carefully. Drain off
before the bearing was mounted. the old oil and refill with the correct
amount of fresh oil.
The complete rotor and pillow block Correctly align the rotor and pillow
housing have not been correctly block housings with shims.
aligned. Completely support the housing foot.
11 Technical Data
100% A
90
80
70
60
50
M/MN
40
30
20
10
PW
0
0 10 20 30 40 50 60 70 80 90 100% M N 9550
nL
n/nL
Volume flow at fan inlet V1 780.000 m³/h
Temperature (at fan inlet) te 120,00 °C
Total pressure (E - A) Δpt 8.443 Pa
Fan speed nv =nL 993 1/min
Basic torque at ρe = 0,822 kg/m³ and te = 120,00 °C MN 21.187,74 Nm
Mass moment of inertia of the rotor J 4900 kg m²
Required power PW 2.203,24 kW
Recommended motor nominal power PM 2550 kW
Motor basic speed nM 993 1/min
When placing an order for spare parts, please let us have the following information:
We make every endeavour to fulfil your wishes for spare parts as promptly as possible.
Please contact:
Ventilatorenfabrik Oelde GmbH Telephone +49 2522 75-0
After sales service Fax +49 2522 75-250
P.O.B. 3709 _ D-59286 Oelde E-Mail info@venti-oelde.de
Robert-Schuman-Ring 21 Internet www.venti-oelde.de
D-59302 Oelde
*) special accessories
13 Appendix
Declaration of incorporation
in accordance with EU Machinery Directive 2006/42/EC, Annex IIB
We hereby declare that the a.m. product is an incomplete machine as defined by the Machinery Directive,
Article 2g. The product is exclusively designed for incorporation in a machine or an incomplete machine and
does not, therefore, yet fulfil all requirements of the Machinery directive.
Not all essential health and safety requirements in accordance with Annex 1 of this Directive are applied and
were fulfilled. These are listed in the attachment to this declaration.
The special technical documents in accordance with Annex VII B were prepared and will be forwarded to the
responsible national authorities on demand (documents sent by postal mail).
This incomplete machine conforms with the conditions of the following EU Directives:
This incomplete machine must not be put into operation until it has been determined that the machine in which
this incomplete machine is to be incorporated, complies with the conditions of the machinery directive.
Oelde, 15.07.2016
Description of the essential health and safety requirements in accordance with 2006/42/EC, Annex 1, which are
implemented and were complied with.
Designation Remarks
applicable
complied
entirety /
ANNEX I
Number
1.1.1. Definitions
1.1.2. Principles of safety integration
1.1.3. Materials and products
1.1.4. Lighting
1.1.5. Design of machinery to facilitate its handling
1.1.6. Ergonomics
1.1.7. Operating positions
1.1.8. Seating
1.2.1. Safety and reliability of control systems
1.2.2. Control devices
1.2.3. Starting
1.2.4. Stopping
1.2.4.1. Normal stop
1.2.4.2. Operational stop
1.2.4.3. Emergency stop
1.2.4.4. Assembly of machinery
1.2.5. Selection of control or operating modes
1.2.6. Failure of the power supply
1.3. Protection against mechanical hazards
1.3.1. Risk of loss of stability
1.3.2. Risk of break-up during operation
1.3.3. Risks due to falling or ejected objects
1.3.4. Risks due to surfaces, edges or angles
1.3.5. Risks related to combined machinery
1.3.6. Risks related to variations in operating conditions
1.3.7. Risks related to moving parts
1.3.8. Choice of protection against risks arising from
moving parts
1.3.8.1. Moving transmission parts
1.3.8.2. Moving parts involved in the process
1.3.9. Risks of uncontrolled movements
1.4. Required characteristics of guards and protective
devices
Designation Remarks
applicable
complied
entirety /
ANNEX I
Number
Risk of injury!
Do not insert your hand between components during installation. You are
assembling/dismantling heavy components (baseframe and casing bottom half).
Fingers/hands can be caught and crushed.
General assembly
During the loading and assembly operations the louver damper should be raised uniformly on at least two
anchoring points to prevent warping of the frame. For this purpose please use the eye-bolts which you should fix
at the flange.
There must be no tension cables attached to the valves or the displacement linkage!
Final assembly
Clean the flange sealing surfaces of the channel duct and louver dampers carefully.
Remove unevenness
Before the assembly prepare the flange with sealing (see figure 1). Here please ensure that the sealing is
placed as close to the holes for the screws as possible to seal the louver damper effectively.
1. Flange
2. Seal
1 2
When fitting the louver damping, there must be no recognisable offset. It must be fitted tension-free in the
specified mounting position and flow direction (make sure that the counter flange is straight).
Tighten the bolts evenly.
Perform a functional test by opening and closing the valve several times.
Initial Operation
Before initial operation, tools, assembly parts and other objects must be removed from the
rotation range of the dampers.
During initial operation of the accessories, such as drives and limit switches, the manufacturer's instructions
must always be observed.
Installation notes
The louver damper can be used for the following operating conditions:
Temperatures: 5 to 150 °C
Max. Pressure 15000 Pa
difference p:
Seal situation:
2
The sealing strip must lie on the
neighbouring damper blade. If this is not the
case, it must be readjusted.
1. Sealing strip
2. Flap wing
3. Fin 1 3
The louver damper is adjusted and tested at the factory. When properly stored and assembled, readjustment
should not be necessary before initial operation. During the initial operation, only the setting of the travel switch
and torque switch of the actuator must be tested.
1. Connecting rod
2. Counter nut
1 2
Different positions of the damper blades with each other can be adjusted by turning the connecting rod (1). To
do this, the counter nuts (2) are first loosened. The connecting rod is lengthened or shortened by turning. This
changes the damper angle. Afterwards, tighten the counter nuts again.
Maintenance
Louver dampers are practically maintenance-free. The maintenance instructions of the respective manufacturer
apply for the built-on drives and other accessories. Depending on operating conditions and long downtime
periods, the seal should be checked from time to time for possible damage and deposits.
Inspect twice a year if the damper leaves are running synchronously. To do this close the louver into the
position „up“and subsequently again to down position. If the louver leaves, especially the one behind the power
train, deviate by several degrees, this may have different causes.
Cause Remedy
The connection louver shaft adjusting lever has Tighten the screws at the lever
clearance
Ball joint is worn out Replace the ball joint and adjust the louver afresh
Jumpy sequence of the movement of the individual drive elements indicated a clearance in the
connections.
If the initial tension is too great it may block the shaft so that the louver can no longer move.
After doing the adjustment check for freedom of movement and secure the screw connection
with counter nut.
Gland nut with shaft drive side Stopfbuchse mit Welle Gegenseite
1. Packing ring
2. Gland bearing
3. Pressure ring
2
GS 50.3 – GS 250.3
Table of contents
3
GS 50.3 – GS 250.3
Safety instructions
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
EC 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.
Safety instructions/warn- All personnel working with this device must be familiar with the safety and warning
ings 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.
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 part-turn gearboxes are designed for the operation of industrial valves, e.g.
butterfly valves, ball valves and dampers.
Other applications require explicit (written) confirmation by the manufacturer.
4
GS 50.3 – GS 250.3
Safety instructions
Information The term Information preceding the text indicates important notes and information.
5
GS 50.3 – GS 250.3
Safety instructions
6
GS 50.3 – GS 250.3
Identification
2. Identification
2.1. Name plate
Figure 1: Arrangement of name plates
7
GS 50.3 – GS 250.3
Identification
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
Description of the serial number (with the example of 0512CG12345)
05 15 CG12345
05 Positions 1 + 2 : Assembly in week = week 05
15 Positions 3 + 4 : Year of manufacture = 2015
CG12345 Internal number for unambiguous product identification
Reduction ratio The reduction ratio within gearing and primary reduction 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
Type of lubricant AUMA abbreviation for type of lubricant used in the gear housing.
Duty class The duty class specifies the application range of a gearbox relating to the lifetime
requirements. The duty class is only specified for gearboxes in operation mode class
A (OPEN-CLOSE duty).
● Duty class 1: suitable for motor operation, meets the lifetime requirements of
EN 15714-2
● Duty class 2: suitable for motor operation of rarely or infrequently operated
valves which do not exceed 1,000 operations across their total lifetime.
● Duty class 3: suitable (exclusively) for manual operation with approximately
250 operations, in compliance with the specified lifetime requirements in EN
1074-2.
Please refer to separate Technical data for further information on duty classes.
Version The first letter of the version indicates the position of the worm shaft in relation to
the worm wheel (view on input shaft).
The second letter indicates the direction of rotation at the output drive (view on
housing cover) for clockwise rotation at the input shaft.
8
GS 50.3 – GS 250.3
Identification
Versions: Worm shaft position and direction of rotation of output drive GS 50.3 – GS 250.3
RR LL RL LR
Initials Direction of rotation at input shaft Position of worm shaft Direction of rotation at output drive
RR Clockwise Right Clockwise
LL Clockwise Left Counterclockwise
RL Clockwise Right Counterclockwise
LR Clockwise Left Clockwise
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 of serial number.
Figure 4: Link to the App store:
9
GS 50.3 – GS 250.3
Transport, storage and packaging
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 eyebolts for tight seat in housing (verify reach of the screws).
→ Observe manufacturer specifications for fixing lifting straps and roundslings.
→ Respect total weight of combination (gearbox, primary reduction gearing, actu-
ator).
Table 1:
Weights including grease filling in gear housing
Type Standard version Version with base and lever
[kg]1) [kg]
GS 50.3 7 10
GS 63.3 12 23
GS 80.3 16 29
GS 100.3 (52:1/107:1) 33 58
GS 100.3 (126:1/160:1/208:1) 39 64
GS 125.3 (52:1) 40 89
GS 125.3 (126:1/160:1/208:1) 46 95
GS 160.3 (54:1) 80 139
GS 160.3 (218:1/442:1/880:1) 91 150
GS 200.3 (53:1) 140 258
GS 200.3 (214:1/434:1) 160 278
GS 200.3 (864:1/1 752:1) 170 288
GS 250.3 (52:1) 273 467
GS 250.3 (210:1/411:1) 296 490
GS 250.3 (848:1/1 718:1) 308 502
Additional weights when mounting extension flanges
F30 for GS 125.3 18
F35 for GS 160.3 33
F40 for GS 200.3 48
F48 for GS 250.3 75
3.2. Storage
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.
10
GS 50.3 – GS 250.3
Transport, storage and packaging
11
GS 50.3 – GS 250.3
Assembly
4. Assembly
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.
Screws to actuator
Screws are included in the scope of delivery of the gearbox for mounting AUMA
multi-turn actuators. When mounting other actuators, the screws might be either too
long or too short (insufficient reach of screws).
12
GS 50.3 – GS 250.3
Assembly
Risk of actuator falling off in case inappropriate screws used should shear.
Risk of death or serious injury!
→ Check length of screws.
→ Only use screws with strength class specified herein.
The reach of screws must be sufficient for the internal threads to ensure the
supporting strength of the device and to accept the lateral forces due to the applied
torque.
Screws which are too long could make contact with the housing parts, presenting
the risk that the device performs a radial shift with respect to the gearbox. This can
lead to shearing of the screws.
4.3.1. Mounting positions Multi-turn actuators with part-turn gearboxes
GS versions LL and LR
A1) B C D
1) Caution: For multi-turn actuators SA/SAR 14.2 and 14.6 with GS 125.3, mounting position C is not possible for RR and RL versions;
mounting position A is not possible for LL and LR versions.
Please consider possible space constraints on site when selecting the mounting
position.
Mounting positions may easily be changed at a later date.
Up to size GS 125.3, the multi-turn actuator-gearbox combination is delivered in the
ordered mounting position. For packing reasons, actuator and gearbox will be
delivered separately from size GS 160.3.
4.3.2. 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.
13
GS 50.3 – GS 250.3
Assembly
Table 2:
Suitable input mounting flanges
Gearboxes Reduction ratio Input shaft Input mounting flange for mounting multi-turn actuators
[mm] EN ISO 5210 DIN 3210
GS 50.3 51:1 16 F07, F10 G0
51:1 20
GS 63.3 F07, F10 G0
82:1 20
53:1 20
GS 80.3 F07, F10 G0
82:1 20
52:1 30/(20) F14 (F10) G1/2 (G0)
107:11) 30 F14 (F10) G1/2 (G0)
GS 100.3 126:11) 30 F10 G0
260:11) 30 F10 G0
208:11) 30 F10 G0
52:1 30 F14 G1/2
126:11) 30/(20) F14 (F10) (G0)
GS 125.3
160:11) 30/(20) F14 (F10) (G0)
208:11) 20 F10, F14 G0
54:1 30 F16 (F14) G3 (G1/2)
218:11) 30/(20) F14 (F10) G1/2 (G0)
GS 160.3
442:11) 20 F10 G0
880:11) 20 F10 G0
53:1 40 F25 (F16) (G3)
1) 30 F14 G1/2
GS 200.3 434:11) 30/(20) F14 (F10) G1/2 (G0)
864:11) 20 F14 G0
1,752:11) 20 F10 G0
52:1 50 F30 (F25) –
210:11) 40/(30) F16 (F14) G3 (G1/2)
GS 250.3 411:11) 30 F14 G1/2
848:11) 30/(20) F14 (F10) G1/2 (G0)
1 718:11) 20 F10 G0
1) Equipped with primary reduction gearing or planetary gearing to reduce input torques.
Assembly steps 1. Clean mounting faces, thoroughly degrease uncoated mounting surfaces.
Figure 6: Mounting example, input mounting flange fitted to gearbox with primary
reduction gearing
14
GS 50.3 – GS 250.3
Assembly
The gearbox is mounted to the valve using a coupling (standard) or via lever. Separate
instructions are available for actuator mounting to the valve when equipped with
base and lever.
4.4.1. Output drive for coupling
Assembly steps 1. If required, move gearbox in same end position as valve using the handwheel.
2. Clean mounting faces, thoroughly degrease uncoated mounting surfaces.
3. Apply a small quantity of grease to the valve shaft [2].
15
GS 50.3 – GS 250.3
Assembly
4. Fit coupling [1] onto valve shaft [2] and secure against axial slipping by using
a grub screw [3] or a washer and a screw [4]. Thereby, ensure that dimensions
X, Y or L are observed (refer to figure and table <Mounting positions for coup-
ling>).
