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auma india

Product Catalogue
Head Office
auma [india] ltd,
Plot # 39-B, II Phase,
Colony,
Peenya Indl Area.
Bangalore-560 058
Pune-411 038.
080-8394655/56
Fax:080-8392809

Delhi Branch
auma [india] ltd,
# 8-C, Block B-H, Munirka
New Delhi-110 067.

Pune Branch
auma [india] ltd,
#112,Kalpadrum, Pandurang
Behind New Kamataka
High School, Erandwana,

011-6187063
Fax:011-6109637

E-mail: info@auma.com
aumandl@mantraonline.com
aumapn@pn3.vsnl.net.in

020-5410645
Fax:020-5443186

auma india
CONTENTS

PAGE Nos.

1. Introduction

1.1

Auma Products

2. Auma Actuators
2.1

2.2

Types & duty

Open-Close
Regulating

5
5

Versions
Norm
Compact

2.3

5
5

Specifications for Basic actuators

6-24

Open Close Duty


Open Close Integral starter
Regulating duty
Regulating Integral starter
Benefits of auma india actuators

6-8

2.4

Optional / Accessories

27

2.5

Electronic Cards

28-54

2.6

Details of enclosure IP67

55

2.7

Technical data

56-60

2.8

9-13
14-18
19-24
25-26

SA3
SA6, SA12, SA25
SA15, SA30 & SA60
SA50, SA100
SAR15, SAR30, SAR60

56
57

Electrical data

61-67

58
59
60

auma india
SA3
SA6, SA12, SA25
SA15, SA30 & SA60
SA50, SA100
SAR15, SAR30, SAR60
2.9

61
62-63
64-65
66
67

Actuator catalogue

2.10 Sectional, Exploded view, Parts list


3.

Auma Gear Operator

3.1

Gear Operators Catalogue

3.2

68-71
72

Specification for
Worm Gear box

73
Foot mounted Worm Gear box
74
Bevel Gear box
3.3

Special features of Worm Gear box


77

3.4

Gear box versions

Selection of actuator or a gear box


81-84

4.1
81-84

Selection procedure

5
Operation & Maintenance Manual
85-128

75
7678-80

auma india

INTRODUCTION

auma india

INTRODUCTION
In the course of constantly increasing automation in the entire sector of
industries, Electric Actuators for process control and regulation have become
more and more important.
Auma (india) limited, a ISO 9001 company, is one of the leading manufacturers
of Electric Actuators, suitable for both weather proof and explosion proof
applications, Gearboxes (quarter turn/multi-turn worm/bevel/spur type), Electronic
accessories and control for automation of all types of valves and dampers.
Auma India is a subsidiary unit of M/s. auma, Armaturen-und-Maschinenantriebe
Gmbh of Germany, which is regularly catering to the needs of customers in
Valve/Damper sector and end user segments like Cement Plants, Thermal Power
Plants, Pollution Control equipment manufacturers, Water Works Engineering,
Petrochemical sector, Process Plants, Paper Mills, Steel Plants, Instrumentation
and Control Sector, etc.,
Sales support and after sales services are provided worldwide by auma
companies and representative offices. This ensures that experienced sales
engineers and qualified service technicians are close to the customers.
Auma India Actuators cover a Torque range, starting from 30 Nm upto 1000 Nm
both in ON/OFF and Regulating duty with or without Integral Starters. Also we
can supply Actuators along with Worm Gearboxes, up to 3,60,000 Nm.
Keeping in view the market demand, company has also started manufacturing
Explosion/Flame proof electric actuators conforming to Group IIA, IIB as per
IS: 2148 - 1981. A proven design certified by nodal agencies like Bureau of
Indian Standards (BIS), Central Mining Research Institute (CMRI), The Directorate
General Factory Advise Services and Labour Institute, The Chief Controllerate of
Explosives (C. C.E).
Auma India product range includes:
Electric actuators from 30 Nm 1000 Nm
Explosion/Flame proof actuators from
30 Nm 1000 Nm.
Enclosure to IP67/IP68 ,
Group IIA, IIB as per IS: 2148 1981
Suitable for (On-off /regulating
duty)
1)
2)

3)
4)
5)

Worm Gearboxes - upto 3,60,000 Nm


Bevel Gear Boxes upto 8000Nm Torque and 820KN Thrust .
Spur Gear Boxes upto 16,000Nm Torque and 1375KN Thrust.

auma india
Auma India also undertakes replacement/retrofitting of Actuators/Gearboxes for
Modernisation /Renovation of old plants and represents auma Germany range of
products.

AUMA PRODUCTS

ACTUATORS

GEAR OPERATORS

WEATHER PROOF & FLAME PROOF


WORM GEAR BOX
NORM
OPEN-CLOSESA & SAEx
REGULATING SAR & SAREx
Torque Range : 30 Nm 1000
Nm

FLANGE MOUNTED GS
FOOT MOUNTED GF
Torque Range : 300 Nm 3,60,000 Nm

COMPACT / EPAC
OPEN-CLOSE & REGULATING
Torque Range : 30 Nm 1000
Nm

BEVEL GEAR BOX GK


Torque Range : 120 Nm 800
Nm

SIGNALLING & CONTROL


ACCESSORIES

SPUR GEAR BOX GST


Torque Range : 120 Nm
16000 Nm

EPT
POWER SUPPLY UNITS
POSITIONER
ISOLATORS

POSITION INDICATORS

auma india

AUMA ACTUATORS (Weather


Proof)

NORM
(WITHOUT INBUILT STARTERS)

ON OFF
(OPEN CLOSE)

COMPACT/EPAC
(WITH INBUILT STARTERS & LOCAL
CONTROLS)

REGULATING
(MODULATING)

SA3

SAR3

SA6

SAR6

SA12

SAR12

SA15

SAR15

SA25

SAR25

SA30

SAR30

SA50

SAR50

SA60

SAR60

SA100

SAR100

auma india

AUMA ACTUATORS (Explosion


Proof)

NORM
(WITHOUT INBUILT STARTERS)

ON OFF
(OPEN CLOSE)

REGULATING
(MODULATING)

SAEx3

SAREx3

SAEx6

SAREx6

SAEx12

SAREx12

SAEx15

SAREx15

SAEx25

SAREx25

SAEx30

SAREx30

SAEx50

SAREx50

SAEx60

SAREx60

SAEx100

SAREx100

auma india
AUMA ACTUATORS (Explosion
Proof)

COMPACT
(WIT INBUILT STARTERS)

ON OFF
(OPEN CLOSE)

REGULATING
(MODULATING)

SACEx3

SARCEx3

SACEx6

SARCEx6

SACEx12

SARCEx12

SACEx15

SARCEx15

SACEx25

SARCEx25

SACEx30

SARCEx30

SACEx50

SARCEx50

SACEx60

SARCEx60

SACEx100

SARCEx100

auma india
SPECIFICATION FOR BASIC ELECTRICAL ACTUATOR
FOR OPEN-CLOSE DUTY
1

ELECTRICAL ACTUATOR

1.1

Actuator should be totally enclosed weather proof and dust proof


construction with IP67 protection class.

1.2

The Actuator should be suitable for installation in any position without


lubrication leakage or other operational difficulty.

1.3

The Gear Box of the Actuator offered shall be special grease filled.

1.4

Each Actuator should have a hand wheel fitted on it for emergency manual
operation. The hand wheel shall automatically disengage when the power
to the motor is restored.

1.5

Actuators offered shall be suitable for mounting in any position.

LIMIT AND TORQUE SWITCHES

2.1

Independent torque and limit switches should be provided one each for
each direction of travel having 2 NO + 2NC potential free contacts.

2.2

Torque switch dial should be graduated directly in Nm for easy setting to


desired value within the range specified. Separate dials should be provided
for CLOSE & OPEN torque switches.

2.3

The rating of both torque and limit switches should be 250V, 5A AC/250V,
0.46A DC.

2.4

The switches shall individually be enclosed to a minimum of IP 66 protection


class.

2.5

Torque & Limit switches shall have only stainless steel flaps for better
protection against environmental condition.

2.6

Limit switches shall be operated by gear driven cams, which are


mechanically linked to the driving devices. The counter gear used for
counting and tripping the limit switches shall be of metallic construction like
brass, etc. No plastic gearing shall be allowed.

3.

Each Actuator shall have a continuous local mechanical position indicator.

4. Entire counter gear assembly, torque switch drive assembly, mechanical


position indicator assembly, etc., shall be individually replaceable.
5.

ACTUATOR MOTOR

5.1

Motor shall be suitable for power supply of 415V, 3Ph, 50Hz, AC.

5.2

Motor shall be squirrel cage induction type and shall generally conform to IS
325.

auma india
5.3
5.4

Motor shall be of continuous duty (S2-15 mins).


Motor shall have minimum Class F insulation with temperature rise
restricted to Class B.

5.5

Motor shall be of totally enclosed surface cooled (TESC) type with IP 67


protection class after mounting on Actuator.

5.6

Motor shall have 3 thermostats connected in series, one in each winding of


motor for protection against overheating.

5.7

Motor shall be for operation under voltage variation of 10%, frequency of


5% & combined (voltage & frequency) variation of 10%.

5.8

Motor shall be suitable for direct on-line (DOL) starting

5.9

It should be possible to separate the motor from the lubricant filled gearing
of the Actuator allowing easy replacement of motor without loosing any
lubricant regardless of mounting position.

6.