Figure 8: Examples: Fit coupling
[1] Coupling
[2] Valve shaft
[3] Grub screw
[4] Screw with washer
Figure 9: Mounting positions for coupling
Table 4:
Dimensions GS 50.3 GS 63.3 GS 80.3 GS 100.3 GS 125.3
[mm]
EN ISO 5211 F05 F10 F10 F12 F12 F14 F14 F16 F16 F25 F301)
X max. 6 14 7 10 13 23 22 22 17 17 35
Y max. 5 5 18 13 18 5 13 8 35 27 0
L max. 61 61 61 73 76 78 88 123 123 126 126
16
GS 50.3 – GS 250.3
Assembly
Table 5:
Dimensions GS 160.3 GS 200.3 GS 250.3
[mm]
EN ISO 5211 F25 F301) F35 F30 F35 F401) F35 F40 F481)
X max. 15 30 30 19 44 44 8 13 20
Y max. 11 0 0 19 0 0 8 0 5
L max. 130 140 130 160 190 160 220 230 220
Information Ensure that the spigot (if provided) fits uniformly in the recess and that the flanges
are in complete contact.
17
GS 50.3 – GS 250.3
Assembly
18
GS 50.3 – GS 250.3
Indications
5. Indications
5.1. Mechanical position indicator/running indication
Mechanical position indicator:
● continuously indicates the valve position
(pointer cover [2] follows the valve movement)
● indicates whether the actuator is moving (running indication)
● indicates that end positions have been reached
(mark on pointer cover [3] points to symbols OPEN [4] or CLOSED [5])
Figure 11: Mechanical position indicator
19
GS 50.3 – GS 250.3
Commissioning
6. Commissioning
Information ● In general, gearboxes with a swing angle > 190° are multi-turn (without end
stops). Consequently, end position setting is not possible. Therefore, no protect-
ive function is available for the valve.
● In general, only one end stop (either OPEN or CLOSED) must be set, due to
the fact that the swing angle was already set in the factory.
Figure 12: End stop (left: up to size 125.3, right: from size 160.3)
[1] Screws
[2] End stop
[3] Housing
2. Turn valve via handwheel to position CLOSED. Check whether end stop [2]
rotates simultaneously.
→ Otherwise: Turn end stop [2] clockwise to the stop.
20
GS 50.3 – GS 250.3
Commissioning
3. With mounted multi-turn actuator (not required for manual operation): Turn end
stop [2] counterclockwise by 1/4 turn.
➥ This ensures that the gearbox end stop cannot be approached during motor
operation if a multi-turn actuator is mounted and that the valve can close tightly
for torque seating.
4. In case the four holes of the end stop [2] do not match the four threaded bores
within the housing [3]: Remove end stop [2] until it disengages from the toothing
and replace in correct position.
5. Fasten screws [1] crosswise with a torque according to table <Tightening torques
for screws at end stop> .
Table 7:
Tightening torques for screws at end stop
Gearbox Screws [1] Tightening torque TA [Nm]
GS 50.3 M6 10
GS 50.3 – GS 80.3 M8 24
GS 100.3 – GS 125.3 M12 82
GS 160.3 M10 48
GS 200.3 M12 82
GS 250.3 M16 200
Figure 13: End stop (left: up to size 125.3, right: from size 160.3)
[1] Screws
[2] End stop
[3] Housing
2. Turn valve via handwheel in position OPEN. Check whether end stop [2] rotates
simultaneously.
→ Otherwise: Turn end stop [2] counterclockwise to the stop.
21
GS 50.3 – GS 250.3
Commissioning
3. With mounted multi-turn actuator (not required for manual operation): Turn end
stop [2] clockwise by 1/4 turn.
➥ This ensures that the gearbox end stop cannot be approached during motor
operation if a multi-turn actuator is mounted and that the valve can close tightly
for torque seating.
4. In case the four holes of the end stop [2] do not match the four threaded bores
within the housing [3]: Remove end stop [2] until it disengages from the toothing
and replace in correct position.
5. Fasten screws [1] crosswise with a torque according to table <Tightening torques
for screws at end stop>.
Further settings hereafter:
● If the gearbox is equipped with a pointer cover: Check whether the mark aligns
with the symbol OPEN. Refer to <Mechanical position indicator: set>.
● If the gearbox is mounted to a multi-turn actuator, set the seating in end position
OPEN straight after completion of the current setting: <Seating in end positions
via multi-turn actuator>.
6.2. Seating in end positions via multi-turn actuator
This chapter supplies basic information and notes 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.
● 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)
● If the swing angle set in the factory for opening and closing the valve is not
sufficient: refer to <Swing angle>.
6.2.1. Seating in end position CLOSED: set
22
GS 50.3 – GS 250.3
Commissioning
23
GS 50.3 – GS 250.3
Commissioning
24
GS 50.3 – GS 250.3
Commissioning
[1] Screws
[2] Protective cap
[3] Screw with washer
[4] Clamping washer
[5] Setting ring
[6] End stop nut
[7] Travelling nut
[8] Pairs of safety wedge discs (for OPEN and CLOSE)
1. Remove all four screws [1] and pull off protective cap [2].
2. Remove the screw with the washer [3] and clamping washer [4].
3. Pull off setting ring [5].
4. Swing angle increase:
4.1 Turn end stop nut [6] counterclockwise.
4.2 Move valve manually to the desired end position OPEN.
4.3 Turn end stop nut [6] clockwise until it is tight to the travelling nut [7].
5. Swing angle reduction:
5.1 Move valve manually to the desired end position OPEN.
5.2 Turn end stop nut [6] clockwise until it is tight to the travelling nut [7].
6. Fit setting ring [5], secure with clamping washer [4], washer and screw [3].
7. Check whether O-ring at protective cap is in good condition, replace if damaged.
8. Place protective cap [2] and fasten screws [1] crosswise with a torque according
to table <Tightening torques for screws at end stop>.
Information If the gearbox is mounted to a multi-turn actuator, the limit switching for the end po-
sition OPEN must be set first in compliance with the operation instructions of the
multi-turn actuator.
End position CLOSED 1. Move valve to end position CLOSED and check setting.
➥ The setting is correct if the mark aligns with the symbol CLOSED.
25
GS 50.3 – GS 250.3
Commissioning
26
GS 50.3 – GS 250.3
Servicing and maintenance
AUMA
AUMA offer extensive service such as servicing and maintenance as well as customer
Service & Support product training. For the relevant contact addresses, please refer to <Addresses>
in this document or to the Internet (www.auma.com).
27
GS 50.3 – GS 250.3
Servicing and maintenance
28
GS 50.3 – GS 250.3
Technical data
8. 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).
General information
For motor or manual operation of valves (e.g. butterfly valves, ball and plug valves).
For special applications, e.g. dampers, gas diverters, flue gas dampers, toggle arm driven diverters and guillotine isolators, special sizing is
required. Special technical data apply for special applications. Available special applications on request.
Type GS 200.3
Reduction ratio 53:1 67:1 214:1 434:1 864:1 1752:1
[Nm] 8000 250 2000 1000 500 250
Type GS 250.3
Reduction ratio 52:1 210:1 411:1 848:1 1718:1
[Nm] 8000 2000 1000 500 250
Swing angle GS 50.3 – GS 125.3 Standard: Fixed swing angle between 10° and 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°
Swing angle > 190°, refer to Technical data GS 50.3 – GS 250.3 for modulating duty and
shorter operating times
Swing angle GS 160.3 – GS 250.3 Standard: Adjustable 80° – 100°; set in the factory to 92° unless ordered otherwise.
Options: Adjustable in steps of:
0° – 20°, 20° – 40°, 40° – 60°, 60° – 80°, 90° – 110°, 110° – 130°, 130° – 150°, 150° –
170°, 170° – 190°
Swing angle > 190°, refer to Technical data GS 50.3 – GS 250.3 for modulating duty and
shorter operating times
Swing angle at special reduction Standard: Adjustable 80° – 100°; set in the factory to 92° unless ordered otherwise.
ratio GS 200.3 - 67:1 Options: Adjustable in steps of:
0° – 20°, 20° – 40°, 40° – 60°, 60° – 80°
Swing angle > 100°, multi-turn version without end stops, GSD version, specific sizing
required
29
GS 50.3 – GS 250.3
Technical data
Operation
Motor operation ● Via electric multi-turn actuator
● Input mounting flanges for mounting multi-turn actuators
Due to gear tooth geometry and the material characteristics of bronze, worm gearboxes with a worm
wheel made of bronze can transmit lower torques
Calculation of operating time for a 90° swivel movement
30
GS 50.3 – GS 250.3
Technical data
Operation
Manual operation Standard: ● Handwheel made of aluminium with electrophoretic coating
● Handwheel with ball handle
Type GS 250.3
Reduction ratio 52:1 210:1 411:1 848:1 1718:1
Handwheel Ø [mm] 500
– 800 400 315
630
31
GS 50.3 – GS 250.3
Technical data
Valve attachment
Valve attachment Dimensions according to EN ISO 5211: The maximum torques of mounting flanges according to EN
ISO 5211 are to be met.
Spigot Flanges with spigot, recess or plane flanges are available. Up to GS 125.3, spigots are implemented by
means of spigot rings. From GS 160.3 to GS 250.3, recesses and spigots are directly integrated into
the housing.
Bore for locating pins (option) Two bores for locating pins shifted by 180°. The locating pins are not included in the scope of delivery.
Refer to dimension drawing U4.4135. Further pitch circle diameters and bore depths for locating pins
on request
Splined coupling for connection to Standard: ● Without bore or pilot bore from GS 160.3
the valve shaft
● Worm gearbox can be mounted on coupling
Options: Finish machining with bore and keyway, square bore or two-flat with grub screw for secure
fixing to valve shaft.
Service conditions
Mounting position Any position
Ambient temperature –40 °C to +80 °C
II2D c –60 °C to +60 °C
T130°C 0 °C to +120 °C
Note: When using mechanical microswitches, the temperature ranges indicated here are
reduced to –30 °C up to max. +90 °C.
Enclosure protection according to Standard: IP68, dust-tight and water-tight up to max. 8 m head of water
EN 60529 Options: IP68-20, dust-tight and water-tight up to max. 20 m head of water
Corrosion protection Standard: GS 50.3 – GS 80.3: KS
GS 100.3 – GS 250.3: KN
Options: GS 50.3 – GS 80.3: KX
GS 100.3 – GS 250.3: KS/KX
KN Suitable for installation in industrial units, in water or power plants with a low pollutant
concentration
KS Suitable for use in areas with high salinity, almost permanent condensation, and high
pollution.
KX Suitable for use in areas with extremely high salinity, permanent condensation, and high
pollution.
Finish coating GS 50.3 – GS 80.3: Powder coating
GS 100.3 – GS 250.3: Two-component iron-mica combination
Colour AUMA silver-grey (similar to RAL 7037)
Option: Available colours on request
32
GS 50.3 – GS 250.3
Technical data
Service conditions
AUMA load profile AUMA worm gearboxes meet or exceed the lifetime requirements of EN 15714-2.
For open-close duty with worm wheel made of spheroidal cast iron:
Duty class 2: Lifetime for 90° swivel movement for valves which are infrquently operated.
Further information
EU Directives ATEX Directive: (94/9/EC)
Machinery Directive: (2006/42/EC)
33
GS 50.3 – GS 250.3
Spare parts
9. Spare parts
9.1. Part-turn gearboxes GS 50.3 – GS 125.3
34
GS 50.3 – GS 250.3
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. Delivered spare parts may slightly vary from the
representation in these instructions.
35
GS 50.3 – GS 250.3
Spare parts
36
GS 50.3 – GS 250.3
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. Delivered spare parts may slightly vary from the
representation in these instructions.
37
GS 50.3 – GS 250.3
Spare parts
38
GS 50.3 – GS 250.3
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. Delivered spare parts may slightly vary from the
representation in these instructions.
39
GS 50.3 – GS 250.3
Spare parts
9.4. Primary reduction gearing for GS 160.3 (218:1/442:1) GS 200.3 (214:1/434:1) GS 250.3 (210:1/411:1)
40
GS 50.3 – GS 250.3
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. Delivered spare parts may slightly vary from the
representation in these instructions.
41
GS 50.3 – GS 250.3
Spare parts
42
GS 50.3 – GS 250.3
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. Delivered spare parts may slightly vary from the
representation in these instructions.
43
GS 50.3 – GS 250.3
Certificates
10. Certificates
10.1. Declaration of Incorporation and EC Declaration of Conformity
44
GS 50.3 – GS 250.3
45
GS 50.3 – GS 250.3
46
GS 50.3 – GS 250.3
Index
M
Index Maintenance 4 , 27
Maintenance intervals 27
A Manual operation 31
Ambient temperature 7 , 32 Mechanical position indicator 19 , 25 , 30
Applications 4 Motor operation 30
Assembly 12 Mounting position 12 , 32
B Multi-turn actuators for motor 12
Base 31 operation
C N
Certificates 44 Name plate 7
Commissioning 4 , 20 O
Corrosion protection 10 , 32 Operating times 30
Coupling 15 , 32 Operation 4 , 31
D Order number 7, 8
Data Matrix code 9 Output torque 7
Declaration of Incorporation 44 P
Deflection 31 Packaging 11
Device type 7 Pointer cover 19 , 25
Directives 4 Position indicator 25
Disposal 27 Protective measures 4
Duty class 7, 8
Q
E Qualification of staff 4
EC Declaration of Conformity 44
Enclosure protection 7 , 32 R
End stops 20 , 29 Range of application 4
Explosion protection version 7 Recycling 27
Reduction ratio 7, 8
F Replacing the seals 27
Factor 7, 8 Running indication 19
Features and functions 30
Flange 7 S
Flanges 13 Safety instructions 4
Safety instructions/warnings 4
H Screws to actuator 12
Handwheel 12 Seating 22
Housing material 29 Self-locking 29
I Serial number 7, 8
Identification 7 Service 27
Indications 19 Service conditions 33
Input mounting flanges 13 Servicing 27
Input shaft 30 Size 7
Input speeds 30 Spare parts 34
Inspection certificate 8 Spigot 32
Standards 4
L Storage 10
Lever 31 Strength of end stop 29
Lifetime 33 Support 27
Load profile 33 Support App 9, 9
Locating pins 32 Swing angle 7 , 23 , 29
47
GS 50.3 – GS 250.3
Index
T
Technical data 29
Transport 10
Type (device type) 7
Type designation 7
Type of duty 30
Type of lubricant 7, 8
V
Valve attachment 7 , 32
Valve torque 7
Version 7 , 8 , 29
W
Worm wheel material 29
Y
Year of manufacture 8
Year of production 8
48
AUMA worldwide
49
AUMA worldwide
AUMA South Africa (Pty) Ltd. Mikuni (B) Sdn. Bhd. Mustafa Sultan Science & Industry Co LLC
ZA 1560 Springs BN KA1189 Kuala Belait OM Ruwi
Tel +27 11 3632880 Tel + 673 3331269 / 3331272 Tel +968 24 636036
aumasa@mweb.co.za mikuni@brunet.bn r-negi@mustafasultan.com
Ferrostaal de Colombia Ltda. ITG - Iranians Torque Generator AUMA ACTUATORS (Singapore) Pte Ltd.
CO Bogotá D.C. IR 13998-34411 Teheran SG 569551 Singapore
Tel +57 1 401 1300 +982144545654 Tel +65 6 4818750
dorian.hernandez@ferrostaal.com info@itg-co.ir sales@auma.com.sg
www.ferrostaal.com www.auma.com.sg
Trans-Jordan Electro Mechanical Supplies
AUMA Región Andina & Centroamérica JO 11133 Amman NETWORK ENGINEERING
EC Quito Tel +962 - 6 - 5332020 SY Homs
Tel +593 2 245 4614 Info@transjordan.net +963 31 231 571
auma@auma-ac.com eyad3@scs-net.org
www.auma.com AUMA JAPAN Co., Ltd.
JP 211-0016 Kawasaki-shi, Kanagawa Sunny Valves and Intertrade Corp. Ltd.
Corsusa International S.A.C. Tel +81-(0)44-863-8371 TH 10120 Yannawa, Bangkok
PE Miraflores - Lima mailbox@auma.co.jp Tel +66 2 2400656
Tel +511444-1200 / 0044 / 2321 www.auma.co.jp mainbox@sunnyvalves.co.th
corsusa@corsusa.com www.sunnyvalves.co.th
www.corsusa.com DW Controls Co., Ltd.
KR 153-702 Gasan-dong, GeumChun-Gu,, Top Advance Enterprises Ltd.
Control Technologies Limited Seoul TW Jhonghe City, Taipei Hsien (235)
TT Marabella, Trinidad, W.I. Tel +82 2 2624 3400 Tel +886 2 2225 1718
Tel + 1 868 658 1744/5011 import@actuatorbank.com support@auma-taiwan.com.tw
www.ctltech.com www.actuatorbank.com www.auma-taiwan.com.tw
50
AUMA worldwide
51
AUMA Riester GmbH & Co. KG
P.O.Box 1362
DE 79373 Muellheim
Tel +49 7631 809 - 0
Fax +49 7631 809 - 1250
riester@auma.com
www.auma.com
Y003.822/003/en/1.15
2
SA 07.2 – SA 16.2/SAR 07.2 – SAR 16.2
Table of contents
6. Operation................................................................................................................................ 21
6.1. Manual operation 21
6.1.1. Manual operation: engage 21
6.1.2. Manual operation: disengage 21
6.2. Motor operation 21
7. Indications.............................................................................................................................. 22
7.1. Mechanical position indicator/running indication 22
8. Signals..................................................................................................................................... 23
8.1. Feedback signals from actuator 23
9. Commissioning...................................................................................................................... 24
9.1. Switch compartment: open 24
9.2. Torque switching: set 24
9.3. Limit switching: set 25
9.3.1. End position CLOSED (black section): set 25
9.3.2. End position OPEN (white section): set 26
9.4. Intermediate positions: set 26
9.4.1. Running direction CLOSE (black section): set 27
9.4.2. Running direction OPEN (white section): set 27
9.5. Test run 27
9.5.1. Direction of rotation: check 27
9.5.2. Limit switching: check 28
9.6. Electronic position transmitter EWG 01.1 29
9.6.1. Measuring range: set 30
9.6.2. Current values: adjust 30
9.6.3. LED end position signalling: switch on/off 31
9.7. Potentiometer 31
9.7.1. Potentiometer setting 31
9.8. Electronic position transmitter RWG 32
9.8.1. Measuring range: set 32
9.9. Mechanical position indicator: set 33
9.10. Switch compartment: close 34
10. Corrective action.................................................................................................................... 35
10.1. Faults during commissioning 35
10.2. Motor protection (thermal monitoring) 35
11. Servicing and maintenance................................................................................................... 37
11.1. Preventive measures for servicing and safe operation 37
11.2. Maintenance 37
11.3. Disposal and recycling 38
12. Technical data......................................................................................................................... 39
12.1. Technical data Multi-turn actuators 39
13. Spare parts............................................................................................................................. 42
13.1. Multi-turn actuators SA 07.2 – SA 16.2/SAR 07.2 – SAR 16.2 42
14. Certificates.............................................................................................................................. 44
14.1. Declaration of Incorporation and EC Declaration of Conformity 44
Index........................................................................................................................................ 47
Addresses............................................................................................................................... 49
3
SA 07.2 – SA 16.2/SAR 07.2 – SAR 16.2
Safety instructions
1. Safety instructions
1.1. Basic information on safety
Standards/directives AUMA products are designed and manufactured in compliance with recognised
standards and directives. This is certified in a Declaration of Incorporation and an
EC 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.
Safety instructions/warn- All personnel working with this device must be familiar with the safety and warning
ings 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.
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.
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 actuators are designed for the operation of industrial valves, e.g.
globe valves, gate valves, butterfly valves, and ball valves.
Other applications require explicit (written) confirmation by the manufacturer.
4
SA 07.2 – SA 16.2/SAR 07.2 – SAR 16.2
Safety instructions
● Escalators
● Continuous duty
● Buried service
● Permanent submersion (observe enclosure protection)
● Potentially explosive areas, with the exception of zone 22
● 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.
Information These operation instructions are only valid for the "clockwise closing" standard
version, i.e. driven shaft turns clockwise to close the valve.
1.3. Applications in Ex zone 22 (option)
Actuators of the indicated series basically meet the requirements for applications in
dust hazardous locations of ZONE 22 in compliance with the ATEX directive 94/9/EC.
The actuators are designed to meet enclosure protection IP68 and fulfil the
requirements of EN 50281-1-1:1998 section 6 - Electrical apparatus for use in
presence of combustible dust, requirements for category 3 electrical equipment -
protected by enclosures.
To comply with all requirements of EN 50281-1-1:1998, it is imperative that the
following points are observed:
● In compliance with the ATEX directive 94/9/EC, the actuators must be equipped
with an additional identification – II3D IP6X T150 °C.
● The maximum surface temperature of the actuators, based on an ambient
temperature of +40 °C in accordance with EN 50281-1-1 section 10.4, is +150
°C. In accordance with section 10.4, an increased dust deposit on the equipment
was not considered for the determination of the maximum surface temperature.
● The correct connection of the thermoswitches or the PTC thermistors as well
as fulfilling the requirements of the duty type and the technical data are pre-
requisites for compliance with the maximum surface temperature of devices.
● The connection plug may only be plugged in or pulled out when device is dis-
connected from the mains.
● The cable glands used also have to meet the requirements of category II3 D
and must at least comply with enclosure protection IP67.
● The actuators must be connected by means of an external ground connection
(accessory part) to the potential compensation or integrated into an earthed
piping system.
● The threaded plug (part no. 511.0) or the stem protection tube with protective
cap (part nos. 568.1 and 568.2) for sealing the hollow shaft must imperatively
be mounted to guarantee tightness and therefore the combustible dust hazard
protection.
● As a general rule, the requirements of EN 50281-1-1 must be respected in dust
hazardous locations. During commissioning, service, and maintenance, special
care as well as qualified and trained personnel are required for the safe operation
of actuators.
1.4. Warnings and notes
5
SA 07.2 – SA 16.2/SAR 07.2 – SAR 16.2
Safety instructions
Information The term Information preceding the text indicates important notes and information.
6
SA 07.2 – SA 16.2/SAR 07.2 – SAR 16.2
Identification
2. Identification
2.1. Name plate
Each device component (actuator, motor) is equipped with a name plate.
Figure 1: Arrangement of name plates
7
SA 07.2 – SA 16.2/SAR 07.2 – SAR 16.2
Identification
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 compiled.
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 serial number (with example)
05 14 MD12345
st nd
1 +2 position: Assembly in week
05 Week 05
rd th
3 +4 position: Year of production
14 Year of production: 2014
All other positions
MD12345 Internal number for unambiguous product identification
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 of serial number.
Figure 4: Link to the App store:
8
SA 07.2 – SA 16.2/SAR 07.2 – SAR 16.2
Transport, storage and packaging
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.
→ Actuators mounted on valves: Attach ropes or hooks for the purpose of lifting
by hoist to valve and NOT to actuator.
→ Actuators mounted to gearboxes: Attach ropes or hooks for the purpose of lifting
by hoist only to the gearbox using eyebolts and NOT to the actuator.
→ Actuators mounted to controls: Attach ropes or hooks for the purpose of lifting
by hoist only to the actuator and NOT to the controls.
3.2. Storage
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.
9
SA 07.2 – SA 16.2/SAR 07.2 – SAR 16.2
Assembly
4. Assembly
Figure 5: Handwheel
[1] Spacer
[2] Input shaft
[3] Handwheel
[4] Circlip
10
SA 07.2 – SA 16.2/SAR 07.2 – SAR 16.2
Assembly
4.3.1.1. Multi-turn actuator (with output drive types B1 – B4 or E): mount to valve/gearbox
11
SA 07.2 – SA 16.2/SAR 07.2 – SAR 16.2
Assembly
✔ This working step is only required if stem nut is supplied unbored or with pilot
bore.
Figure 7: Design of output drive type A
12
SA 07.2 – SA 16.2/SAR 07.2 – SAR 16.2
Assembly
4.3.2.2. Multi-turn actuator (with output drive type A): mount to valve
1. If the output drive type A is already mounted to the multi-turn actuator: Loosen
screws [3] and remove output drive type A [2].
2. Check if the flange of output drive type A matches the valve flange [4].
3. Apply a small quantity of grease to the valve stem [1].
4. Place output drive type A on valve stem and turn until it is flush on the valve
flange.
5. Turn output drive type A until alignment of the fixing holes.
6. Screw in fastening screws [5], however do not completely tighten.
7. Fit multi-turn actuator on the valve stem so that the stem nut dogs engage into
the output drive sleeve.
➥ The flanges are flush with each other if properly engaged.
8. Adjust multi-turn actuator until alignment of the fixing holes.
9. Fasten multi-turn actuator with screws [3].
10. Fasten screws [3] crosswise with a torque according to table.
11. Turn multi-turn actuator with handwheel in direction OPEN until valve flange
and output drive A are firmly placed together.
12. Tighten fastening screws [5] between valve and output drive type A crosswise
applying a torque according to table.
13
SA 07.2 – SA 16.2/SAR 07.2 – SAR 16.2
Assembly
14
SA 07.2 – SA 16.2/SAR 07.2 – SAR 16.2
Electrical connection
5. Electrical connection
5.1. Basic information
Wiring diagram/terminal
The pertaining wiring diagram/terminal plan (both in German and English) is attached
plan to the device in a weather-proof bag, together with these operation instructions. It
can also be requested from AUMA (state order number, refer to name plate) or
downloaded directly from the Internet (http://www.auma.com).
Delay time
The delay time is the time from the tripping of the limit or torque switches to the motor
power being switched off. To protect the valve and the actuator, we recommend a
delay time < 50 ms. Longer delay times are possible provided the operating time,
output drive type, valve type, and the type of installation are considered. We
recommend switching off the corresponding contactor directly by limit or torque
switch.
Protection on site
For short-circuit protection and for disconnecting the actuator from the mains, fuses
and disconnect switches have to be provided by the customer.
The current value for respective sizing is derived from the current consumption of
the motor (refer to electrical data sheet).
Limit and torque
Limit and torque switches can be provided as single, tandem, or triple switches. Only
switches the same potential can be switched on the two circuits (NC/NO contact) of each
single switch. If different potentials are to be switched simultaneously, tandem
switches or triple switches are required. When using tandem/triple switches:
● For signalling use the leading contacts TSC1, TSO1, LSC1, LSO1.
● For switching off use the lagging contacts TSC, TSO, LSC, LSO.
Type of current, mains Type of current, mains voltage and mains frequency must match the data on the
voltage and mains fre- motor name plate.
quency
15
SA 07.2 – SA 16.2/SAR 07.2 – SAR 16.2
Electrical connection
● Power terminals (U1, V1, W1, U2, V2, W2): max. 6 mm² flexible/10 mm² solid
●
PE connection : max. 6 mm² flexible/10 mm² solid
● Control contacts (1 to 50): max. 2.5 mm²
5.2.1. Terminal compartment: open
[1] Cover
[2] Screws for cover
[3] O-ring
[4] Screws for socket carrier
[5] Socket carrier
[6] Cable entry
[7] Blanking plug
[8] Cable gland (not included in delivery)
16
SA 07.2 – SA 16.2/SAR 07.2 – SAR 16.2
Electrical connection
Hazardous voltage!
Risk of electric shock.
→ Disconnect device from the mains before opening.
4. Seal unused cable entries [6] with suitable blanking plugs [7].
5. Insert the cables into the cable glands [8].
5.2.2. Cable connection
17
SA 07.2 – SA 16.2/SAR 07.2 – SAR 16.2
Electrical connection
Information Some actuators are equipped with an additional motor heater. The motor heater
minimises condensation within the motor.
18
SA 07.2 – SA 16.2/SAR 07.2 – SAR 16.2
Electrical connection
[1] Cover
[2] Screws for cover
[3] O-ring
[4] Screws for socket carrier
[5] Socket carrier
[6] Cable entry
[7] Blanking plug
[8] Cable gland (not included in delivery)
1. Insert the socket carrier [5] into the cover [1] and fasten with screws [4].
2. Clean sealing faces of cover [1] and housing.
3. Check whether O-ring [3] is in good condition, replace if damaged.
4. Apply a thin film of non-acidic grease (e.g. petroleum jelly) to the O-ring and
insert it correctly.