All control and power connections are brought out to plug in type
connectors for customer connections. Separate plug in type connectors
shall be provided for control and power connections. The plug in type
connectors shall be suitable for termination of wires of size 2.5 mm (max.)
for control and 4 mm (max.) for power connections.

7.

Actuators shall be provided with double compression nickel plated brass


cable glands to suit cable sizes furnished by Purchaser. Separate cable
glands shall be provided for power and control.

8.

The Actuator shall be painted with corrosion proof epoxy resin paint. Paint
shade shall be DA grey.

9.

ELECTRONIC POSITION TRANSMITTER (OPTIONAL)

9.1

The Position Transmitter provided shall be of 2-wire R-I converter to give an


output of 4-20 mA. Input power supply to transmitter card shall be 24V, DC.

9.2

Accuracy of Position Transmitter card shall be less than 1%.

9.3

Position Transmitter card shall be suitable for operating in a temperature


range of
-20C to +80C .

9.4

Position Transmitter card shall be epoxy filled with minimum IP 66


protection class. Bare PCB card is not acceptable.

auma india
SPECIFICATION FOR ELECTRICAL ACTUATOR WITH INTEGRAL STARTERS
WITH ELECTRONIC CONTROLS FOR OPEN-CLOSE DUTY
1

ELECTRICAL ACTUATOR

1.1

Actuator should be totally enclosed


construction with IP67 protection class.

1.2

The Actuator should be suitable for installation in any position without


lubrication leakage or other operational difficulty.

1.3

The Gear Box of the Actuator offered shall be special grease filled.

1.4

Each Actuator should have a handwheel fitted on it for emergency manual


operation. The handwheel shall automatically disengage when the power
to the motor is restored.

1.5

Actuators offered shall be suitable for mounting in any position.

2.

LIMIT AND TORQUE SWITCHES

2.1

Independent torque and limit switches should be provided one each for
each direction of travel having 2 NO + 2NC potential free contacts.

2.2

Torque switch dial should be graduated directly in Nm for easy setting to


desired value within the range specified. Separate dials should be provided
for CLOSE & OPEN torque switches.

2.3

The rating of both torque and limit switches should be 250V, 5A AC/250V,
0.46A DC.

2.4

The switches shall individually be enclosed to a minimum of IP 66 protection


class.

2.5

Torque & Limit switches shall have only stainless steel flaps for better
protection against environmental condition.

2.6

Limit switches shall be operated by gear driven cams, which are


mechanically linked to the driving devices. The counter gear used for
counting and tripping the limit switches shall be of metallic construction like
brass, etc. No plastic gearing shall be allowed.

3.

Each Actuator shall have a continuous local mechanical position indicator.

4.

Entire counter gear assembly, torque switch drive assembly, mechanical


position indicator assembly, etc., shall be individually replaceable.

5.

ACTUATOR MOTOR

5.1

Motor shall be suitable for power supply of 415V, 3Ph, 50Hz, AC.

5.2

Motor shall be squirrel cage induction type and shall generally conform to IS
325.

weatherproof

and

dust

proof

auma india
5.3

Motor shall be of continuous duty (S2-15 mins).

5.4

Motor shall have minimum Class F insulation with temperature rise


restricted to Class B.

5.5

Motor shall be of totally enclosed surface cooled (TESC) type with IP 67


protection class after mounting on Actuator.

5.6

Motor shall have 3 thermostats connected in series, one in each winding of


motor for protection against overheating.

5.7

Motor shall be for operation under voltage variation of 10%, frequency of


5% & combined (voltage & frequency) variation of 10%.

5.8

Motor shall be suitable for direct on-line (DOL) starting

5.9

It should be possible to separate the motor from the lubricant filled gearing
of the Actuator allowing easy replacement of motor without loosing any
lubricant regardless of mounting position.

6.

All control and power connections are brought out to plug in type
connectors for customer connections. Separate plug in type connectors
shall be provided for control and power connections. The plug in type
connectors shall be suitable for termination of wires of size 2.5 mm (max.)
for control and 4 mm (max.) for power connections.

7.

Actuators shall be provided with double compression nickel-plated brass


cable glands to suit cable sizes furnished by Purchaser. Separate cable
glands shall be provided for power and control.

8.

The Actuator shall be painted with corrosion proof epoxy resin paint. Paint
shade shall be DA grey.

9.

ELECTRONIC POSITION TRANSMITTER

9.1

The Position Transmitter provided shall be of 2-wire R-I converter to give an


output of 4-20 mA. Input power supply to transmitter card shall be 24V, DC.

9.2

Accuracy of Position Transmitter card shall be less than 1%.

9.3

Position Transmitter card shall be suitable for operating in a temperature


range of
-20C to +80C .

9.4

Position Transmitter card shall be epoxy filled with minimum IP 66


protection class. Bare PCB card is not acceptable.

10

INTEGRAL STARTERS WITH ELECTRONIC CONTROLS

10.1 Integral starter unit will be with Electronic control logic. Entire unit along
with basic Actuator will conform to IP67 Encl standards.
10.2 Selector switch LOCAL-OFF-REMOTE with push buttons OPEN-STOP-CLOSE
(for local operation) with indication lamps for running OPEN and running
CLOSE.

auma india
10.3 Electromechanically interlocked contactors are to be offered as starters.
10.4 The selection of the following models will be available through DIP switch
programming.
Tripping by close torque or close limit switch will be available.
Inching or non inching (hold-on) for remote command will be field
configurable.
10.5 Isolated 24V DC output will be available for customers use or for position
transmitter within Actuator.
10.6 24V DC remote command signal (OPEN-STOP-CLOSE) from DCS will be
isolated from control electronics through opto-isolator.
10.7 The following individual status annunciation LEDs (Color-Green) will be
available locally (integral to Actuator) to annunciate the following for easy
local monitoring.
Actuator in local mode
Actuator in remote mode
Actuator running in OPEN
Actuator running in CLOSE
Actuator in inching mode
Actuator in self retaining mode
Limit switch OPEN trip
Limit switch CLOSE trip
24V DC Control voltage availability
24V DC availability for customers use.
View port shall be provided on integral starter unit to monitor the above
status annunciation.
10.8 The following individual fault annunciation LEDs (Color-Red) will be made
available locally (integral to Actuator) for easy trouble shooting by field
personnel.
Torque switch OPEN
Torque switch CLOSE
Thermoswitch trip
Thermal overload relay trip
Motor single phasing
Common fault (inclusive of any one or combination of above fault)
View port shall be provided on integral starter unit to monitor the above
status annunciation.
10.9 A common potential free contact will be available to annunciate the
following faults.
Thermoswitch trip
TOLR trip
Torque switch trip
10.10 Thermal overload relay to trip Actuator in case of overload.

auma india
10.11 The PCBs will be split into different functional modules mounted on a
motherboard to facilitate easy trouble shooting and replacement. The
different functional PCBs will be slot specific and non interchangeable
among themselves.
10.12 For easy maintainability, interchangeability and less maintenance down
time plug in connections / design shall be provided between : a)
Integral starter unit and basic Actuator.
b)
Between external customer connections and Actuator.
10.13 OPEN-CLOSE indication LAMP/ LED will be available for indication of full
open / full close position.
10.14 Potential free contacts for LOCAL-OFF remote positions will be available.
10.15 Time delay will be introduced between tripping of torque switch close and
torque switch open, i.e., torque switch open will be ignored for 3 seconds
after tripping of Torque switch close.
10.16 Automatic phase correction facility will be available.
10.17 Potential free contact for annunciation of power failure will be available.
OPTIONALS
10.18
The following individual potential free relay contacts will be available in the
Actuator for remote annunciation to facilitate continuous monitoring of the
Actuator.
Actuator (valve) running in OPEN direction.
Actuator (valve) running in CLOSE direction.
Actuator in remote mode.
Actuator in local mode.
Actuator power switched off / single phasing.
Common fault (torque switch trip, thermoswitch clip and thermal
overload relay trip).
10.19 Remote annunciation of Actuator faults should be available at a
DCS/remote through 2-wire system. Suitable multiplexer and demultiplexer
should be provided in Actuator and DCS panel respectively. Annunciation of
Actuator faults signal should be through LEDs. Optionally potential free
contacts of faults annunciation should be provided, if specified. The 2-wire
system should be valid for a maximum distance of 2 kms. beyond which
repeaters should be provided. The communication from Actuator to remote
panels/DCS should be unidirectional.
The following faults should be
annunciated:

Torque switch OPEN


Torque switch CLOSE
Thermoswitch trip
Thermal overload relay trip
Motor single phasing

auma india

Common fault (inclusive of any one or combination of above fault)

auma india
SPECIFICATION FOR BASIC ELECTRICAL ACTUATOR
FOR REGULATING DUTY
1

ELECTRICAL ACTUATOR

1.1

Actuator should be totally enclosed weather proof and dust proof


construction with IP67 protection class.

1.2

The Actuator should be suitable for installation in any position without


lubrication leakage or other operational difficulty.

1.3

The Gear Box of the Actuator offered shall be special grease filled.

1.4

Each Actuator should have a handwheel fitted on it for emergency manual


operation. The handwheel shall automatically disengage when the power
to the motor is restored.

1.5

Actuators offered shall be with self-locking worm.

2.

LIMIT AND TORQUE SWITCHES

2.1

Independent torque and limit switches should be provided one each for
each direction of travel having 2 NO + 2NC potential free contacts.

2.2

Torque switch dial should be graduated directly in Nm for easy setting to


desired value within the range specified. Separate dials should be provided
for CLOSE & OPEN torque switches.