5. Fit cover [1] and fasten screws [2] evenly crosswise.
6. Fasten cable glands [8] applying the specified torque to ensure the required
enclosure protection.
5.3. Accessories for electrical connection
— Option —
5.3.1. Parking frame
Application Parking frame for safe storage of a disconnected plug.
For protection against touching the bare contacts and against environmental
influences.
19
SA 07.2 – SA 16.2/SAR 07.2 – SAR 16.2
Electrical connection
20
SA 07.2 – SA 16.2/SAR 07.2 – SAR 16.2
Operation
6. Operation
Controls are required to operate an actuator during motor operation. If the actuator
is to be operated locally, additional local controls are required.
21
SA 07.2 – SA 16.2/SAR 07.2 – SAR 16.2
Indications
7. Indications
7.1. Mechanical position indicator/running indication
— Option —
Mechanical position indicator:
● Continuously indicates the valve position
(For complete travel from OPEN to CLOSED or vice versa, the indicator disc
[2] rotates by approximately 180° to 230°.)
● Indicates whether the actuator is running (running indication)
● Indicates that the end positions are reached (via indicator mark [3])
Figure 18: Mechanical position indicator
[1] Cover
[2] Indicator disc
[3] Mark
[4] Symbol for position OPEN
[5] Symbol for position CLOSED
22
SA 07.2 – SA 16.2/SAR 07.2 – SAR 16.2
Signals
8. Signals
8.1. Feedback signals from actuator
Information The switches can be provided as single switches (1 NC and 1 NO), as tandem
switches (2 NC and 2 NO) or as triple switches (3 NC and 3 NO). The precise version
is indicated in the terminal plan or on the order-related technical data sheet.
23
SA 07.2 – SA 16.2/SAR 07.2 – SAR 16.2
Commissioning
9. Commissioning
The switch compartment must be opened to perform the following settings (options).
1. Loosen screws [2] and remove cover [1] from the switch compartment.
24
SA 07.2 – SA 16.2/SAR 07.2 – SAR 16.2
Commissioning
Black section:
[1] Setting spindle: End position CLOSED
[2] Pointer: End position CLOSED
[3] Mark: End position CLOSED is set
White section:
[4] Setting spindle: End position OPEN
[5] Pointer: End position OPEN
[6] Mark: End position OPEN is set
25
SA 07.2 – SA 16.2/SAR 07.2 – SAR 16.2
Commissioning
Black section:
[1] Setting spindle: Running direction CLOSE
[2] Pointer: Running direction CLOSE
[3] Mark: Intermediate position CLOSED is set
White section:
[4] Setting spindle: Running direction OPEN
[5] Pointer: Running direction OPEN
[6] Mark: Intermediate position OPEN is set
26
SA 07.2 – SA 16.2/SAR 07.2 – SAR 16.2
Commissioning
Information After 177 turns (control unit for 1 – 500 turns/stroke) or 1,769 turns (control unit for
1 – 5,000 turns/stroke), the intermediate switches release the contact.
9.4.1. Running direction CLOSE (black section): set
27
SA 07.2 – SA 16.2/SAR 07.2 – SAR 16.2
Commissioning
28
SA 07.2 – SA 16.2/SAR 07.2 – SAR 16.2
Commissioning
Setting elements The EWG is housed in the actuator switch compartment. The switch compartment
must be opened to perform any settings. ➔ Refer to <Switch compartment: open>.
All settings are made via the two push buttons [S1] and [S2].
Figure 23: View on control unit when switch compartment is open
29
SA 07.2 – SA 16.2/SAR 07.2 – SAR 16.2
Commissioning
For measuring range setting, voltage must be applied at the position transmitter.
Information ● Both measuring ranges 0/4 – 20 mA and 20 – 0/4 mA (inverse operation) can
be set.
During setting process, the measuring range (normal or inverse operation) is
assigned to the end positions by push button S1/S2 assignment.
● Setting mode activating clears the setting in both end positions and sets the
output current to a value of 3.5 mA. After activation, both end values (0/4 mA
and 20 mA) need to be reset.
● In case of inadvertent incorrect adjustment, the settings can always be reset
by renewed activation of the setting mode (simultaneous pressing of [S1] and
[S2]).
Activate setting mode 1. Press both push buttons [S1] and [S2] and hold down for 5 seconds:
➥ By pulsing double flashes, the LED indicates that the setting mode is correctly
activated:
➥ For any other LED flash sequence (single/triple flashing): ➔ Refer to <Faults
during commissioning>.
Set measuring range 2. Operate valve in one of the end positions (OPEN/CLOSED).
3. Set desired output current (0/4 mA or 20 mA):
→ for 4 mA: Hold down push button [S1] for approx. 3 seconds,
until LED is slowly blinking .
→ for 0 mA: Hold down push button [S1] for approx. 6 seconds,
until LED is blinking fast .
→ for 20 mA: Hold down push button [S2] for approx. 3 seconds,
until LED is illuminated .
4. Operate valve into opposite end position.
➥ The value set in end position (0/4 mA or 20 mA) does not change during travel
in setting mode.
5. Perform setting in the second end position following the same steps.
6. Approach both end positions again to check the setting.
→ If the measuring range cannot be set:
Refer to <Faults during commissioning>.
→ If the current values (0/4/20 mA) are incorrect:
Refer to <Current values: adjust>.
→ If the current value fluctuates (e.g. between 4.0 – 4.2 mA):
<LED end position signalling: switch on/off>.
9.6.2. Current values: adjust
The current values (0/4/20 mA) set in end positions can be adjusted at any time.
Conventional values are e.g. 0.1 mA (instead of 0 mA) or 4.1 mA (instead 4 mA).
Information If the current value fluctuates (e.g. between 4.0 – 4.2 mA), the <LED end position
signalling> must be switched on for current adjustment.
30
SA 07.2 – SA 16.2/SAR 07.2 – SAR 16.2
Commissioning
The LED behaviour for end position reached can be set as follows: blinking/continuous
illumination or no illumination. During setting mode, end positions signalling is
switched on.
Switching on and off 1. Operate valve in one of the end positions (OPEN/CLOSED).
2. Hold down push buttons [S1] or [S2] for approx. 3 seconds.
➥ End position signalling is switched on or off.
9.7. Potentiometer
— Option —
The potentiometer is used as travel sensor and records the valve position.
Setting elements The potentiometer is housed in the actuator switch compartment. The switch
compartment must be opened to perform any settings. ➔ Refer to <Switch
compartment: open>.
Setting is made via potentiometer [1].
Figure 24: View on control unit
[1] Potentiometer
Information Due to the ratio of the reduction gearing, the complete resistance range/stroke is not
always covered. Therefore, external adjustment (setting potentiometer) must be
provided.
1. Move valve to end position CLOSED.
31
SA 07.2 – SA 16.2/SAR 07.2 – SAR 16.2
Commissioning
Setting elements The RWG is housed in the actuator switch compartment. The switch compartment
must be opened to perform any settings. Refer to <Switch compartment: open>.
Setting is made via three potentiometers [1], [2] and [3].
Figure 25: View on control unit when switch compartment is open
For measuring range setting, voltage must be applied at the position transmitter.
32
SA 07.2 – SA 16.2/SAR 07.2 – SAR 16.2
Commissioning
33
SA 07.2 – SA 16.2/SAR 07.2 – SAR 16.2
Commissioning
34
SA 07.2 – SA 16.2/SAR 07.2 – SAR 16.2
Corrective action
Switch check
The red test buttons [1] and [2] are used for manual operation of the switches:
1. Turn test button [1] in direction of the TSC arrow: Torque switch CLOSED trips.
3. Turn test button [2] in direction of the TSO arrow: Torque switch OPEN trips.
If the actuator is equipped with a DUO limit switching (option), the intermediate
position switches (LSA and LSB) will be operated at the same time as the torque
switches.
1. Turn test button [1] in direction of the LSC arrow: Limit switch CLOSED trips.
2. Turn test button [2] in direction of the LSO arrow: Limit switch OPEN trips.
10.2. Motor protection (thermal monitoring)
In order to protect against overheating and impermissibly high temperatures at the
actuator, PTC thermistors or thermoswitches are embedded in the motor winding.
They trip as soon as the max. permissible winding temperature has been reached.
35
SA 07.2 – SA 16.2/SAR 07.2 – SAR 16.2
Corrective action
Behaviour during failure If the signals are correctly wired within the controls, the actuator is stopped and can
only resume its operation once the motor has cooled down.
Possible causes Overload, running time exceeded, max. number of starts exceeded, ambient
temperature is too high.
Remedy Check cause, eliminate if possible.
36
SA 07.2 – SA 16.2/SAR 07.2 – SAR 16.2
Servicing and maintenance
AUMA
AUMA offer extensive service such as servicing and maintenance as well as customer
Service & Support product training. For the relevant contact addresses, please refer to <Addresses>
in this document or to the Internet (www.auma.com).
37
SA 07.2 – SA 16.2/SAR 07.2 – SAR 16.2
Servicing and maintenance
38
SA 07.2 – SA 16.2/SAR 07.2 – SAR 16.2
Technical data
39
SA 07.2 – SA 16.2/SAR 07.2 – SAR 16.2
Technical data
40
SA 07.2 – SA 16.2/SAR 07.2 – SAR 16.2
Technical data
Service conditions
Use Indoor and outdoor use permissible
Mounting position Any position
Installation altitude ≤ 2 000 m above sea level
> 2,000 m above sea level, please contact AUMA
Ambient temperature Standard: –40 °C to +80 °C
–40 °C to +60 °C (multi-turn actuators for modulating duty with DC motors)
Options: –50 °C to +60 °C (1-phase AC motors)
–60 °C to +60 °C (3-phase AC motors)
0 °C to +120 °C (multi-turn actuators for modulating duty with 3-phase AC motors)
For exact version, refer to actuator name plate.
Enclosure protection according Standard: IP68
to EN 60529 For special motors differing enclosure protection: refer to name plate.
Option: DS Terminal compartment additionally sealed against interior (double sealed)
According to AUMA definition, enclosure protection IP68 meets the following requirements:
● Depth of water: maximum 8 m head of water
● Duration of continuous immersion in water: max. 96 hours
● Up to 10 operations during flooding.
Modulating duty is not possible during continuous immersion.
For actual version, refer to actuator name plate.
Pollution degree Pollution degree 4 (when closed) according to EN 50178
Vibration resistance according 2 g, from 10 to 200 Hz
to IEC 60068-2-6 Resistant to vibration during start-up or for failures of the plant. However, a fatigue strength
may not be derived from this. Valid for multi-turn actuators in version AUMA NORM (with
AUMA plug/socket connector, without actuator controls). Not valid in combination with
gearboxes.
Corrosion protection Standard: KS: Suitable for installation in industrial units, in water or power plants with a
low pollutant concentration as well as for installation in occasionally or perman-
ently aggressive atmosphere with a moderate pollutant concentration (e.g.
wastewater treatments plants, chemical industry)
Option: KX: Suitable for installation in extremely aggressive atmospheres with high hu-
midity and high pollutant concentration
KX-G : same as KX, however aluminium-free version (outer parts)
Finish coating Powder coating
Two-component iron-mica combination
Colour Standard: AUMA silver-grey (similar to RAL 7037)
Option: Other colours are possible on request.
Lifetime AUMA multi-turn actuators meet or exceed the lifetime requirements of EN 15714-2. For
further details, please contact AUMA
Further information
EU Directives Electromagnetic Compatibility (EMC): (2004/108/EC)
Low Voltage Directive: (2006/95/EC)
Machinery Directive: (2006/42/EC)
41
SA 07.2 – SA 16.2/SAR 07.2 – SAR 16.2
Spare parts
42
SA 07.2 – SA 16.2/SAR 07.2 – SAR 16.2
Spare parts
Information: 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. Delivered spare parts may slightly vary from the representation in these instructions.
Ref. Designation Type Ref. Designation Type
no. no.
001.0 Housing Sub-assembly 539.0 Screw plug Sub-assembly
002.0 Bearing flange Sub-assembly 542.0 Handwheel with ball handle Sub-assembly
003.0 Hollow shaft Sub-assembly 549.0 Output drive B1/B3/B4/C Sub-assembly
005.0 Drive shaft Sub-assembly 549.1 Output drive sleeve B1/B3/B4/C
005.1 Motor coupling 553.0 Mechanical position indicator Sub-assembly
005.3 Manual drive coupling 554.0 Socket carrier for motor plug/ socket Sub-assembly
connector with cable harness
009.0 Planetary gear for manual drive Sub-assembly 556.0 Potentiometer for position transmitter Sub-assembly
017.0 Torque lever Sub-assembly 556.1 Potentiometer without slip clutch Sub-assembly
018.0 Gear segment 557.0 Heater Sub-assembly
019.0 Crown wheel 558.0 Blinker transmitter including pins at Sub-assembly
wires (without impulse disc and insula-
tion plate)
022.0 Drive pinion II for torque switching Sub-assembly 559.0-1 Control unit with torque switching Sub-assembly
heads and switches
023.0 Output drive wheel for limit switching Sub-assembly 559.0-2 Control unit with magnetic limit and Sub-assembly
torque transmitter (MWG) for Non- in-
trusive version in combination with
AUMATIC integral controls
024.0 Drive wheel for limit switching Sub-assembly 560.0-1 Switch stack for direction OPEN Sub-assembly
025.0 Locking plate Sub-assembly 560.0-2 Switch stack for direction CLOSE Sub-assembly
058.0 Wire for protective earth Sub-assembly 560.1 Switch for limit/torque switching Sub-assembly
070.0 Motor (VD motor incl. ref. no. 079.0) Sub-assembly 560.2 Switch case
079.0 Planetary gear for motor drive Sub-assembly 566.0 Position transmitter EWG/RWG Sub-assembly
(SA/SAR 07.2 — 16.2 for VD motor)
155.0 Reduction gearing Sub-assembly 566.1 Potentiometer for RWG without slip Sub-assembly
clutch
500.0 Cover Sub-assembly 566.2 Position transmitter board for RWG Sub-assembly
501.0 Socket carrier (complete with sockets) Sub-assembly 566.3 Wire harness for RWG Sub-assembly
502.0 Pin carrier without pins Sub-assembly 567.1 Slip clutch for potentiometer Sub-assembly
503.0 Socket for controls Sub-assembly 568.1 Stem protection tube (without cap)
504.0 Socket for motor Sub-assembly 568.2 Cap for stem protection tube
505.0 Pin for controls Sub-assembly 568.3 V-seal
506.0 Pin for motor Sub-assembly 574.1 Radial seal for output drive type A with
ISO flange
507.0 Cover for electrical connection Sub-assembly 575.1 Stem nut A (without thread)
511.0 Threaded plug Sub-assembly 583.0 Motor coupling on motor shaft Sub-assembly
514.0 Output drive form A (without stem nut) Sub-assembly 583.1 Pin for motor coupling
514.1 Axial needle roller bearing Sub-assembly 584.0 Retaining spring for motor coupling Sub-assembly
516.0 Output drive D S1 Seal kit, small Set
535.1 Snap ring S2 Seal kit, large Set
43
SA 07.2 – SA 16.2/SAR 07.2 – SAR 16.2
Certificates
14. Certificates
14.1. Declaration of Incorporation and EC Declaration of Conformity
44
SA 07.2 – SA 16.2/SAR 07.2 – SAR 16.2
45
SA 07.2 – SA 16.2/SAR 07.2 – SAR 16.2
46
SA 07.2 – SA 16.2/SAR 07.2 – SAR 16.2
Index
M
Index Mains frequency 15
Mains voltage 15
A Maintenance 4 , 37 , 37
Accessories (electrical con- 19 Manual operation 21
nection) Mechanical position indicator 22 , 33
Accessories for assembly 14 Motor heater 18
Ambient temperature 7 , 41 Motor operation 21
Applications 4 Motor protection 35
Assembly 10
N
C Name plate 7 , 15
Certificates 44
Commissioning 4 , 24 O
Corrective action 35 Operation 4 , 21
Corrosion protection 9 , 41 Order number 7, 8
Cross sections 16 Output drive type A 11
Current consumption 15 Output drive types B, B1, B2, 10
B3, B4, and E
D Output speed 7
Data Matrix code 8
Declaration of Incorporation 44 P
Delay time 15 Packaging 9
Device type 8 Parking frame 19
Direction of rotation 27 Position indicator 33
Directives 4 Position transmitter EWG 29 , 29
Disposal 38 Position transmitter RWG 32
Double sealed 20 Potentiometer 31
DUO limit switching 26 Power supply 15
Production, year 8
E Protection cover 20
Earth connection 20 Protection on site 15
EC Declaration of Conformity 44 Protective measures 4
Electrical connection 15 PTC thermistors 35
Electronic position transmitter 29 , 32
Enclosure protection 7 , 41 Q
EWG 29 Qualification of staff 4
F R
Fault 35 Range of application 4
Flange size 8 Recycling 38
Running indication 22
H RWG 32
Handwheel 10
I
Identification 7
Indications 22
Indicator disc 22 , 33
Inspection record 8
Intermediate frame 20
Intermediate positions 26
Inverse operation (0/20 – 4 30
mA)
L
Limit switches 15
Limit switching 25 , 28
Lubrication 37
47
SA 07.2 – SA 16.2/SAR 07.2 – SAR 16.2
Index
S
Safety instructions 4
Safety instructions/warnings 4
Serial number 7, 8
Service 37
Servicing 37
Short-circuit protection 15
Signals 23
Size 8
Spare parts 42
Standards 4
Stem nut 12
Stem protection tube 14
Storage 9
Support 37
Support App 8, 8
Switch check 35
Switches 15
T
Tandem switches 15
Technical data 39
Technical data for switches 40
Terminal plan 15
Test run 27
Thermal monitoring 35
Thermoswitches 35
Torque range 7
Torque switches 15
Torque switching 24
Transport 9
Type (device type) 8
Type designation 7
Type of current 15
Type of lubricant 7
V
Valve stem 14
W
Wiring diagram 8 , 15
Y
Year of production 8
48
AUMA worldwide
49
AUMA worldwide
AUMA South Africa (Pty) Ltd. AUMA Actuators Middle East AUMA Malaysia Office
ZA 1560 Springs BH 152 68 Salmabad MY 70300 Seremban, Negeri Sembilan
Tel +27 11 3632880 Tel +97 3 17896585 Tel +606 633 1988
aumasa@mweb.co.za salesme@auma.com sales@auma.com.my
America Mikuni (B) Sdn. Bhd. Mustafa Sultan Science & Industry Co LLC
BN KA1189 Kuala Belait OM Ruwi
AUMA Argentina Rep.Office Tel + 673 3331269 / 3331272 Tel +968 24 636036
AR Buenos Aires mikuni@brunet.bn r-negi@mustafasultan.com
Tel +54 11 4737 9026
contacto@aumaargentina.com.ar AUMA Actuators China Co., Ltd FLOWTORK TECHNOLOGIES
CN 215499 Taicang CORPORATION
AUMA Automação do Brazil ltda. Tel +86 512 3302 6900 PH 1550 Mandaluyong City
BR Sao Paulo mailbox@auma-china.com Tel +63 2 532 4058
Tel +55 11 4612-3477 www.auma-china.com flowtork@pldtdsl.net
contato@auma-br.com
PERFECT CONTROLS Ltd. M & C Group of Companies
TROY-ONTOR Inc. HK Tsuen Wan, Kowloon PK 54000 Cavalry Ground, Lahore Cantt
CA L4N 8X1 Barrie, Ontario Tel +852 2493 7726 Tel +92 42 3665 0542, +92 42 3668 0118
Tel +1 705 721-8246 joeip@perfectcontrols.com.hk sales@mcss.com.pk
troy-ontor@troy-ontor.ca www.mcss.com.pk
PT. Carakamas Inti Alam
AUMA Chile Representative Office ID 11460 Jakarta Petrogulf W.L.L
CL 9500414 Buin Tel +62 215607952-55 QA Doha
Tel +56 2 821 4108 auma-jkt@indo.net.id Tel +974 44350151
aumachile@auma-chile.cl pgulf@qatar.net.qa
AUMA INDIA PRIVATE LIMITED.
Ferrostaal de Colombia Ltda. IN 560 058 Bangalore AUMA Saudi Arabia Support Office
CO Bogotá D.C. Tel +91 80 2839 4656 SA 31952 Al Khobar
Tel +57 1 401 1300 info@auma.co.in Tel + 966 5 5359 6025
dorian.hernandez@ferrostaal.com www.auma.co.in Vinod.Fernandes@auma.com
www.ferrostaal.com
ITG - Iranians Torque Generator AUMA ACTUATORS (Singapore) Pte Ltd.
Transcontinental Trading Overseas SA. IR 13998-34411 Teheran SG 569551 Singapore
CU Ciudad Habana +982144545654 Tel +65 6 4818750
Tel +53 7 208 9603 / 208 7729 info@itg-co.ir sales@auma.com.sg
tto@ttoweb.com www.auma.com.sg
Trans-Jordan Electro Mechanical Supplies
AUMA Región Andina & Centroamérica JO 11133 Amman NETWORK ENGINEERING
EC Quito Tel +962 - 6 - 5332020 SY Homs
Tel +593 2 245 4614 Info@transjordan.net +963 31 231 571
auma@auma-ac.com eyad3@scs-net.org
www.auma.com AUMA JAPAN Co., Ltd.
JP 211-0016 Kawasaki-shi, Kanagawa Sunny Valves and Intertrade Corp. Ltd.
Corsusa International S.A.C. Tel +81-(0)44-863-8371 TH 10120 Yannawa, Bangkok
PE Miraflores - Lima mailbox@auma.co.jp Tel +66 2 2400656
Tel +511444-1200 / 0044 / 2321 www.auma.co.jp mainbox@sunnyvalves.co.th
corsusa@corsusa.com www.sunnyvalves.co.th
www.corsusa.com DW Controls Co., Ltd.
KR 153-702 Gasan-dong, GeumChun-Gu,, Top Advance Enterprises Ltd.
Control Technologies Limited Seoul TW Jhonghe City, Taipei Hsien (235)
TT Marabella, Trinidad, W.I. Tel +82 2 2624 3400 Tel +886 2 2225 1718
Tel + 1 868 658 1744/5011 import@actuatorbank.com support@auma-taiwan.com.tw
www.ctltech.com www.actuatorbank.com www.auma-taiwan.com.tw
50
AUMA worldwide
51
AUMA Riester GmbH & Co. KG
P.O.Box 1362
DE 79373 Muellheim
Tel +49 7631 809 - 0
Fax +49 7631 809 - 1250
riester@auma.com
www.auma.com
Y004.750/003/en/1.14
2
Short description
1. Short description
The gearbox described here is based on a GS.3 part-turn gearbox. Instead of the
output drive flange and the coupling, a base flange and a lever are mounted for the
"base and lever" version. Typically, a lever arrangement with ball joints is mounted
to the lever for valve operation.
Version The first letter of the version indicates the position of the worm shaft in relation to
the worm wheel (view on input shaft).
The second letter indicates the direction of rotation at the output drive (view on
housing cover) for clockwise rotation at the input shaft.
Versions: Worm shaft position and direction of rotation of actuator GS 50.3 – GS 250.3 with base and lever
RR LL RL LR
Initials Direction of rotation at input shaft Position of worm shaft Direction of rotation at output drive
RR Clockwise Right Clockwise
LL Clockwise Left Counterclockwise
RL Clockwise Right Counterclockwise
LR Clockwise Left Clockwise
3
Assembly
2. Assembly
1. Adjust mounting position to ensure that tube to valve [1] as well as swing lever
of gearbox [2] are in parallel.
Information: Observe permissible angle deflection between tube and swing
lever.
- in the opposite direction as swing lever [2]: max 10°
- in the same direction as swing lever [2]: max 3°
Figure 1: Permissible angle deflection and bores in base
4
Assembly
3. Fasten lever gearbox with 4 screws (quality min. 8.8) and lock washers.
Table 1:
Dimensions of base bores
Type G H J
GS 50.3 80 40 15
GS 63.3 110 45 15
GS 80.3 110 50 15
GS 100.3 140 60 25
GS 125.3 200 60 30
GS 160.3 250 80 30
GS 200.3 320 95 35
GS 250.3 400 125 45
[1] Circlip
[2] Swing lever
[3] Output shaft
1. Remove circlip [1].
2. Remove swing lever [2] from output shaft [3] and replace again in desired pos-
ition to output shaft.
Table 2:
Lever adjustment by one indent
Type Degrees per indent
GS 50.3 15°
GS 63.3 11.25°
GS 80.3 9°
GS 100.3 11.25°
GS 125.3 9°
GS 160.3
GS 200.3
GS 250.3
5
Assembly
6
Assembly
α Angle deflection
β Angle depending on valve
7
Technical data
3. Technical data
Information The technical data relating to the GS.3 part-turn gearbox type range as well as the
supplement on the version with base and lever (see below) also comprise options
further to the standard version. 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 at http://www.auma.com in both German and English
(please state the order number).
The gearbox is based on a GS.3 part-turn gearbox. Consequently, the technical data
of GS.3 type range applies. The special features for the base and lever version are
described hereafter.
Table 4:
Special features for the base and lever version
Not suitable for load class 3.
Base Made of spheroidal cast iron; for mounting to base, 4 holes for fastening screws are available.
Lever Made of spheroidal cast iron; with 2 or 3 bores for fixing lever arrangement. Considering the environ-
mental conditions, the lever may be mounted to the output shaft in any desired position.
Ball joints Two ball joints matching the lever, as an option including lock nuts and 2 welding nuts; suitable for pipe
according to dimension sheet.
Mechanical position indicator Standard: No position indicator (protection cover)
Option: Pointer cover instead of protection cover for continuous position indication
8
Spare parts
4. Spare parts
4.1. Part-turn gearbox GS 50.3 – GS 125.3 with base and lever
9
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. Delivered spare parts may slightly vary from the
representation in these instructions.
10
Spare parts
11
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. Delivered spare parts may slightly vary from the
representation in these instructions.
12
13
14
15
AUMA Riester GmbH & Co. KG
P.O.Box 1362
DE 79373 Muellheim
Tel +49 7631 809 - 0
Fax +49 7631 809 - 1250
riester@auma.com
www.auma.com
Y006.918/003/en/1.15
order13358799
pos 1
article SAR 07.6
description AUMA NORM modulating actuator
Produktmerkmale
Order code Description
Mounted to : 0
Valve attachment : F10 F10 acc. to EN ISO 5210
Output socket vers.: ST output drive sleeve made of
steel
Output drive : B3-20 B3, bore 20mm, DIN6885.1
Output speed : 45 45 rpm
Type of duty : 1 S4 - 25% ED
Torque : 30-60 setting range 30 - 60 Nm
Max.modul.torque : 30 30 Nm
set to CLOSE : 30 Nm in sense of rotation
CLOSE
set to OPEN : 30 Nm in sense of rotation
OPEN
Temperature version: N-30-70 -30*C - +70*C
Lubricant : F15 ALVANIA 1029
Corrosion protect. : KS-P1.001 powder coating, primer
coatingfinish coating
Colour : A0001 AUMA silver-grey
Enclosure protect. : IP68 IP68 acc. to EN 60529
Handwheel : 160 160mm, aluminium
Close direction : RH clockwise closing
Mains : 380/50/3 380 V 50 Hz 3-ph AC
Insulation class : F F, tropicalised
Motor protection : 00 thermoswitch 140*C NC
Motor : AD0R063-4-0,20 0,2 kW, 4-poles
Position transm. : 40.2 EWG 2-wire system
RWG/IWG value : 4-20 4-20 mA
Travel set to : 111 t/stroke at output drive
multi-turn actuator
Reduction gearing : 10.2 reduction gearing adjustable
Limit switching : 300 1,5-500 t/stroke adjustable
Torque switches : 6.2 tandem switches Ag (2 NC/2
NO)for each direction
Limit switches : 8.2 tandem switches Ag (2 NC/2
NO)for each direction
Heater : 22.1 110V-250V AC/DC
self-regula- ting PTC heater,
5-20W
Terminal plan : 00R1BB-0C1-000 TPA
El. connection : 1 S0 plug
Electrical connect.: S0-105 M20;M25;M32 plug
Mount.pos.pin car. : A
Name plate : EN-AL English, aluminium
Oper. instructions : EN English
Inspect. accord. KV: 01.03.200.01 inspect. record/decl.of compl.