2.3

The rating of both torque and limit switches should be 250V, 5A AC/250V,
0.46A DC.

2.4

The switches shall individually be enclosed to a minimum of IP 66 protection


class.

2.5

Torque & Limit switches shall have only stainless steel flaps for better
protection against environmental condition.

2.6

Limit switches shall be operated by gear driven cams, which are


mechanically linked to the driving devices. The counter gear used for
counting and tripping the limit switches shall be of metallic construction like
brass, etc. No plastic gearing shall be allowed.

3.

Each Actuator shall have a continuous local mechanical position indicator.

4.

Offered Actuators shall be suitable for regulating/modulating application


with the following minimum starts/hour.
Motor upto 0.55 kW
Motor above 0.55 kW

1200 starts/hour
600 starts/hour

5.

Entire counter gear assembly, torque switch drive assembly, mechanical


position indicator assembly, etc., shall be individually replaceable.

6.

ACTUATOR MOTOR

auma india
6.1

Motor shall be suitable for power supply of 415V, 3Ph, 50Hz, AC.

6.2

Motor shall be squirrel cage induction type and shall generally conform to IS
325.

6.3

Motor shall be of intermittent duty (S4-25%).

6.4

Motor shall have minimum Class F insulation with temperature rise


restricted to Class B.

6.5

Motor shall be of totally enclosed surface cooled (TESC) type with IP 67


protection class after mounting on Actuator.

6.6

Motor shall have 3 thermostats connected in series, one in each winding of


motor for protection against overheating.

6.7

Motor shall be for operation under voltage variation of 10%, frequency of


5% & combined (voltage & frequency) variation of 10%.

6.8

Motor shall be suitable for direct on-line (DOL) starting

6.9

It should be possible to separate the motor from the lubricant filled gearing
of the Actuator allowing easy replacement of motor without loosing any
lubricant regardless of mounting position.

7.

All Actuator motors for regulating application shall be 4-pole to minimize


overshoot and provide better positioning accuracy.

8.

The output speed of the Actuator shall be restricted to a maximum of 45


RPM to ensure better positioning accuracy.

9.

All control and power connections are brought out to plug in type
connectors for customer connections. Separate plug in type connectors
shall be provided for control and power connections. The plug in type
connectors shall be suitable for termination of wires of size 2.5 mm (max.)
for control and 4 mm (max.) for power connections.

10.

Actuators shall be provided with double compression nickel plated brass


cable glands to suit cable sizes furnished by Purchaser. Separate cable
glands shall be provided for power and control.

11.

The Actuator shall be painted with corrosion proof epoxy resin paint. Paint
shade shall be DA grey.

12.

ELECTRONIC POSITION TRANSMITTER

12.1 The Position Transmitter provided shall be of 2-wire R-I converter to give an
output of 4-20 mA. Input power supply to transmitter card shall be 24V, DC.
12.2 Accuracy of Position Transmitter card shall be less than 1%.
12.3 Position Transmitter card shall be suitable for operating in a temperature
range of -20C to +80C .
12.4 Position Transmitter card shall be epoxy filled with minimum IP 66
protection class. Bare PCB card is not acceptable.

auma india
13

ELECTRONIC POSITIONER (LOOSE SUPPLY)

13.1 Electronic positioner shall be a loose supply.


13.2 Positioner shall be suitable for accepting command and feedback signals of
4-20mA and position the Actuator accordingly.
13.3 Positioner shall be suitable for receiving the regulated supply voltage of
24V,
DC ( 1V).
13.4 Position shall have deadband adjustable from 1% to a maximum of 2.5% to
ensure better positioning accuracy.
13.5 Positioner shall have inbuilt time delay adjustable from 0.5 to 15 seconds.
13.6 Positioner shall have output relay contacts with maximum load capacity of
230V, 10A (resistive load).
13.7 Positioner shall have enclosure of ABS housing with protection class IP10
13.8 Positioner mounting shall be suitable for DIN/C channel.
13.9 Positioner shall be suitable for an ambient temperature of -20C to +80C.
13.10 The Positioner shall be field configurable having DIP Switches to enable
selection of any of the following modes on loss of remote command signal
(4-20mA)
Fail Open
Fail Close
Fail As is
14

SIGNAL ISOLATOR (LOOSE SUPPLY)

14.1 Signal Isolator shall be a loose supply.


14.2 Isolator shall be suitable for input power supply of 230V, 1Ph, 50Hz, AC.
14.3 Isolator shall be suitable for accepting 4-20mA as input and give 2 isolated
outputs of 4-20mA each.
14.4 Isolator output signals shall be isolated between themselves and input
signal.
14.5 Load driving capacity of each output shall be at least 500 ohms.
14.6 Zero and span adjustments shall be available on the isolator for each
output.
14.7 Signal isolator shall be suitable for DIN and C channel mounting.
14.8 Isolator Enclosure shall be at least of IP 10 protection class.
14.9 Isolator shall be suitable for an ambient temperature of -20C to +80C .
15
POWER SUPPLY UNIT (LOOSE SUPPLY) - for Electronic Positioner and
Position Transmitter.

auma india
15.1 Power supply unit shall be a loose supply.
15.2 Power Supply Unit shall be suitable for an input power supply of 230V,1Ph,
50Hz, AC.
15.3 Power Supply Unit shall give 24V, DC (1V) regulated output with maximum
output current of 150mA.
15.4 Power Supply Unit shall be suitable for operating in an ambient temperature
of
-20C to +80C .
15.5 The Enclosure of Power Supply Unit shall be of ABS with minimum
protection class of IP 10.
15.6 Power Supply Unit shall be suitable for DIN and C channel mounting.
15.7 Suitable screw type terminals for power and control shall be provided on the
panel board for customer and field connections. Control terminals shall be
suitable for terminating wires of cross sectional area 2.5 mm (max.) and
power terminals shall be capable of terminating wires of cross sectional
area 4 mm.
15.8 1 No. Isolation switch shall be provided for isolating power and control
supply on each panel board.
15.9 The output of the power supply unit shall be short circuit protected.

auma india
SPECIFICATION FOR ELECTRICAL ACTUATOR WITH INTEGRAL
STARTERS WITH ELECTRONIC CONTROLS FOR REGULATING DUTY
1

ELECTRICAL ACTUATOR

1.1

Actuator should be totally enclosed weather proof and dust proof


construction with IP67 protection class.

1.2

The Actuator should be suitable for installation in any position without


lubrication leakage or other operational difficulty.

1.3

The Gear Box of the Actuator offered shall be special grease filled.

1.4

Each Actuator should have a handwheel fitted on it for emergency manual


operation. The handwheel shall automatically disengage when the power
to the motor is restored.

1.5

Actuators offered shall be with self-locking worm.

2.

LIMIT AND TORQUE SWITCHES

2.1

Independent torque and limit switches should be provided one each for
each direction of travel having 2 NO + 2NC potential free contacts.

2.2

Torque switch dial should be graduated directly in Nm for easy setting to


desired value within the range specified. Separate dials should be provided
for CLOSE & OPEN torque switches.

2.3

The rating of both torque and limit switches should be 250V, 5A AC/250V,
0.46A DC.

2.4

The switches shall individually be enclosed to a minimum of IP 66 protection


class.

2.5

Torque & Limit switches shall have only stainless steel flaps for better
protection against environmental condition.

2.6

Limit switches shall be operated by gear driven cams, which are


mechanically linked to the driving devices. The counter gear used for
counting and tripping the limit switches shall be of metallic construction like
brass, etc. No plastic gearing shall be allowed.

3.

Each Actuator shall have a continuous local mechanical position indicator.

4.

Offered Actuators shall be suitable for regulating/modulating application


with the following minimum starts/hour.
Motor upto 0.55 kW
Motor above 0.55 kW

1200 starts/hour
600 starts/hour

5.

Entire counter gear assembly, torque switch drive assembly, mechanical


position indicator assembly, etc., shall be individually replaceable.

6.

ACTUATOR MOTOR

auma india
6.1

Motor shall be suitable for power supply of 415V, 3Ph, 50Hz, AC.

6.2

Motor shall be squirrel cage induction type and shall generally conform to IS
325.

6.3

Motor shall be of intermittent duty (S4-25%).

6.4

Motor shall have minimum Class F insulation with temperature rise


restricted to Class B.

6.5

Motor shall be of totally enclosed surface cooled (TESC) type with IP 67


protection class after mounting on Actuator.

6.6

Motor shall have 3 thermostats connected in series, one in each winding of


motor for protection against overheating.

6.7

Motor shall be for operation under voltage variation of 10%, frequency of


5% & combined (voltage & frequency) variation of 10%.

6.8

Motor shall be suitable for direct on-line (DOL) starting

6.9

It should be possible to separate the motor from the lubricant filled gearing
of the Actuator allowing easy replacement of motor without loosing any
lubricant regardless of mounting position.

7.

All Actuator motors for regulating application shall be 4-pole to minimize


overshoot and provide better positioning accuracy.

8.

The output speed of the Actuator shall be restricted to a maximum of 45


RPM to ensure better positioning accuracy.

9.

All control and power connections are brought out to plug in type
connectors for customer connections. Separate plug in type connectors
shall be provided for control and power connections. The plug in type
connectors shall be suitable for termination of wires of size 2.5 mm (max.)
for control and 4 mm (max.) for power connections.

10.

Actuators shall be provided with double compression nickel plated brass


cable glands to suit cable sizes furnished by Purchaser. Separate cable
glands shall be provided for power and control.

11.

The Actuator shall be painted with corrosion proof epoxy resin paint. Paint
shade shall be DA grey.

12.

ELECTRONIC POSITION TRANSMITTER

12.1 The Position Transmitter provided shall be of 2-wire R-I converter to give an
output of 4-20 mA. Input power supply to transmitter card shall be 24V, DC.
12.2 Accuracy of Position Transmitter card shall be less than 1%.
12.3 Position Transmitter card shall be suitable for operating in a temperature
range of
-20C to +80C.
12.4 Position Transmitter card shall be epoxy filled with minimum IP 66
protection class. Bare PCB card is not acceptable.

auma india
13

INTEGRAL STARTERS WITH ELECTRONIC CONTROLS

13.1 Integral starter unit will be with Electronic control logic. Entire unit along
with basic Actuator will conform to IP67 Encl standards.
13.2 Selector switch LOCAL-OFF-REMOTE with push buttons OPEN-STOP-CLOSE
(for local operation) with indication lamps for running OPEN and running
CLOSE.
13.3 Electromechanically interlocked contactor are to be offered as starters.
Optionally thyristor starters can be offered instead of electro-mechanically
interlocked reversing contactors.
13.4 The selection of the following models will be available through DIP switch
programming.
Tripping by close torque or close limit switch will be available.
Inching or non-inching (hold-on) for remote command will be field
configurable.
13.5 Isolated 24V DC output will be available for customers use or for position
transmitter within Actuator.
13.6 24V DC remote command signal (OPEN-STOP-CLOSE) from DCS will be
isolated from control electronics through opto-isolator.
13.7 The following individual status annunciation LEDs (Color-Green) will be
available locally (integral to Actuator) to annunciate the following for easy
local monitoring.
Actuator in local mode
Actuator in remote mode
Actuator running in OPEN
Actuator running in CLOSE
Actuator in inching mode
Actuator in self retaining mode
Limit switch OPEN trip
Limit switch CLOSE trip
24V DC Control voltage availability
24V DC availability for customers use.
View port shall be provided on integral starter unit to monitor the above
status annunciation.
13.8 The following individual fault annunciation LEDs (Color-Red) will be made
available locally (integral to Actuator) for easy trouble shooting by field
personnel.
Torque switch OPEN
Torque switch CLOSE
Thermoswitch trip
Thermal overload relay trip
Motor single phasing
Common fault (inclusive of any one or combination of above fault)
View port shall be provided on integral starter unit to monitor the above
status annunciation.

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13.9 A common potential free contact will be available to annunciate the
following faults.
Thermoswitch trip
TOLR trip
Torque switch trip
13.10 Thermal overload relay to trip Actuator in case of overload.
13.11 The PCBs will be split into different functional modules mounted on a
motherboard to facilitate easy trouble shooting and replacement. The
different functional PCBs will be slot specific and non interchangeable
among themselves.
13.12 For easy maintainability, interchangeability and less maintenance down
time plug in connections / design shall be provided between : a)
Integral starter unit and basic Actuator.
b)
Between external customer connections and Actuator.
13.13 OPEN-CLOSE indication LAMP/ LED will be available for indication of full
open / full close position.
13.14 Potential free contacts for LOCAL-OFF remote positions will be available.
13.15 Time delay will be introduced between tripping of torque switch close and
torque switch open, i.e., torque switch open will be ignored for 3 seconds
after tripping of Torque switch close.
13.16 Automatic phase correction facility will be available.
13.17 Potential free contact for annunciation of power failure will be available.
13.18 ELECTRONIC POSITIONER
13.18.1 Electronic positioner shall be a part of the integral starter unit.
13.18.2 Positioner shall be suitable for accepting command and feedback signals
of
4-20mA and position the Actuator accordingly.
13.18.3 Position shall have deadband adjustable from 1% to a maximum of 2.5%
to ensure better positioning accuracy.
13.18.4 Positioner shall have inbuilt time delay adjustable from 0.5 to 15
seconds.
13.18.5 Positioner shall have output relay contacts with maximum load capacity
of 230V, 10A (resistive load).
13.18.6 Positioner shall be suitable for an ambient temperature of -20C to
+80C.
13.18.7 The Positioner shall be field configurable having DIP Switches to enable
selection of any of the following modes on loss of remote command
signal (4-20mA)
Fail Open

auma india
13.19

Fail Close
Fail As is
SIGNAL ISOLATOR

13.19.1 Signal Isolator shall be a part of the Integral starter unit.


13.19.2 Isolator shall be suitable for accepting 4-20mA as input and give 2
isolated outputs of 4-20mA each.
13.19.3 Isolator output signals shall be isolated between themselves and input
signal.
13.19.5 Load driving capacity of each output shall be at least 500 ohms.
13.19.6 Zero and span adjustments shall be available on the isolator for each
output.
13.19.7 Isolator Enclosure shall be at least of IP 10 protection class.
13.19.8 Isolator shall be suitable for an ambient temperature of -20C to +80C .
13.20 OPTIONALS
The following individual potential free relay contacts will be available in the
Actuator for remote annunciation to facilitate continuous monitoring of the
Actuator.
Actuator (valve) running in OPEN direction.
Actuator (valve) running in CLOSE direction.
Actuator in remote mode.
Actuator in local mode.
Actuator power switched off / single phasing.
Common fault (torque switch trip, thermoswitch clip and thermal
overload relay trip).
13.21

Remote annunciation of Actuator faults should be available at a


DCS/remote through 2-wire system. Suitable multiplexer and demultiplexer
should be provided in Actuator and DCS panel respectively. Annunciation of
Actuator faults signal should be through LEDs. Optionally potential free
contacts of faults annunciation should be provided, if specified. The 2-wire
system should be valid for a maximum distance of 2 kms. beyond which
repeaters should be provided. The communication from Actuator to remote
panels/DCS should be unidirectional.
The following faults should be
annunciated : Torque switch OPEN
Torque switch CLOSE
Thermoswitch trip
Thermal overload relay trip
Motor single phasing
Common fault (inclusive of any one or combination of above fault)

auma india

1.

2.

3.

4.

SPECIAL FEATURES & BENEFITS OF AUMA INDIA


ELECTRICAL ACTUATORS.
Suitability to the valve
a)
Output drives as per DIN/ISO standards can be mounted to the
actuator.
b)
All output drive types of same standard size interchangeable.
c)
Mounting dimensions as per standard.
d)
Hollow output shaft with large acceptance for rising valve spindle.
e)
Auma actuators are suitable for mounting at all positions on to the
valve.
f)
Suitable for floor stand operation.
Wide speed ranges to meet operating speed demands
a)
Large range and fine steps ranging from 4-180 rpm.
b)
Operating speed can easily be changed by using another set of
change wheels or by changing the motor (this can be done at any time).
Well protected against environment
a)
High class enclosure of the whole actuator IP67.
b)
High class protection of micro switches for limit and torque switches
IP68.
c)
Auma motor in high class enclosure (IP67 after mounting on the
actuator).
d)
IP68 enclosure offered as optional.
Conditions of service and duty
a)SA

Standard version open-close control duty, short time duty,


S2-15mins, optional, S2-30 mins and other special
requirements.
For regulating application.

6.

b) SAR
Safety
a) Double-break micro switches or limit and torque switching.
b) If the switching point of limit switch gear has been overturned
inadvertently by manual operation, the switching point itself does not
change. No resetting is therefore required.
c) Handwheel does not rotate during power operation.
d) Manual drive is automatically disengaged when motor starts.
e) Design of stem nut makes it possible to remove the actuator from the
valve but maintaining valve operability.
f) 3 nos. Thermal switches embedded into the motor windings for direct
monitoring of winding temperatures as standard.
Easy setting

7.

a) Easy setting of limit switches (counter-wheel-mechanism).


b) The tripping torque is easily read at the circular scale of the torque
switch mechanism.
Extras available

5.

8.
a.

a) Additional instruments for position indication and sequence control.


b) Extras can be easily fitted at a later date, if required.
Service simplicity & ease of maintenance
To remove the electric motor it is not necessary to open grease filled gear
box.

auma india
b.
c.

Change wheels are outside of the grease filled space.