Motormerkmale
Order code Description
Article number : Z100.831
Type designation : AD0R063-4-0,20
Type of current : 3ph-AC
Nominal voltage [V]: 380
Technical data sheet Page: 1 of 2
AUMA Riester GmbH & CoKG
Armaturen- und Maschinenantriebe
Aumastr. 1 ° D-79379 Müllheim
Tel +49 7631 809-0 ° Fax +49 7631 809-1250
www.auma.com ° email: Riester@auma.com
pos 2
article GS. 160.3
description AUMA worm gearbox
Produktmerkmale
Order code Description
Mounted to : 0
Explosion protect. : 0 not suitable for use in
poten-tially explosive
atmospheres
Duty classes : DC1 motor operation: DC1,
accord. to EN15714-2
Version : GF 160.3-442:1 lever gearbox with primary
reduction gearings
Version : LL input shaft clockw.:counter-
clockw. rotation o.valve shaft
Reduction ratio : 442:1
Swing angle [*]: 80-100 adjustable
set to [*]: 92 adjusted at factory
Worm wheel : BZ worm wheel bronze
Gearbox input : EW20 input shaft D=20mm
Input flange : F10 F10 according to EN ISO
5210
Valve attachment : FS with base
Swing lever : H001 bore 26mm H8 taper (1:10)
M1=300mm M2=400mm
Material : GJL housing cast iron
Max. output torque : 11250 11250 Nm output torque
Max. mod. torque : 4000 4000 Nm
Max. input torque 68 68 Nm input torque
Temperature version: N-40-80 -40C - +80C
Lubricant : F15 ALVANIA 1029
Corrosion protect. : KN-N1.001 wet painting, finish coating
Colour : A0001 AUMA silver-grey
Enclosure : IP68 IP68 according to EN 60529
max. 8m head of water
Housing cover : SD-11 protect.cover sealed
Name plate : EN-AL English, aluminium
Oper. instructions : EN English
Inspect. acc. to KV: 02.03.016.01 inspect. record/works certif.
Operating instructions
BA 3600 en 02/2016
FLENDER couplings
Technical data 1
FLENDER RUPEX® 2
Notes
couplings
Fitting 3
Faults, causes
and remedy 5
Operating instructions
Maintenance
Translation of the original operating instructions and repair 6
Declarations 8
BA 3600 en 02/2016
2 / 28
Notes and symbols in these operating instructions
Note: The term "operating instructions" will in the following also be shortened to "instructions" or "manual".
The term "2014/34/EU" used in these instructions applies to the version designed in conformity to directive
94/9/EC, if the product is put on the market by 19.04.2016, and to the version designed in conformity to
directive 2014/34/EU, if the product is put on the market on or after 20.04.2016.
Legal notes
Warning-note concept
This manual comprises notes which must be observed for your personal safety and for preventing material damage.
Notes for your personal safety are marked with a warning triangle or an "Ex" symbol (when applying
Directive 2014/34/EU), those only for preventing material damage with a "STOP" sign.
WARNING! Imminent explosion!
The notes indicated by this symbol are given to prevent explosion damage.
Disregarding these notes may result in serious injury or death.
The notes indicated by this symbol are given to prevent personal injury.
Disregarding these notes may result in serious injury or death.
The notes indicated by this symbol are given to prevent damage to the product.
Disregarding these notes may result in material damage.
NOTE!
The notes indicated by this symbol must be treated as general operating information.
Disregarding these notes may result in undesirable results or conditions.
The notes indicated by this symbol are made to prevent risk of burns due to hot surfaces
and must always be observed.
Disregarding these notes may result in light or serious injury.
Where there is more than one hazard, the warning note for whichever hazard is the most serious is always used.
If in a warning note a warning triangle is used to warn of possible personal injury, a warning of material damage may
be added to the same warning note.
Qualified personnel
The product or system to which these instructions relate may be handled only by persons qualified for the work
concerned and in accordance with the instructions relating to the work concerned, particularly the safety and
warning notes contained in those instructions. Qualified personnel must be specially trained and have the
experience necessary to recognise risks associated with these products or systems and to avoid possible hazards.
BA 3600 en 02/2016
3 / 28
Intended use of Siemens products
Observe also the following:
Siemens products must be used only for the applications provided for in the catalogue and the relevant
technical documentation. If products and components of other makes are used, they must be
recommended or approved by Siemens. The faultfree, safe operation of the products calls for proper
transport, proper storage, erection, assembly, installation, startup, operation and maintenance. The
permissible ambient conditions must be adhered to. Notes in the relevant documentations must be
observed.
Trademarks
All designations indicated with the registered industrial property mark ® are registered trademarks of Siemens AG.
Other designations used in these instructions may be trademarks the use of which by third parties for their own
purposes may infringe holders’ rights.
Exclusion of liability
We have checked the content of the instructions for compliance with the hard and software described.
Nevertheless, variances may occur, and so we can offer no warranty for complete agreement. The information
given in these instructions is regularly checked, and any necessary corrections are included in subsequent editions.
BA 3600 en 02/2016
4 / 28
Contents
1. Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.1 Speeds, geometric data and weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.2 Buffers (5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2. Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.1 Safety instructions and general notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.2 Marking of the coupling parts for use in potentially explosive zones . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.3 Service conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3. Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.1 Machining the finished bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.2 Machining the parallel keyway . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.3 Axial fastening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.4 Balancing after machining the finished bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.5 Placing the coupling parts with cylindrical and conical bore with parallel key . . . . . . . . . . . . . . . . . 16
3.6 Fitting of coupling parts in case of a cylindrical and tapered interference fit set up
for removal by oilhydraulic shrinkingoff . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.7 Fitting the coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.8 Possible misalignments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.8.1 Axial misalignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.8.2 Angular misalignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.8.3 Radial misalignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.9 Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.10 Shaftmisalignment values during operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.11 Assignment of the tightening torques and wrench widths . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4. Startup and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5. Faults, causes and remedy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5.1 Possible cause of fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5.2 Incorrect use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5.2.1 Frequent faults when selecting the coupling and/or coupling size . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5.2.2 Frequent faults when fitting the coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5.2.3 Frequent faults in maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
6. Maintenance and repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
6.1 Maintenance interval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
6.2 Replacement of wearing parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
6.2.1 Extracting the bolts in the case of coupling sizes 450 to 2000 with the demountijg box . . . . . . . . . 23
6.2.2 Extracting the bolts in the case of coupling sizes 450 to 2000 with grease . . . . . . . . . . . . . . . . . . . 23
6.3 Demounting the coupling parts in case of shafthub connection with parallel key . . . . . . . . . . . . . . 23
6.4 Demounting the coupling parts in case of a cylindrical
and tapered interference fit set up for removal by oilhydraulic shrinkingoff . . . . . . . . . . . . . . . . . . 24
7. Stocking spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
7.1 Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
8. Declarations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
8.1 EU declaration of conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
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1. Technical data
The instructions describe the coupling in horizontal mounting position with shafthub connection by
cylindrical or conical bores with parallel key or with shrink fit. If a vertical or inclined arrangement or other
shafthub connections, such as splines to DIN 5480, are to be used, Siemens must be consulted.
The coupling described below may be used in potentially explosible areas. The couplings must have
a CE marking (for marking, see item 2.3).
Couplings which do not have a CE marking must not be used in potentially explosive
areas.
If a dimensioned drawing has been made out for the coupling, the data in this drawing must be given
priority. The dimensioned drawing including any other documents should be made available to the user
of the system.
For part numbers and part designations, see the corresponding spareparts drawing in section 7 or the
dimensioned drawing.
U2
S
P U1
1 2
NL1 NL2
∅ND2
∅ND1
∅DA
∅D1
∅D2
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Table 1: Types RWN and RWS
Speed Maximum bore 1) Weight 2)
NL1
nmax. D1 D2 D1 D2 DA ND1 ND2 ND1 ND2 NL2 P S U1 U2 m m
Size
RWN RWS RWN RWS RWN RWS RWN RWS
1/min 1/min mm mm mm mm mm mm mm mm mm mm mm mm mm mm kg kg
105 7000 10000 32 38 32 38 105 53 59 53 59 45 30 2 ... 4 13 12 1.9 1.9
125 6000 9000 40 48 42 48 125 65 68 65 68 50 35 2 ... 4 16 15 3.2 3.2
144 5250 7800 45 55 50 60 144 76 84 76 84 55 35 2 ... 4 16 15 4.5 4.5
162 4650 6900 50 60 55 65 162 85 92 85 92 60 40 2 ... 5 20 18 6.7 6.7
178 4200 6300 60 70 70 75 178 102 108 102 108 70 40 2 ... 5 20 18 9.7 9.7
198 3750 5600 70 80 80 85 198 120 128 120 128 80 40 2 ... 5 20 18 12.9 12.9
228 3300 4900 80 90 85 95 228 129 140 129 140 90 50 2 ... 5 26 24 19 19
252 3000 4400 90 100 100 110 252 150 160 150 160 100 50 2 ... 5 26 24 26.3 26.3
285 2650 3900 100 110 110 120 285 164 175 164 175 110 60 3 ... 6 32 30 39 39
320 2350 3500 110 120 125 130 320 180 192 180 192 125 60 3 ... 6 32 30 53 53
360 2100 3100 120 130 135 140 360 200 210 200 210 140 75 3 ... 6 42 42 78 78
400 2050 2800 140 140 150 150 400 230 230 230 230 160 75 3 ... 6 42 42 105 110
450 1800 2500 160 160 170 170 450 260 260 260 260 180 90 4 ... 7 52 52 156 163
500 1600 2200 180 180 190 190 500 290 290 290 290 200 90 4 ... 7 52 52 200 217
140 140 165 165 250 250 250 250 280 274
560 1450 2000 180 180 200 200 560 300 300 300 300 220 120 4 ... 8 68 68 290 292
200 200 210 210 320 320 320 320 295 305
140 140 165 165 250 250 250 250 345 352
630 1280 1800 180 180 200 200 630 300 300 300 300 240 120 4 ... 8 68 68 370 370
220 220 235 235 355 355 355 355 400 400
160 160 190 190 290 290 290 290 510 507
710 1150 1600 200 200 220 220 710 330 330 330 330 260 140 5 ... 9 80 80 515 530
240 240 250 250 385 385 385 385 540 560
180 180 210 210 320 320 320 320 670 683
800 1000 1400 220 220 240 240 800 360 360 360 360 290 140 5 ... 9 80 80 690 715
260 260 280 280 420 420 420 420 730 762
210 210 320 320 907
220 220 360 360 940
240 240 360 360 933
900 900 1250 260 260 900 425 425 320 160 5...10 90 90 960
280 280 425 425 1000
290 290 465 465 1030
310 310 465 465 1025
230 230 355 355 1170
240 240 395 395 1200
260 260 395 395 1208
1000 810 1100 280 280 1000 460 460 350 160 5...10 90 90 1250
300 300 460 460 1290
320 320 515 515 1310
340 340 515 515 1343
200 200 240 240 360 360 360 360 1470 1560
250 250 270 270 410 410 410 410 1510 1660
1120 700 1000 1120 380 180 6...11 100 100
300 300 330 330 495 495 495 495 1600 1730
350 350 370 370 560 560 560 560 1690 1870
230 230 270 270 410 410 410 410 1850 2000
280 280 300 300 460 460 460 460 1900 2150
1250 650 900 1250 420 180 6...11 100 100
330 330 360 360 540 540 540 540 2025 2200
380 380 400 400 610 610 610 610 2210 2420
260 260 310 310 465 465 465 465 2820 3020
320 320 350 350 525 525 525 525 2900 3120
1400 570 800 1400 480 210 6...12 120 120
380 380 410 410 620 620 620 620 3180 3350
440 440 460 460 700 700 700 700 3260 3570
320 320 370 370 565 565 565 565 3780 3890
380 380 410 410 625 625 625 625 3870 4270
1600 500 700 1600 540 210 6...12 120 120
440 440 480 480 720 720 720 720 4150 4300
480 480 510 510 770 770 770 770 4290 4630
380 380 440 440 660 660 660 660 5550 6230
440 440 480 480 720 720 720 720 5630 6460
1800 450 600 1800 600 240 8...16 140 140
500 500 540 540 820 820 820 820 6000 6770
540 540 580 580 870 870 870 870 6250 7030
440 440 500 500 760 760 760 760 6800 8140
500 500 540 540 820 820 820 820 7000 8430
2000 400 550 2000 660 240 8...16 140 140
560 560 610 610 920 920 920 920 7350 8860
600 600 640 640 960 960 960 960 7620 9050
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S BB
P U1
1 3
∅ND1
∅ND2
∅DB
∅D2
∅D1
∅DA
NL1 NL2
Fig. 2: Types RWB and RBS with brake drum to DIN 15431
Table 2: Types RWB and RBS with brake drum to DIN 15431
Speed Maximum bore 1) Weight 2)
BB
nmax. D1 D2 D1 D2 DA ND1 ND2 NL1 P S U1 DB m m
Size NL2
RWB RBS RWB RBS RWB RBS
1/min 1/min mm mm mm mm mm mm mm mm mm mm mm mm mm kg kg
144 3400 5000 45 55 50 60 144 76 84 55 35 2 ... 4 16 200 75 9.5 10
162 2750 5000 50 60 55 65 162 85 92 60 40 2 ... 5 20 250 95 17 18
2750 4900 250 95 20 22
178 60 70 70 75 178 102 108 70 40 2 ... 5 20
2150 4350 315 118 28 30
2750 4600 250 95 24 26
198 70 80 80 85 198 120 128 80 40 2 ... 5 20
2150 4350 315 118 32 35
228 1700 3400 80 90 85 95 228 129 140 90 50 2 ... 5 26 400 150 54 60
1700 3400 400 150 63 68
252 90 100 100 110 252 150 160 100 50 2 ... 5 26
1400 2750 500 190 93 103
1400 2750 500 190 104 115
285 100 110 110 120 285 164 175 110 60 3 ... 6 32
1100 2150 630 236 157 171
1100 2150 630 236 172 185
320 110 120 125 130 320 180 192 125 60 3 ... 6 32
950 1900 710 265 217 230
1100 2150 630 236 191 210
360 120 130 135 140 360 200 210 140 75 3 ... 6 42
950 1900 710 265 236 255
1) Maximum bore with keyway to DIN 6885/1.