Once commissioned properly, frequent maintenance is not necessary.
OPTIONALS / ACCESSORIES

Reduction gear unit (RGU) and dial type continuous local mechanical position
indicator for local indication. (RGU converts no. of turns of Actuator output
into 2700 rotation).
Potentiometer for remote position transmission, which gives voltage feedback
corresponding to valve position.
2 limit switches and 2 torque switches of 2 NO + 2 NC contacts (instead of
standard
1 NO + 1 NC contacts).
Four train gear limit switching consisting of :
a) 4 limit switches of 2 NO +2 NC contacts.
OR
b) 4 limit switches of 1 NO + 1 NC contacts.
OR
c) 2 limit switches of 2 NO + 2 NC & 2 nos. of 1 NO + 1 NC.
Auxiliary limit switches (2 nos. OR 4 nos.) of 1 NO + 1 NC
Space heater in switch compartment (240 v single phase, 10 watts).
Electronic position transmitter OR resistance to current convector (3 wire / 2
wire) (RWG 1001/2002) which takes input from potentiometer and converts
into the feed back signal of 4 - 20mA DC (RWG needs supply voltage of 24
volts DC 15%).
RWG has a span setting screw and is mounted in actuator switch
compartment.
Electronic Positioner (CU01), which compares the incoming 4-20mA signals
from the actuator and the controller in case of difference, operated the
actuator through relay till both the signals equalise (Positioner needs supply
voltage of 24V DC 1V).
Power supply unit (PS01) to convert 110 V AC or 220 V AC supply to 24 V DC,
which is used as an input to RWG/CU01.
Remote position indicator (96mm x 96mm) supplied loose for analog position
indicator.

auma india
R-I CONVERTER

RWG 1001

Application :
This device is for the transformation of a resistance value into a proportionate
current signal. It can be placed e.g. in actuators, where the position is determined
by potentiometer and a 0/4-20mA signal is being brought out.
Version :
The components are enclosed in a plastic housing and covered by an epoxy filling
Electrical connection is by faston plug 2.8 x 0.5mm.
As potentiometer transmitter preferably a potentiometer of 4.7k Ohm should be
used, so that the reference voltage source is not overloaded.
Block diagram :

MODE OF OPERATION :
A reference voltage point Uref in the device (temperature compensated) delivers
the supply voltage for the potentiometer transmitter. With the multiturn
potentiometers P1 & P2 the position of the zero point and the total amplification
can be adjusted over the input amplifier V1. The amplifier V2 converts the output
signal from V1 into an output current of 0-20mA or 4-20mA. This is independent
of the load within the range of 0 to 600 ohms. The lowest value 0mA or 4mA can
be adjusted with P1.

auma india
R-I CONVERTER RWG 1001

Setting instruction :
When delivered the device is adjusted so that the mechanical and electrical zero
point coincide, i.e. the initial value 0 Ohm from the potentiometer transmitter
corresponds to an output current of 0mA.
Sequence of operations :
1. Setting for Actual-Value-Signal 0-20mA
1.1
1.2
1.3
1.4
1.5
1.6

Drive actuator to end position CLOSED (corresponds to 0 mA).


Turn adjusting potentiometer P1 to the right till the output current starts
increasing.
Turn adjusting potentiometer P1 back till a residual current of 4mA is
reached. Herewith it is assured that the 0-point is not crossed.
Drive actuator to end position OPEN
By adjusting potentiometer P2 (amplifying) set to the end value 20 mA.
Move once again to end position CLOSED for checking the setting, if
necessary readjust.

2. Setting for Actual-Value-Signal 4-20mA


2.1
2.2
2.3
2.4
2.5

Carry out working steps as mentioned above under 1.1 till 1.6
With potentiometer P2 adjust to 16mA
Bring actuator to end position CLOSED
Set the initial value to 4mA with adjusting potentiometer P1. Herewith the
end values
Check setting for both positions and when necessary, readjust slightly.

auma india
ELECTRONIC POSITION TRANSDUCER - RWG 2002

Setting instruction :
When delivered the device is adjusted so that the mechanical and electrical zero
point coincide, i.e. the initial value 0 Ohm from the potentiometer transmitter
corresponds to an output current of 4mA.
Sequence of operations :
Setting for Actual-Value-Signal 4-20mA
1.1

Drive actuator to end position CLOSED (corresponds to 4 mA).

1.2

Turn adjusting spindle at the reduction gearing to the left (anti-clockwise)


for bringing potentiometer transmitter to mechanical starting position
(a=0). A slip clutch prevents damages at the potentiometer transmitter.

1.3

Turn adjusting potentiometer P1 to the right till the output current starts
increasing.

1.4

Turn adjusting potentiometer P1 back till a residual current of 4mA is


reached. Herewith it is assured that the 0-point is not crossed.

1.5

Turn adjusting spindle at reduction gear to the right till the output signal
starts increasing. This is necessary since at potentiometers the electrical
swing angle is often not the same as the mechanical swing angle.

1.6

Drive actuator to end position OPEN

1.7

By adjusting potentiometer P2 (amplifying) set to the end value 20 mA.

1.8

Move once again to end position CLOSED for checking the setting, if
necessary readjust.

auma india
INDUCTIVE POSITION TRANSMITTER SYSTEM IWG - 1002

Setting instruction :
For setting of zero position or max. swing, beginning always with setting zero
position. The mechanical zero position (
- 0) must correspond to the electrical
zero position, otherwise setting of potentiometers P1 and P2 will be influenced by
each other. For example, displacement of the zero position by 1mA will cause the
same displacement of end position, since zero position correction is done by
additive process.
When delivered from our works the device is adjusted so that mechanical and
electrical zero point coincide, i.e., the initial value ( - 0) of the IWG corresponds to
an output current of
0 mA.
Sequence of operations :
1.

Setting for Actual Value Signal 4-20 mA

1.1

Drive actuator to end position CLOSED (corresponds to 4 mA).

1.2 Turn adjusting potentiometer P1 clockwise till the output current starts
increasing.
1.3

Turn adjusting potentiometer P1 back till a current of 4 mA is reached


herewith it is assured that the 0 point is not crossed.

1.4

Drive actuator to end position OPEN

1.5

By adjusting potentiometer P2 (span) set to the end value 20mA.

1.6

Move once again to end position CLOSED for checking the 0 point, if
necessary readjust.

Maintenance :
The inductive transmitter system IWG 1002 needs no maintenance.

auma india
INDUCTIVE POSITION TRANSMITTER SYSTEM IWG 1003

Setting instruction :
For setting of zero position or max. swing, Begin always with setting zero position.
The mechanical zero position must correspond to the electrical zero position,
otherwise setting of potentiometer P1 and P2 will be influenced by each other. For
e.g : Displacement of the zero position by 1mA will cause the same displacement
of end position, since zero position correction is done by additive process.
When delivered the device is adjusted so that the mechanical and electrical zero
point coincide, i.e. the initial value 0 Ohm from the potentiometer transmitter
corresponds to an output current of 0mA.
Sequence of operations :
Setting for Actual-Value-Signal 4-20mA
a) Drive actuator to end position CLOSED (corresponds to 4 mA).
b) Turn adjusting spindle at the reduction gearing to the left (anti-clockwise)
for bringing potentiometer transmitter to mechanical starting position
(a=0). A slip clutch prevents damages at the potentiometer transmitter.
c) Turn adjusting potentiometer P1 to the right till the output current starts
increasing.
d) Turn adjusting potentiometer P1 back till a residual current of 4mA is
reached. Herewith it is assured that the 0-point is not crossed.
e) Turn adjusting spindle at reduction gear to the right till the output signal
starts increasing. This is necessary since at potentiometers the electrical
swing angle is often not the same as the mechanical swing angle.
f) Drive actuator to end position OPEN
g) By adjusting potentiometer P2 (amplifying) set to the end value 20 mA.
h) Move once again to end position CLOSED for checking the setting, if
necessary readjust.
i) Setting for Actual-Value-Signal 4-20mA
j) Carry out working steps as mentioned above under 1.1 till 1.6
k) With potentiometer P2 adjust to 16mA
l) Bring actuator to end position CLOSED
m) Set the initial value to 4mA with adjusting potentiometer P1. Herewith the
end values
n) Check setting for both positions and when necessary, readjust slightly.
Maintenance
The inductive transmitter system IWG 1003 needs no maintenance

auma india
SPARE PARTS
(SA6 - 100)
When placing orders for spare parts it is essential to mention order number,
works number and type of the actuator (refer to name plate). Parts with number
in a circle,
e.g 8 , will be supplied complete only.
Part
No.

Designation

Part
No.

Designation

Gear box housing

27

Helical gear (SA 6 only)

Switch compartment cover

29

Handwheel

External bearing retainer

30

Handwheel retainer

Internal bearing retainer

35

L. sw. Drive helical pinion

Declutch lever

36

Pinion gear (shaft assembly)

Clutch roller pin, short

37

Compression spring

Clutch roller pin, long

Clutch fork assembly

01

O-ring (clutch roller pin)

Declutch latch

02

O-ring (Declutch lever)

10

Tension spring

03

O-ring (drive assly. Flange)

12

Clutch ring support pin

04

O-ring (bearing retainer)

13

Spring tension plate

05

O-ring (handwheel)

14

Declutch tripping arm

06

O-ring (Bearing flange)

15

Retaining plate

07

O-ring (switch comp. Cover)

16

Return spring

010

Quad ring

17

Spacer

013

Oil seal

18

Bushing

014

Oil seal

19

Retaining ring (SA 6 only)

017

Ball bearing

21

Worm shaft assembly

021

Circlip

23

Bearing flange

022

Circlip

24

Hollow drive shaft

023

Circlip

25

Compressing spring

024

Circlip

26

Clutch ring

025

Circlip

auma india
(SA6 - 100)
Part
No.

Designation

Part
No.

Designation

027

Snap ring

2.05

Hexagon head bolt

028

Lid

2.06

Lock washer

030

Hexagon head bolt *

2.09

Flat washer

031

Hexagon head bolt

2.010 Lock washer

032

Thin shank hex. head bolt

2.011 Lock washer

033

Countersunk oval head screw 2.012 Fillister head screw

034

Hexagon head bolt

035

Fillister head screw

038

Cotter pin

3.1

Indicator assembly

039

Parallel key

3.5

Indicator glass

041

Blinker switch (SPST)

3.6

Glass retaining ring

043

Spring washer

3.01

O-ring

045

Lock washer

3.02

Fillister head screw

047

Lock washer

3.03

Lock washer

048

Fillister head screw

2.013 Lock washer

4.4

Stem protection tube

052

Support washer

4.7

Stub shaft (type D)

056

Roll pin

4.8

Mounting flange (type D&F)

058

Star washer

4.11

Mounting flange (type A)

4.12

Stem nut (type A)

2.1

Motor pinion

4.13

Bearing locknut

2.2

Spur gear

4.21

Mounting flange (type B&C)

2.3

Motor mounting flange

4.22

Dog drive sleeve (type C)

2.4

Shield

4.23

Thrust ring

2.6

Worm gear

4.24

Keyway drive sleeve (type B)

2.7

Motor

4.75

Drive socket (type E)

2.8

Gasket

4.05

Stud bolt

2.02

O-ring

4.06

Flat washer

auma india
(SA6 - 100)
Part
No.

Designation

Part
No.

Designation

4.07

Hexagon head bolt

6.1

Pin carrier (motor)

4.08

Cap

6.2

Socket carrier (motor)

4.09

Hexagon head bolt

6.7

Plug pin (motor)

6.8

Plug socket (motor)

7.1

Limit switch (SPDT)

7.2

Torque switch (SPDT)

4.010 Lock washer


4.011 Parallel key
4.012 Lock washer

44.01 Set screw

7.05

Fillister head screw

44.02 Grease nipple

7.06

Lock washer

44.034 Thrust bearing


4.04

Thrust bearing race

5.1

Terminal box cover

5.2

Terminal mounting plate

9.1

Potentiometer *

9.01

Fillister head screw

9.02

Lock washer

5.01

Pin carrier (control)

31

Limit switch drive assembly

5.02

Socket carrier (control)

44

Limit switch counter gear

5.03

Plug pin (control)

45

Torque switch drive assembly

5.04

Plug socket (control)

46

Reduction gearing assembly

5.05

Fillister head screw

5.06

Lock washer

5.07

Conduit gland

5.08

Thrust washer

5.09

Seal ring

5.10

O-ring

* state resistance when


ordering

auma india
SPECIFICATION FOR SECONDARY WORM GEAR BOXES
1

FLANGE MOUNTED SECONDARY WORM GEAR BOX

1.1

The secondary worm Gear shall be so selected that in combination with


Electrical Actuator it shall meet specified torque and operating time.

1.2

Secondary Gear Box shall be flange mounted.

1.3

The secondary Gear Box shall be self-locking having 360 degree full worm
wheel. It shall be possible to position and use extra 3 quadrants of worm
wheel available.

1.4

Gear Box shall be provided with adjustable mechanical stoppers on the


input shaft so that only the input torque is sensed ensuring safety and to
have positive feeling when end position is reached while operating
manually.

1.5

The Gear Box shall be provided with adjustable mechanical stopper


arrangement adjustable from 80 to 120 degree angle of travel.

1.6

The secondary Gear Box shall have minimum IP67 protection class.

1.7

The Gear Box housing shall be grease filled and suitable for any position
mounting.

1.8

It shall be possible to change the version of the Gear Box for the following
operation:
a)

Clockwise rotation at the input shaft of Gear resulting in clockwise


rotation of the valve shaft.

b)

Clockwise rotation at the input shaft of Gear resulting in


clockwise rotation of the valve shaft.

anti-

This shall be an inherent feature of the Gear Box to have maximum


flexibility at site.
1.9

An adjustable mechanical pointer cover to show valve position shall be


available.

1.10 The Gear Box shall be painted with corrosion proof epoxy resin paint. Paint
shade shall be manufacturers standard.
2

FOOT MOUNTED SECONDARY WORM GEAR BOX

2.1

The secondary worm Gear shall be so selected that in combination with


Electrical Actuator it shall meet specified torque and operating time.

2.2

Secondary Gear Box shall be foot mounted with lever arrangement design.

2.3

The secondary Gear Box shall be self-locking having 360 0 full worm wheel. It
shall be possible to position and use extra 3 quadrants of worm wheel
available.

auma india
2.4

2.5

Gear Box shall be provided with adjustable mechanical stoppers on the


input shaft so that only the input torque is sensed ensuring safety and to
have positive feeling when end position is reached while operating
manually.
The Gear Box shall be provided with adjustable mechanical stopper
arrangement adjustable from 80 to 120 degree angle of travel.

2.6

The secondary Gear Box shall have minimum IP67 protection class.

2.7

The Gear Box housing shall be grease filled and suitable for any position
mounting.

2.8

It shall be possible to change the version of the Gear Box for the following
operation:
a)

Clockwise rotation at the input shaft of Gear resulting in clockwise


rotation of the valve shaft.

b)

Clockwise rotation at the input shaft of Gear resulting in


clockwise rotation of the valve shaft.

anti-

This shall be an inherent feature of the Gear Box to have maximum


flexibility at site.
2.9

An adjustable mechanical pointer cover to show valve position shall be


available.

2.10 The Gear Box shall be painted with corrosion proof epoxy resin paint. Paint
shade shall be manufacturers standard.

auma india
SPECIFICATION FOR SECONDARY BEVEL GEAR BOXES
1.

All Gear Operators shall have Bevel Gear transmission with completely
enclosed construction. The gear casing shall be designed adequately to
withstand shock and vibration of the pipe line. The design shall be compact
and less weight and shall not cause any trouble during operation at sites.

2.

The Gear Box shall be filled with Grease. The specification of lubricant i.e.,
Grease shall be furnished. There shall be no leakage of lubricant from the
Gear Box.

3.

The Gear Operator shall be suitable for mounting in any position to suit the
site requirements.

4.

It shall be possible to use the same Gear Operator for different application
(Rising and Non-Rising stem) by changing only the output drive of the Gear
Operator.

5.

The Gear Operator shall have base suitable to take the thrust with Needle
roller bearing. A blank High Tensile Brass or Aluminum Bronze drive sleeve
shall be provided as a standard supply.

6.

The assembly of all gears, shafts etc., shall be done properly to have a
smooth operation without any noise.

7.

The flange for connecting the valve shall have dimensions as per DIN 3210 /
ISO 5211 standards.

8.

Wherever Gear Boxes are required to be assembled with electrical


Actuators, Gear Operators are to be supplied with input flanges to suit the
keyed shaft of the actuator. The design should be suitable for both Manual as
well as Electrical operation.

9.

The Bevel pinion shall be of case hardened steel and gear of alloy steel
EN19 with suitable heat treatment.

10.

Wherever Gear Boxes are required to be assembled with electrical


Actuators, Gear Operators are to be supplied with input flanges to suit the
keyed shaft of the actuator. The design should be suitable for both Manual as
well as Electrical operation.

11.

The Bevel pinion shall be of case hardened steel and gear of alloy steel
En19 with suitable heat treatment.

12.

All Gear Operators shall have stem protection covers for rising stem
application.

13.

The Gear Operator shall be painted with corrosion protection Epoxy based
paint.

14.

The Gear Operator shall be enclosed to a minimum of IP67 protection class.

15.

Gear Operators shall be suitable for an ambient temperature range of -20


C to +80 C.

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16.

Supplier to furnish the general arrangement drawing of the Gear Operator


incorporating the material specification for all critical components and overall
dimensional details for approval.

17.

The Gear Operator shall be tested to the design requirement of torque /


thrust wherever applicable and type test certificates shall be furnished.

SPECIAL FEATURES & BENEFITS OF AUMA INDIA WORM GEAR BOXES


1.

Rigid casing of the gear box.

2.

Manufactured according to Auma Germany drawings

3.

Full worm wheel design making the gear box suitable for either multi turn or
quarter turn operation. In case of quarter turn operation extra 3 segments
available for repositioning for future use, if required.

4.

A separate spline coupling provided for fixing the gear box on to valve
shaft. No orientation problems while mounting the gear box on to the valve
shaft. Gear box suitable for mounting in any position.

5.

Gear box enclosure conforms to IP67 standards. IP68 enclosure can be


offered, if required.

6.

All gear boxes are special grease lubricated.

7.

Mechanical end stoppers are provided in the form of unique spline guided
bush (screw & nut mechanism for smaller gear boxes) on input worm shaft.
This allows for set 90 operation. Positive feeling when end positions are
reached while manually operating the valve.

8.

The chances of damage to the gear box housing are less as only input
torque is sensed (which is much less than the output torque).

9.

Proven design models upto 18,000 kg-m output torque manufactured and
supplied to customers in india.

10.

The gear boxes beginning with 200 kg-m output torque can be supplied in
various ratios to meet installation demand.

11.

Auma Worm gear boxes offer high mechanical advantages (ratio of output
torque to input torque). This results in lesser input torque requirements and
thus optimizes the electrical actuator selection. This is a great advantage to
the end user considering that the economical selection / sizing is possible.

12.

Different versions of Gear boxes (LR, RL, L & R) are available, giving wide
choice for selection, considering plant requirements.