2) Weights are valid for maximum bores.
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1 S 20
P U1
L1
∅DFN
∅ND1
∅DFA
∅DFK
NL1
∅D1
∅DA
ZF x ∅DFB
FB
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1.2 Buffers (5)
• Buffers may be stored for up to 5 years.
• Buffers must be protected against direct sunlight, artificial light with a high ultraviolet content and
extreme temperatures.
• Buffers must not come into contact with aggressive media.
• Buffers must not be heated up to impermissible temperatures during fitting work (see table 4).
• Buffers must be replaced in sets; only identical buffers may be used in one coupling.
Temperature
Material Hardness Hardness Mark
range
NBR 80 Shore A Standard black buffer - 30 °C to + 80 °C
Special, soft,
black buffer with
shift of rotary resonance
NBR 60 Shore A a green dot - 30 °C to + 80 °C
speed, nominal
on the end face
torque reduced
Special, hard, black buffer with
NBR 90 Shore A shift of rotary a magenta dot - 30 °C to + 80 °C
resonance speed on the end face
Special,
NBR 639 80 Shore A green buffer - 30 °C to + 80 °C
electrically insulating
black buffer with
Special,
NR 80 Shore A a white dot - 50 °C to + 50 °C
use at low temperature
on the end face
black buffer with
Special,
HNBR 80 Shore A a red dot - 10 °C to + 100 °C
use at high temperature
on the end face
Electrically insulating buffers (green) are approved for explosion groups IIA and IIB.
Hightemperature buffers (red marking) are not approved for use in potentially
explosive areas.
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2. Notes
During transport, installation, dismantling, operation and maintenance of the unit, the relevant safety and
environmental regulations must be complied with at all times.
Lifting gears and load equipment for handling the components must be suitable for the
weight of the coupling.
Depending on national regulations, coupling and clutch components may have to be disposed of
separately or separated for recycling.
The coupling must be stored in a dry environment. Adequate preservation must be carried out.
Operators and users must not make any changes to the coupling themselves over and above the treatment
specified in these instructions.
If there is any visible damage the coupling or clutch must not be fitted or put into
operation!
The coupling must not be operated unless housed in a suitable enclosure in accordance with the standards
applying. This also applies to test runs and when checking the direction of rotation.
All work on the coupling must be carried out only when it is at a standstill. Secure the drive unit to prevent
unintentional switchon! A notice should be attached to the ON switch stating clearly that work is in
progress.
In addition to any generally prescribed personal safety equipment (such as safety shoes, safety clothing,
helmet) suitable safety gloves and suitable safety glasses must be worn when handling the coupling
or clutch!
Only spare parts made by the manufacturer Siemens must be used.
Any enquiries should be addressed to:
Siemens AG
Schlavenhorst 100
46395 Bocholt
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2.2 Marking of the coupling parts for use in potentially explosive zones
Couplings which are ordered in Atex configuration, have the following marking on the outer circumference
of coupling part 1:
Siemens AG II 2G T4 / T5 / T6 D120 °C
46393 Bocholt ‐ Germany (- 50 °C) - 30 °C ≤ Ta ≤ + 80 °C / + 50 °C / + 40 °C
FLENDER couplings RUPEX <year built> I M2
When using electrically insulating buffers, the marking of the explosion group IIA, IIB
is added.
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2.3 Service conditions
The coupling is suited for service conditions in accordance with Directive 2014/34/EU:
• Equipment group II (use above ground) of categories 2 and 3 for areas where there are explosible gas,
vapour, mist, air mixtures as well as for areas where dust can form explosible atmospheres.
• The permissible temperature classes and/or maximum surface temperatures are assigned as
a function of the maximum ambient temperature occurring in the immediate vicinity of the coupling
(see table 5).
Table 5: Temperature classes
Ambient temperature Temperature class maximum surface temperature
maximum 80 °C T4 < 108 °C
maximum 50 °C T5 < 80 °C
maximum 40 °C T6 < 68 °C
In the case of types with brake drum (RWB and RBS) the module supplier is
responsible for conformity of the brake drum and/or brake with applicable directives.
To be noted are, amongst other things, hazards from electrostatic charging and hot
surfaces.
If they are to be used below ground in potentially explosive areas the couplings must
only be used with drive motors, which can be switched off on occurring of an
explosible atmosphere.
If coated couplings are used in potentially explosive areas, the requirements made of
the conductivity of the coating and the limitation on the thickness of the coat applied
must be observed in accordance with DIN EN 134631. Where coatings have a
thickness < 200 μm, no electrostatic charge is to be expected.
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3. Fitting
Coupling parts set up for removal by oilhydraulic shrinkingoff are delivered in a finishmachined state
according to the order,
3.1 Machining the finished bore
Remove bolt (4) and buffer (5)
Depreserve and clean coupling parts (1; 2; 3).
Clamp on surfaces marked with , and align.
Machine the finished bore, observe maximum bore described in section 1.
Check finished bore as described in section 4.
BB
IT6 A
A B
∅D1 / D2
IT6 IT6
∅DB
∅D2
3.2 3.2
1)
IT6 B
2)
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3.2 Machining the parallel keyway
Arrangement of the parallel keyway centrally between buffer bores or bolt bores.
• Parallel keyway to DIN 6885/1 ISO JS9 with usual operating conditions.
• Width of parallel keyway ISO P9 with reversing operation.
• Width of parallel keyway ISO P9 with coupling part (3).
3.3 Axial fastening
Arrange set screw on the parallel keyway. Only in case of sizes 105 and 125 place the set screw offset 180°
to the parallel keyway.
Position of the set screw approximately in the middle of the hub, on coupling part 3 under angle of 25°
(see figure 8).
Use threaded studs to DIN 916 with cup points as set screws (setscrew size to table 7).
The set screw should fill out the screw thread as much as possible and must not project beyond the hub.
Alternatively use end plate; as regards recess contact Siemens.
Table 7: Setscrew assignment and tightening torques
Type RWN, RWB, RFN Type RWS, RBS, RFS
Bore range Set-screw Tightening Wrench Bore range Set-screw Tightening Wrench
size torque width size torque width
over up to d1 TA Hexagon over up to d1 TA Hexagon
socket socket
mm mm mm Nm mm mm mm mm Nm mm
8 30 M6 4 3 8 30 M6 4 3
30 38 M8 8 4 30 75 M8 8 4
38 65 M 10 15 5 75 95 M 12 25 6
65 95 M 12 25 6 95 110 M 16 70 8
95 110 M 16 70 8 110 150 M 20 130 10
110 150 M 20 130 10 150 230 M 24 230 12
150 230 M 24 230 12 230 640 M 30 470 14
230 600 M 30 470 14
Tightening torques apply to bolts with untreated surfaces which are not or only lightly oiled (coefficient of
friction μ = 0.14). The use of lubricant paint or lubricant, which affects the coefficient of friction "μ", is not
permitted.
The specified tightening torques TA must be complied with, applying DIN 25202 ScrewConnection
Class "C", with an outputtorque scatter of ± 5 %.
3.4 Balancing after machining the finished bore
The balancing quality is to be specified in accordance with the specific application (however at least G16
to DIN ISO 1940).
Balancing prescription to DIN ISO 8821 of the shaft must be observed.
Balancing bores must not affect the loadbearing capacity of the coupling parts.
The balancing bores must be applied on a large radius with sufficient distance to the buffer bores, bolt
bores and the outer circumference.
The flange must not be completely drilled through. The braking surface of the coupling
part (3) must not be damaged.
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3.5 Placing the coupling parts with cylindrical and conical bore with parallel key
Unscrew the set screw.
Clean the holes and shaft ends.
Coat the bores of the coupling parts (1; 2; 3) and the shafts with MoS2 mounting paste (e.g. Microgleit
LP 405).
Coupling parts (1; 2; 3) with tapered bore and parallelkey connection must be fitted
in cold condition and secured with suitable end plates, without drawing the coupling
parts (1; 2; 3) further onto the taper (fitting dimension = 0).
Place the coupling parts (1; 2; 3); in case of cylindrical bore, heat up to max. + 150 °C, if necessary. When
heating up observe the temperature range of the buffers (5) (see table 5); if necessary demount the buffers
(5).
Heated coupling parts form an explosion hazard, therefor there must not be an
explosible atmosphere when fitting the coupling parts.
Axial securing is effected by means of the set screw or end plate. When securing by set screw the shaft
must not project or be set back from the inner sides of the hub.
Fit the set screw or end plate (tightening torques of the set screw to table 7).
Failure to observe these instructions may result in breakage of the coupling.
Danger from flying fragments!
The coupling then becomes an explosion hazard.
3.6 Fitting of coupling parts in case of a cylindrical and tapered interference fit set up for removal by
oilhydraulic shrinkingoff
The information specified on the dimensioned drawing should be observed with
priority.
Unscrew screw plugs (101 / 201 / 301) from the coupling parts (1; 2; 3). Clean and dry holes and shaft ends.
The oil channels and oilcirculation grooves must also be free from dirt.
The machine shaft and the bore of the coupling part (1; 2; 3) must be absolutely clean
and free of grease and oil!
Before fitting, the bore size of the heated coupling parts (1; 2; 3) must be checked, e.g. with a borehole
gauge.
The coupling parts (1; 2; 3) should be pushed smartly onto the shaft up to the position specified in the
dimensioned drawing.
The coupling parts (1; 2; 3) must be held in position on the shaft with the aid of
a suitable retaining device, until they cool down and seat firmly.
In case of tapered interference fit and non selflocking connection, the axial securing takes place by an end
plate.
After the coupling parts (1; 2; 3) have cooled down to ambient temperature the oil channels must be filled
with clean forcing oil, e.g. ISO VG 150, and resealed with the screw plugs (101 / 201 / 301)
(rust protection).
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3.7 Fitting the coupling
In the case of types RFN and RFS, bolt the coupling part 20 (20) to the counterpart (tightening torques in
accordance with table 10).
If necessary, fit buffer (5) and bolt (4). Observe the temperature range (see table 4).
Bolt and tapered bore must be absolutely clean and free of grease!
Compose balancing groups in accordance with the marking.
Tighten hexagon nuts (7) or bolts (11) using a torque wrench (tightening torques in accordance with
table 9) and secure them with threadlocking medium "mediumfirm" (e.g. Loctite 243). Apply just a small
quantity of Loctite to the bolt (11), otherwise there is a risk that the Loctite may seal the transverse bore.
Align the coupling as described in item 3.8.
Smax. Smax.
ΔKr
ΔKa
ΔKw
Smin. Smin.
1) 2) 3)
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3.9 Alignment
When aligning, the angular and radial misalignment should be kept as low as possible.
Misalignment values specified in table 8 are maximum permissible overall values in operation, resulting
from mispositioning through imprecision during alignment and misalignment through operation
(e.g. deformation through load, heat expansion).
Reduced misalignment in the coupling minimises expected wear on the flexible elements. Misalignment
in the coupling gives rise to restorative forces which may impose inadmissible stress on adjacent machine
parts (e.g. bearings).
3.10 Shaftmisalignment values during operation
The following maximum permissible misalignments must by no means be exceeded during
operation.
When aligning the angular and radial misalignment should be kept appreciably smaller
(tending towards zero).
Table 8: Shaft misalignment values ΔSperm. and ΔKrperm., maximum permissible during operation,
stated in mm (rounded)
Coupling speed in 1/min
Size
250 500 750 1000 1500 2000 3000 4000 5000
105 0.5 0.35 0.3 0.25 0.2 0.15 0.15 0.1 0.1
125 0.55 0.4 0.3 0.25 0.2 0.2 0.15 0.1 0.1
144 0.6 0.4 0.35 0.3 0.25 0.2 0.15 0.15 0.1
162 0.65 0.45 0.35 0.3 0.25 0.2 0.15 0.15 0.15
178 0.7 0.5 0.4 0.35 0.25 0.25 0.2 0.15
198 0.75 0.5 0.4 0.35 0.3 0.25 0.2 0.15
228 0.8 0.55 0.45 0.4 0.3 0.25 0.2 0.2
252 0.85 0.6 0.5 0.45 0.35 0.3 0.25 0.2
285 0.95 0.65 0.55 0.45 0.4 0.3 0.25
320 1.05 0.75 0.6 0.5 0.4 0.35 0.3
360 1.15 0.8 0.65 0.55 0.45 0.4 0.3
400 1.25 0.85 0.7 0.6 0.5 0.45
450 1.35 0.95 0.8 0.7 0.55 0.45
500 1.5 1.05 0.85 0.75 0.6 0.5
560 1.65 1.15 0.95 0.8 0.65 0.55
630 1.85 1.3 1.05 0.9 0.75
710 2.05 1.45 1.15 1 0.8
800 2.25 1.6 1.3 1.1
900 2.5 1.75 1.45 1.25
1000 2.75 1.95 1.6 1.35
1120 3.05 2.15 1.75 1.5
1250 3.4 2.4 1.95
1400 3.75 2.65 2.15
1600 4.3 3
1800 4.8 3.4
2000 5.3 3.75
The numerical values of the table, as well as the intermediate values, can be calculated as follows:
ΔKrperm. = ΔSperm. = (0.1 + DA / 1000) x 40 / √n Coupling speed "n" in 1/min
"DA" in mm, see section 1.
Radial misalignment ΔKrperm. in mm
For speeds < 250 1/min the values in the colon "250 1/min" in table 8 apply.
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3.11 Assignment of the tightening torques and wrench widths
Tightening torques apply to bolts with untreated surfaces which are not or only lightly oiled (coefficient of
friction μ = 0.14). The use of lubricant paint or lubricant, which affects the coefficient of friction "μ", is not
permitted.
The specified tightening torques TA must be complied with, applying DIN 25202 ScrewConnection
Class "C", with an outputtorque scatter of ± 5 %.