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WORM GEAR BOX (FLANGE MOUNTED)

Designation

Output Torque
Kgm

Valve Mtg.
flange

Suitable Actuator

Manual

Motor

GS40.2

42

30

F 07
(F 10)

SA3 / SA6

GS63.2

85

60

F 10
(F 12)

SA3 / SA6

GS80.2

140

100

F 12
(F14)

SA6 / SA12

GS100.2
VZ4

280

200

F 14
(F 16)

SA6 / SA12

GS125.2
VZ4

560

400

F 16
(F 25)

SA 25
SA6 / SA12

GS160
GZ14

1125

800

F25

SA50
SA6/SA12

GS200
GZ16

2250

1600

F30

SA100
SA25/SA12
SA6

GS250 + GZ25

4500

3200

F35

SA50/SA25
SA12

GS315 + GZ30

9000

6300

F40

SA50/SA25
SA12

GS400 + GZ35

18000

12500

F48

SA100/SA50/SA25

GS500 + GZ40

36000

25000

F60

SA100/
SA50/SA25

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Criterion for selection of auma actuator and gear boxes

Valve Type
Gate Valve
Globe Valve
Sluice Valve
Pinch Valve
Gate Valve
Globe Valve
Sluice Valve
Pinch Valve
Gate Valve
Globe Valve
Sluice Valve
Pinch Valve
Gate valves
Control valves
Pinch valves

Operating
Movement

-or -

-or -

-or -

Auma India Electrical


Actuator / GearBox

Multi turn actuators SA3 - SA100


Torques from 30Nm - 1000Nm
Thrust from 25kN - 190kN
Output speeds from 4rpm - 180rpm
Valve attachment according to
ISO 5210 / DIN 3210
Spur Gear boxes GST12 - GST100
Torques from 120Nm - 800Nm
Thrust from 60kN - 820kN
Valve attachment according to
ISO 5210 / DIN 3210
Bevel Gear boxes GK10 - GK35
Torques from 120Nm - 8000Nm
Thrust from 60kN - 820kN
Valve attachment according to
ISO 5210 / DIN 3210
Linear Thrust unit AS6 - AS50
Thrust from 10kN - 50kN
Valve attachment according to
ISO 5210 / DIN 3210

Butterfly valve
Dampers

Foot mounted Worm Gear boxes


lever arrangement
GF63.2 - GF315
Torques from 600Nm - 63000Nm

Butterfly valve
Louver Dampers
Ball valves
Diverters

Flange mounted Worm Gear boxes


GS40.2 - GS500
Torques from 300Nm - 2,50,000Nm

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SELECTION PROCEDURE
PART

TURN VALVES
DAMPERS ETC.)

: (E.g. : BUTTERFLY

VALVES,

BALL

VALVES,

PLUG

VALVES,

LOUVRE

In part turn valves, the final movement of valve shaft required is normally 90 0.
The electrical actuators are primarily multi-turn type and hence it is necessary to
employ an intermediate worm gearbox between the actuator and the valve so as
to achieve 900 angle of rotation.
Auma offers the following two types of worm gearboxes :
Direct flange mounting type GS
Foot mounting type GF
Data required :
1.
2.
3.
4.
5.
6.
7.
*

Type of valve
Max. valve torque * (unseating torque)
Type of service/duty
Angle of travel (normally 900)
Operating time required
Shaft dia.
Mounting flange details

Note : In case of regulating/modulating service, max. (or unseating) torque


and regulating (or running) torque are required for proper selection.
Regulating torque should not exceed 50% of max. torque.
EXAMPLE

Minimum data :
1.
2.
3.
4.

Max. valve torque = 7000Nm ( 700 kgm)


Open - Close duty
Operating time = 30 secs.
Open - Close service

Step 1 : Selection of Gearbox

Refer Technical data of gearbox catalogue (GS40-GS125 & GS160-GS500)

Select a gearbox type whose Output torque for motor operation is more
than or equal to required valve torque.

In this case, gearbox type is GS160 whose maximum torque capacity for
motor operation is 8000Nm.
Step 2 :

Selection of Actuator

Referring to the Technical Data of Gearbox catalogue, suitable multi-turn


actuator (given in the bottom row) to be selected.

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Please note that economical sizing of actuator can be done by using higher
reduction ratios considering operating time requirement. This is achieved
by employing a primary reduction gearbox having different ratios.
Refer to the bottom-most row in the Technical data for different operating
time in seconds for 900 at different actuator output speed.
In this case, 3 options are available for selection :
Option 1 :

Refering to first column of Technical data of GS160.


Model : GS160 with SA50E32 actuator.
Operating time = 25 secs. (for 900)
Actuator designation SA50E32 indicates open close duty actuator
SA50 with output drive type E having output speed
of 32.

Option 2 :

Referring to the second column of GS160.


Model : GS160 + GZ14 (216 : 1) with SA12E125 actuator.
Operating time = 25 secs. (for 900)
Where GZ14 in the primary reduction gearbox and 216:1 is the total
reduction ratio of the gearbox.

Option 3 :

Note :

Referring to the third column of GS160


Model : GS160 + GZ14 (432:1) with SA6E180
Operating time = 36 secs. (for 900)

Always output drive type E should be selected when coupling Auma


actuator with Auma Gearbox.

Out of the above three options, any one suitable combination can be selected
considering the operating time.
After selecting the suitable model, following important points to be checked :
1.
2.
3.

Max. stem/shaft dia. (refer Technical data for details).


Max. stem/shaft length acceptance (refer dimension l max of dimension
sheet)
Mounting flange compatibility (refer Technical data for details).

Note :

i. The Selection procedure is same for foot mounted type worm


gearboxes GF.
ii. In case of manually operated valves, select the gearbox model whose
output torque for manual operation is more than or equal to
required valve torque.

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SELECTION PROCEDURE
LINEAR OR MULTI TURN VALVES
(E.g. : GATE, GLOBE DIAPHRAGM TYPE ETC.)
For output thrust upto 190KN and output torque upto 100 kgm, Auma multi turn
actuators can be directly selected and mounted on the valve. However, Auma
also offers bevel gear boxes type GK and spur gear boxes type GST for upto
and higher torque/thrust requirements.
Data required :
1.
2.
3.
4.
5.
6.
7.
8.

Type of valve
Max. thrust in case of rising stem valves.
Max. torque in case of rotating stem valves.
Type of service/duty.
No. of turns of stem per stroke OR stroke and stem thread details.
Operating time
Stem diameter
Mounting details

EXAMPLE
Minimum data :
1.
2.
3.
4.

Max. thrust = 300KN = 30000 kgf


No. of turns/stroke = 20
Operating time = 60 secs.
Open - Close duty

Step 1 : Selection of Gearbox

Refer Technical data and Output drive types of gearboxes (GK10-35)in


catalogue.

For rising stem valves, always output drive type A to be selected.

Select gearbox type whose max. thrust permissible is more than or equal to
required thrust.
In this case, gearbox type is GK25.1 whose maximum thrust permissible is
320KN.

Step 2 :

Selection of Actuator

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Referring to the Technical Data of Gearbox catalogue (GK10-35), suitable
actuator model given in the table to be selected.
The required output rpm of the actuator can be calculated as follows :
Actuator output rpm = No. of turns of valve/stroke x Reduction ratio of
gearbox
-----------------------------------------------------------------------------x 60
Operating time in Secs.
In this case, suitable actuator model in SA50
and
20 x 6
Actuator output rpm = --------- x 60 = 120 rpm
60
Choose the nearest available actuator output speed (refer Auma actuator
catalogue for details) i.e. 125 rpm.
Hence the selected combination is GK25,1A/SA50E125 and the revised
operating time 52 secs.
Where actuator designation SA50E125 indicates open-close duty actuator
SA50 with output drive type E having output rpm of 125
Note :

When coupling Auma actuator with Auma Gearbox, always output drive
type E should be employed.

Once the suitable model is selected, following points to be verified :


1.
2.
3.

Output torque capacity (refer Technical data for details).


Max. stem acceptance dia. (refer Technical data and output drive for
details).
Mounting flange compatibility (refer Technical data and output drive for
details).

Note : 1.

2.

In case of multi turn non-rising (rotating) stem valves, same selection


procedure to be employed except the following.

Output torque valves to be compared and evaluated.

Output drive types B,C,D or E to be selected depending on type of


coupling required (normally the output drive type will be either B or
E)
The same selection procedure is applicable for Auma spur gear boxes
GST.

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auma india
TRANSPORT, STORAGE AND HANDLING INSTRUCTIONS
a)

ACTUATOR :

Actuators are high-value Electro-mechanical devices. This should be taken into


account during transport and storage. In order to avoid possible damages,
inconvenience and costs for you land us please observe following points:
1.

TRANSPORT :

2.

Transport to the place of installation in a sturdy packing.


Ropes or hooks to lift or transport valves with mounted actuators
should not be attached to the handwheel.
Fix ropes at valve and not at actuator. Output drive of actuator is
meant to mount actuators, but not to carry the whole weight of valve.
Do not hit with handwheel against walls, floor or machine parts.

STORAGE :
Even in watertight enclosed actuators condensed water collects due to
temperature fluctuations.
This may damage sensitive internal parts.
Damages can be avoided by observing the following points:

3.

Store in well-ventilated and dry rooms.


Protect against humidity from the floor by storage on wooden frame, on
pallets, in cage boxes or on shelves.
Cover actuators with plastic foil to protect against dust and dirt etc.
Protect suitably against mechanical damages.
Check (at least random checks) after approx. every 3 months. In case
condensed water is inside switch compartment, all actuators have to
be checked and, if necessary, dried out.

LONG-TIME STORAGE :
In case actuators are stocked for a long period (more than 6 months) the
following points must be observed additionally :

4.

Before storage: Protect bright surfaces, especially output drive parts


and mounting surface, by long-time corrosion protection agent.
Check for possible corrosion approx. every 6 months. In case
corrosion has started, check all actuators and apply new corrosion
protection wherever necessary.