The tightening torques and wrench widths of the set screws are specified in table 7.
Table 9: Tightening torques and wrench widths of the screw connection with bolts
162 1120
125 178 228 285 360 450 560 710 900 1250 1800
Size 105 144 252 320 400 500 630 800 1000 1400 2000
198
1600
Tightening
torque TA 8 15 30 55 100 170 180 340 580 600 1150 2000
Wrench width
SW 10 13 17 19 24 27 24 30 36 36 46 55
Hexagon head
Table 10: Tightening torques for bolting coupling part 20 to the counterpart
125 228 320 450
144 178 252 360 500 630
Size 105 198 710 800
162 285 400 560
Bolt size M8 M10 M12 M16 M20 M24 M30 M36
Tightening
torque TA 24.6 48 84 206 415 714 1428 2482
Bolts of strength class 8.8 with a shim to DIN 125 must be used.
Bolttightening torques for the coupling and tightening torques for the foundation
bolts of the coupled machine must be checked before startup. Enclosures (coupling
protection, contact guard) must be fitted!
Overload conditions during startup cannot be excluded. If the coupling breaks
through overload, metal parts may fly off and cause personal injury and/or material
damage.
The coupling must run with little noise and without vibration. Irregular behaviour must be treated as a fault
requiring immediate remedy. In case of fault the drive must be stopped at once. The necessary measures
for repair must be taken in accordance with the safety regulations applying.
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5. Faults, causes and remedy
5.2.1 Frequent faults when selecting the coupling and/or coupling size
• Important information for describing the drive and the environment are not communicated.
• System torque too high.
• System speed too high.
• Application factor not correctly selected.
• Chemically aggressive environment not taken into consideration.
• The ambient temperature is not permissible.
• Finished bore with inadmissible diameter and/or inadmissible assigned fits.
• Machining of parallel keyways of which the width across corners is greater than the width across
corners of the parallel keyways to DIN 6885/1 with a maximum permissible bore.
• The transmission capacity of the shafthub connection is not appropriate to the operating conditions.
• Maximum load or overload conditions are not being taken into consideration.
• Dynamic load conditions are not being taken into consideration.
• Shafthub connection resulting in impermissible material stress on the coupling.
• Operating conditions are being changed without authorisation.
• Coupling and machine / drive train form a critical torsional, axial and bending vibration system.
• Fatigue torque load too high.
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5.2.2 Frequent faults when fitting the coupling
• Components with transport or other damage are being fitted.
• When fitting coupling parts in a heated condition, already fitted RUPEX buffers (5) are being
excessively heated.
• The shaft diameter is beyond the specified tolerance range.
• Coupling parts are being interchanged, i.e. their assignment to the specified shaft is incorrect.
• Specified axial fastenings are not fitted.
• Specified tightening torques are not being adhered to.
• Bolts are inserted dry or greased.
• Flange surfaces of screwed connections have not been cleaned.
• Alignment / shaftmisalignment values do not match those in the instructions manual.
• The coupled machines are not correctly fastened to the foundation, and as a result shifting of the
machines e.g. through loosening of the foundationscrew connection is causing excessive
displacement of the coupling parts.
• The coupled machines are not sufficiently earthed.
• RUPEX buffers are not fitted.
• The coupling guard used is not suitable.
5.2.3 Frequent faults in maintenance
• Maintenance intervals are not being adhered to.
• No genuine RUPEX spare parts are being used.
• Old or damaged RUPEX spare parts are being used.
• The fitted buffers (5) are different.
• Leakage in the vicinity of the coupling is not being identified and as a result chemically aggressive
media are damaging the coupling.
• Fault indications (noise, vibration, etc.) are not being observed.
• Specified tightening torques are not being adhered to.
• Alignment / shaftmisalignment values do not match those in the instructions manual.
BA 3600 en 02/2016
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6. Maintenance and repair
The buffers (5) must be replaced, when the torsional backlash exceeds the value stated in table 11.
Δ SV
Fig. 6: Wear mark
Table 11: Wear mark for the torsional backlash
125 162 228 285 360 450 560 710 900 1120 1400 1800
Size 105
144 198 252 320 400 500 630 800 1000 1250 1600 2000
Wear mark ΔSV
3.0 3.5 4.0 4.5 6.0 7.0 8.5 10.0 12.0 13.5 15.0 18.0 20.0
in mm
If the above specified maintenance instructions are not adhered to, a correct operation
within the meaning of the explosionprevention requirements and/or Directive
2014/34/EU can no longer be guaranteed.
Use in potentially explosive areas is then not permitted.
BA 3600 en 02/2016
22 / 28
6.2.1 Extracting the bolts in the case of coupling sizes 450 to 2000 with the demountijg box
For demounting the bolts Siemens offers a hydraulic extracting device, which can be provided on request.
Observe instructions manual BA 3600.1, "Demounting box for extracting RUPEX
bolts"!
6.2.2 Extracting the bolts in the case of coupling sizes 450 to 2000 with grease
Separate the coupling halves (1; 2; 3) and make them free of load. From coupling size 710 upwards the
locking rings (12) and disks (6) can be removed and the buffers (5) pulled off the bolts (4), if a separation
of the coupling halves (1; 2; 3) is not possible.
Unscrew bolt (11) and remove disk (8). Completely remove Loctite residue from the tapped hole.
Fill the tapped hole of the RUPEX bolt to 90 % with commercially available machine grease (e.g. Fuchs
Renolit H443HD88).
Wind Teflon strip or Teflon sealing cord around the bolt (11) and screw it together with the fitted washer (8)
by your fingers some 2 to 3 threads into the bolt (4).
Wear protective glasses!
For axial securing, disk (8) must imperatively be positioned at bolt (11).
Danger of getting caught by the sudden movement of the bolt (11), disk (8) and by
a sudden release of the bolt (4)!
Sudden release of the bolt is accompanied by a loud noise.
Using a spanner, screw the bolt (11) slowly further into the thread. In this manner the grease is pressed
through the transverse bore between the bolt and bolt bore in the coupling part (1; 2; 3). Screw in slowly,
to enable the grease to spread evenly on the bolt (4). If it is not possible to generate enough pressure,
a longer bolt (minimum strength class 8.8) should be used or, if necessary, grease should be refilled.
Grease must not escape; if it does, the bolt (11) must be resealed.
The extraction operation has finished as soon as the bolt (4) is released from the hole.
Demount all the bolts (4) one after the other in this way.
If reusing the old bolts (4), clean them carefully. No grease or Loctite must be left in the tapped or transverse
bores in the bolts (4).
Apply just a small quantity of Loctite to the screw (11), otherwise there is a risk that the Loctite may seal
the transverse hole.
For reassembly, the instructions in sections 3 and 4 must be observed.
6.3 Demounting the coupling parts in case of shafthub connection with parallel key
Move the coupled machines apart.
Remove the axial fastening (set screw, end plate). Mount a suitable detaching device. Using a burner, heat
coupling part (1; 2; 3) along its length and above the parallel keyway (max. + 80 °C). When heating up
observe the temperature range of the buffers (5) (see table 5); if necessary demount the buffers (5).
Burner and heated coupling parts (1; 2; 3) form an explosion hazard, therefor there
must not be an explosible atmosphere when fitting the coupling parts.
Pull off coupling part (1; 2; 3). Examine the hub bore and the shaft for damage, and protect against rust.
Damaged parts must be replaced.
For reassembly, the instructions in sections 3 and 4 must be observed.
BA 3600 en 02/2016
23 / 28
6.4 Demounting the coupling parts in case of a cylindrical and tapered interference fit set up for removal by
oilhydraulic shrinkingoff
Move the coupled machines apart.
Demount buffers (5).
For demounting the following tools are needed:
• For each oil channel (for number, see the dimensioned drawing) an oil pump with pressure gauge
(min. 2 500 bar) or a motor pump with corresponding number of independently closable connections
In case of coupling parts (1; 2; 3) with stepped bore, a motordriven pump must be connected up to the
oil channel located at the point of transition from the smaller bore to the larger, as a large quantity of oil
per unit of time is needed here.
• Suitable connections and pipes.
• 1 detaching device or retaining plate with retaining screws or threaded spindles with nuts (material of
screws and spindles min. 10.9, material of nuts identical to that of the screws).
• 1 hydraulic cylinder with oil pump. Note displacement and pressure of the hydraulic cylinder (for axial
force, consult Siemens or refer to the dimensioned drawing).
In case of tapered interference fit, to prevent the coupling part (1; 2; 3) from suddenly
coming off, it must be secured axially.
The screw plugs (101 / 201 / 301) must be removed from the oil channels. One oil pump must be bled and
connected up to middle oil channel.
Then apply the pressure specified on the dimensioned drawing to the pump until oil emerges from the
adjacent connections or at the end faces.
The maximum pressure specified on the dimensioned drawing must not be exceeded.
During the entire operation the pressure must be maintained at a constant level on all
the oil channels to which pressure is applied.
Bleed the next oil pump, connect it up to the adjacent oil channel and operate it at the pressure specified
on the dimensioned drawing, until oil emerges from the adjacent connections or at the end faces.
If, when pressure is applied, oil emerges to the extent that pressure cannot be maintained, a thicker oil must
be specified.
Only when an unbroken ring of oil emerges from both end faces can pressure be applied to the hydraulic
cylinder to slide the coupling part (1; 2; 3) smartly off the shaft.
All the oil must be completely collected and disposed of in accordance with the regulations applying.
Note stroke of hydraulic cylinder. If readjustment is necessary, the end face of the
hydraulic cylinder must stop between 2 oil channels.
After detaching, the oil pumps and the detaching device must be removed from the coupling part (1; 2; 3).
Examine the hub bore and the shaft for damage, and protect against rust. Damaged parts must be
replaced.
For reassembly, the instructions in sections 3 and 4 must be observed.
BA 3600 en 02/2016
24 / 28
7. Stocking spare parts
1) The screw plugs (101 / 201 / 301; see fig. 7) are used only with an oilhydraulic interference fit
(see item 3.6).
101
201
301
BA 3600 en 02/2016
25 / 28
1 2 1 3 1 20
1) 2) 3)
4 6 5 7 4 6 5 8 11 4 12 6 5 8 11
4) 5) 6)
BA 3600 en 02/2016
26 / 28
8. Declarations
EU declaration of conformity
The manufacturer, Siemens AG, 46395 Bocholt, Germany, declares that the equipment described in these
operating instructions:
FLENDER RUPEX®
couplings
Types RWN, RWS, RWB, RBS
and RFN, RFS
is in conformity with Article 1 and Article 13, Paragraph 1 b) ii) of Directive 2014/34/EU and complies with the
requirements of Directive 2014/34/EU and the following standards:
EN 1127-1 : 2011
EN 13463‐1 : 2009
EN 13463‐5 : 2011
This declaration of conformity is issued under the sole responsibility of the manufacturer.
The object of the declaration described above is in conformity with the relevant Union harmonisation
legislation:
Directive 2014/34/EU OJ L 96, 29.03.2014, p.309-356 (effective from 20.04.2016, 00:00 a.m.)
Directive 94/9/EC OJ L 100, 19.04.1994, p.1-29 (effective until 19.04.2016, 12.00 p.m.)
The technical documentation has been delivered to the body named below:
DEKRA EXAM GmbH, D - 44727 Bochum, code number: 0158
Bocholt, 2016‐02‐22
Nicola Warning / Head of PD MD AP COU
Bocholt, 2016‐02‐22
Thomas Tebrügge / Head of PD MD AP COU BA
BA 3600 en 02/2016
27 / 28
Further Information:
"FLENDER gear units" on the Internet
www.siemens.com/gearunits
Lubricants:
http://support.automation.siemens.com/WW/view/en/42961591/133000
www.siemens.com/drivetechnologies
High efficiency centrifugal fan
DHRV 50-1800/K
PT 100
rt = red
ws = white
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Washer 0,00
330 X 16 B8,4 Cs/galv. ISO 7090
Scheibe . 0,03
Hexagon nut 0,01
340 X 8 M8-8 Cs/galv. ISO 4032
Sechskantmutter . 0,04
Inductive sensor 0,50
350 X 1 NI15U-M18M-VP44X-H1141 Fa. Turck
Nährungsschalter . 0,50
Switch vane 2,00
360 X 1 D=150/400 1.0038 A-289133-4
Schaltfahne . 2,00 (S235 JRG2)
Hexagon head screw 1,99
370 X 4 M36x220-8.8 Cs/galv. ISO 4014
Sechskantschraube . 7,96
Washer 0,09
380 X 4 B36 Cs/galv. ISO 7090
Scheibe . 0,37
Hexagon nut 0,39
390 X 8 M36-8 Cs/galv. ISO 4032
Sechskantmutter . 3,14
Mounting plates for bearing SNOE 236 0,19
400 X 4 pl.8x70x60 1.0038 A-259645-4
Montageplatten für SNOE 236 . 0,75 (S235 JRG2)
set Shims for SNOE 236 pedestal bearing housing 23,30 Cs/galv.
410 X 1 pl.730x220 1.0038 A-264198-4
Satz Unterlegbleche für SNOE 236 Lagergehäuse . 23,30 (S235 JRG2)
Hexagon head screw 0,34
420 X 4 M20x130-8.8 Cs/galv. ISO 4014
Sechskantschraube . 1,36
Hexagon nut 0,06
430 X 4 M20-8 Cs/galv. ISO 4032
Sechskantmutter . 0,26
Hexagon head screw 2,87
440 X 4 M42x240-8.8 Cs/galv. ISO 4014
Sechskantschraube . 11,48
Washer 0,21
450 X 4 B42 Cs/galv. ISO 7090
Scheibe . 0,84
Hexagon nut 0,65
460 X 8 M42-8 Cs/galv. ISO 4032
Sechskantmutter . 5,22
Mounting plates for bearing SNOE 240 0,29
470 X 4 pl.8x90x70 1.0038 A-259628-4
Montageplatten für SNOE 240 . 1,16 (S235 JRG2)
set Shims for SNOE 240 pedestal bearing housing 31,80 Cs/galv.
480 X 1 pl.840x260 1.0038 A-264289-4
Satz Unterlegbleche für SNOE 240 Lagergehäuse . 31,80 (S235 JRG2)
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