COMMISSIONING :
The caution advised for electric devices applies also for actuators.
Especially safety instructions (such as VDE/TAB etc.) must be adhered too.
Check visually for possible damages caused by transport or storage.
Measure insulation resistance of motor before switching on. In case it is
less than 500K Ohms this is an indication for humidity in the winding. Motor

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must be removed in order to dry. It can be heated with a hot-air fan or in an
oven (NOTE : max. permissible temperature 1000 C).
Furthermore please refer to our operation instructions. In case they are not
available with you, request a copy from us.
The following points are very important :
-

auma motors have thermo switches as standard.


integrated in the control circuit.

They must be

Wrong connection or faulty control circuit may cause damage to valve


or actuator.

Bring valve manually to intermediate position, then check for correct


sense or rotation. If wrong, switch off immediately and change
direction. Limit and torque switches are ineffective if sense or
rotation. If wrong, switch off immediately and change direction. Limit
and torque switches are ineffective if sense of rotation is wrong!

In case you do not observe our recommended measures we cannot be held


responsible for possible damages.

auma india
TRANSPORT, STORAGE AND HANDLING INSTRUCTIONS
1. TRANSPORT :

Transport to the place of Installation (till the last destination).


Avoid Packages from exposing to open atmospheres during transit.
Protect against rains.

2. STORAGE :

a)

Store in well ventilated and dry rooms.


Protect against humidity from floor by storage on wooden frame, on
pallets, in cageboxes or on shelves.
Cover Gearboxes with plastic foil to protect against dust and dirt etc.,
Protect suitably against mechanical damages.
During long time storage, protect bright surfaces especially output
drive parts and mounting surface by applying long life corrosion
protection agent. Also check once in six months for corrosion. If
corrosion has started, clean and apply corrosion protection agent.

FOR GS SERIES GEAR BOXES WITH ACTUATORS:


GS 40.2 to GS 400 with corresponding actuators the following handling
procedure may be adopted :

Refer Fig shown below for General arrangement of GS series with


Actuator.
A suitable eyebolt is provided on the gear box side as shown in the Fig
.
Put suitable rope around the actuator & to the eyebolt by using S
hook as shown. (a) Lift gently so that, the output drive of gear box
faces the Valve flange which will be easier for mounting.

auma india

Weight Gear Boxes with Actuator


GS 40.2 with SA6
GS 63.2 with SA6
GS 80.4 with SA6

- 44 Kgs.
- 50 Kgs.
- 54 Kgs.

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GS 100.2 with SA12
- 70 Kgs.
GS 100.2/VZ4 with SA6 - 74 Kgs.

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b)

FOR GS SERIES GEAR BOXES

Refer Fig A shown below for handling of Worm Gear Boxes model GS
160 and above & Fig B for GS with GZ gear box.
Put 2 nos. suitable eyebolt on either side of the assembly as shown in
the above figure and lift gently by putting rope with the hook to
eyebolt.
Handle carefully so that, the gear box does not tilt in opposite
direction or it does not slip.

Fig A

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Fig B

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Fig C

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OPERATION INSTRUCTIONS

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TABLE OF CONTENTS

1.

Transport & storage

2.

Service conditions

3.

Mounting to the valve/gearbox

4.

Manual operation

5.

Electrical connections

6.

Test run

7.

Setting of Limit switching

8.

Setting of Torque switching

9.

Setting of mechanical position indicator (optional extra)

10.

Maintenance

auma india
1.

TRANSPORT & STORAGE

Transport to place of installation in sturdy packing


Do not attach to the hand-wheel ropes or hooks to lift by hoist.
Store in well ventilated, dry room.
Protect against humidity from the floor by storage in shelf or on wooden
frame.
Cover to protect against dust and dirt.
Apply corrosion protection agent to bright surfaces.

Ref : transport storage & handling section of manual


2.

SERVICE CONDITIONS
AUMA multi-turn actuators can be used at following ambient conditions :
SA

- 250 C + 800 C (Standard)

The types SA are designed for short time duty S2 15min.


3.

MOUNTING TO THE VALVE/GEARBOX


Mounting & operation can be in any position
Check whether output drive flange suits the valve/gearbox.
Check whether bore & keyway correspond with the input shaft of the
valve or gearbox.
Degrease mounting surfaces at actuator and valve/gearbox thoroughly.
Apply little grease to input shaft of valve/gearbox.
Place actuator on valve/gearbox and fasten with bolts (quality min. 8.8)
firmly crosswise.

4.

MANUAL OPERATION
Attention : Manual operation should only be engaged if motor stands still.
Push declutch lever as indicated by arrow.
If resistance felt turn handwheel slowly
while lever is pressed till manual drive
engages.

Release declutch lever (snaps back to initial position by spring action).


Manual drive remains engaged. In case lever does not snap back by
itself assist with hand.

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Manual disengages automatically when motor is started.
5.

ELECTRICAL CONNECTION
For 3 phase Ac motor
Check whether power supply (type of current voltage & frequency) suits
the motor (refer to motor name plate).
Take off terminal compartment cover.
Connect control wires according to wiring diagram (ref terminal plan
inside the terminal compartment cover).
Connect earth to terminal marked.
Use suitable size cables for the glands supplied.
Attention : Enclosure IP67 is only guaranteed if correct cable sizes are
used.
The two circuits of one switch are
suitable only for the same potential.
Different potentials require tandem
switches.
Valve manufacturer decides whether
switching off in end positions should
be by limit (limit seating) or torque (torque seating).
AUMA motors have 3 thermo switches as standard in series.
Full motor protection is guaranteed with correct connection of the
thermo switches. If these are not connected, our guarantee for the motor
is invalid.
Clean sealing faces at cover for terminal compartment. Check whether
O-ring is not damaged. Apply thin film of non-acid grease to sealing
faces.
Place cover in position & fasten 4 screws firmly.

Tighten cable glands well to guarantee


enclosure IP67.

6.

TEST RUN

auma india
Remove cover at switch compartment and mechanical position indicator
disc

Check whether limit switches tripped. Valve closed (WSR) valve open
(WOL).
In case tripped ref. pt. 7 for releasing.
Bring valve manually to intermediate
position. Turn handwheel anti-closurewise
for OPEN & clockwise for CLOSE.
Check phase rotation. Switch on actuator
in direction OPEN. Check direction of
rotation observing arrows at limit switch
counter gear. If sense of rotation is wrong,
switch off immediately. Interchange any
two incoming phases to the terminals
RYB (RST).
Switch on again in OPEN direction. Press
limit switch flap WOL. Motor should stop.
Repeat the same with DOL in OPEN
direction. Motor should stop. Then control
circuit is correct.
- If motor not switched off, press stop button.
- Check control circuit & set it right.
Determine overrun in both directions (overrun is turns/travel from
switching off till movement stops).
7.

SETTING OF LIMIT SWITCHING


Engage manual drive as explained under pt. 4
Setting for end position CLOSED.
Turn handwheel clockwise till valve is fully closed. Consider possible
overrun as determined under pt. 6
Press down thrust bolt I and turn. The
bolt remains in this position. Turn spindle
A in direction of arrow. Distinct clicks are
felt & heard. Continue turning the spindle
until the cam operates the switch. At this
stage spindle should not click any more and
should not be turned any further. If turned beyond inadvertently the
point continue turning spindle slowly in the same direction till the

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switches cam goes back to its original tripping position. Turn thrust bolt I
till it snaps back to its original position by spring action.
To test the correctness of above setting turn handwheel in opposite
direction. The cam should release the switch flap immediately (i.e. for
less than one turn of handwheel). In case of not releasing repeat the
above steps again.
Setting for end position OPEN
Turn handwheel anticlockwise till valves is fully open. Consider possible
overrun as in pt.6 by backwinding as required.
Set limit switching by spindle B procedure as explained above for end
position CLOSED.
Check the correctness of setting as explained in CLOSED setting
procedure.
8.

SETTING OF TORQUE SWITCHING


Attention : Adjusted torque must suit the valve.
If actuators have been supplied by a valve manufacturer, setting was made
during testing. The setting should only be changed with the consent of
valve manufacturer.
Figures on torque switch operating
cam indicate values in Nm (1kgm 10Nm).
Loosen screw & turn the cam till the
desired torque coincides with arrow mark,
then fasten lock screw.

If the actuators switched off by torque switch over its travel before
reaching an end position please check whether valve stem is damaged
or dirt adhering to it. If necessary and with valve makers consent the
setting of tripping torque may be raised slightly.

9.

SETTING OF MECHANICAL POSITION INDICATOR

auma india
Indicator disc rotates approximately 2700 at full travel from OPEN to CLOSE
or vice versa.
A suitable reduction gearing was installed at our works. If turns per stroke
are changed subsequently the reduction gears may have to be changed
too.
Run actuator to end position CLOSE
Turn dial
(CLOSE)till the arrow
is in alignment with the mark on the
indicator glass.
Run actuator to end position OPEN
Turn dial
(OPEN) while holding the
other dial position, till the arrow is in
alignment with the mark on the glass.
10.

MAINTENANCE
Attention : After commissioning, check for damages on paint caused by
transport
or installation. Do necessary touch up to avoid corrosion.
AUMA actuators need only little maintenance. Precondition for reliable
service is correct commissioning. It is also very important that the O-rings
at covers are placed correctly and cable glands fastened firmly to prevent
entrance of dirt or water.
We recommend :

If operated very seldom, perform a test run every six months. This
assures that actuator is always ready to operate.
Approximately 6 months after commissioning and then every year
check bolts between actuator and valve/gearbox for tightness. If
required re-tighten.

The gear-housing was filled with lubricant in our factory. This filling lasts for
several years of service.

auma india

PRECAUTIONS
( DOs & DONTs )