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High efficiency centrifugal fan
HRV 63S-1600/K
Assembly and Operating instructions
High efficiency
centrifugal fan
Type: HRV 63S-1600/K
Job-No.: 12300051 / 120
Item: 04.FN-03
Customer: Loesche GmbH
Project: Bim Son Clinker

PO No.: 45096131
4.FN-03
15.07.2016 2842
T:\AUFTRAG\12300XXX\12300051\KDOKU\VORBEREITUNG\POS_0120\12300051_120_HRV_63S-1600_K_EN.DOCX; Date: 01.09.2016 1

HRV 63S-1600/K
CONTENTS
1 Fundamental safety instructions ...................................................................3

1.1 Special Safety Information ................................................................................4
1.2 Symbols ............................................................................................................4
2 General Requirements ....................................................................................5
3 Area of Application and Correct Use.............................................................6
4 Design and Method .........................................................................................7
5 Transport .........................................................................................................8
5.1 Storage .............................................................................................................8
6 Installation ..................................................................................................... 10
6.1 Electrical Connection ...................................................................................... 13
7 Commissioning ............................................................................................. 15
7.1 Checklist for maintenance, servicing and commissioning ............................... 17
8 Operation ....................................................................................................... 19
8.1 Switching the fan on ........................................................................................ 19
8.2 Switching off the fan ........................................................................................ 19
9 Servicing ........................................................................................................ 22
9.1 Maintenance and Care .................................................................................... 22
9.2 Inspection and Maintenance List ..................................................................... 27
10 What to do first if a malfunction occurs...................................................... 28
11 Technical Data ............................................................................................... 30
11.1 Speed torque curve ......................................................................................... 32
11.2 Electrical Values.............................................................................................. 33
12 Stocking of Spare Parts ................................................................................ 34
12.1 Diagram and Spare Parts List ......................................................................... 35
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

HRV 63S-1600/K
1 Fundamental safety instructions

The instruction manual contains important information on how to operate the machine/plant safely, properly and
most efficiently. Observing these instructions helps to avoid danger, to reduce repair costs and downtimes and
to increase the reliability and life of the machine/plant.
The instruction manual is to be supplemented by the respective national rules and regulations for accident
prevention and environmental protection.
The operating instructions must always be available wherever the machine/plant is in use.
These operating instructions must be read and applied by any person in charge of carrying out work with and on
the machine/plant, such as
 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.

HRV 63S-1600/K
1.1 Special Safety Information

The rotating drive elements between the motor and the impeller are secured with guards in compliance with
DIN EN ISO 12100, DIN EN ISO 13857 and DIN EN ISO 12499.
The guards may only be removed when the mains supply is switched off for the duration of maintenance work.
Caution, hot surfaces!

Certain parts of the fan can cause skin burns if touched.
Protect yourself by suitable measures such as allowing the machine to cool before starting
maintenance work or by wearing protective clothing.
1.2 Symbols
Warning of danger. Be sure to read and observe this information first.
General danger warning Warning of danger to persons which you must observe
Useful information and supplementary information

Note / hint
which you should observe
Transport information
Attention! Electrical voltage
Attention! Automatic start of rotating parts
Attention! Hot surfaces
Secure against reactivation during repair

work.
Information on explosion protection.
Observe the operating instructions!

HRV 63S-1600/K
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.

HRV 63S-1600/K
3 Area of Application and Correct Use

The fan is to be used exclusively to handle clean air or air containing dust, gas or vapour which
are not flammable or explosive.
The fan must not be installed or operated in an area subject to explosion hazards.
Any other use is not its usage as prescribed.
Gas handled: Air
Type of dust: Cooler Exhaust Air
Mass flow of dust: 3124 kg/h
Max. dust concentration: g/m³
Any constructional alterations or increase of the performance data must be discussed with the manufacturer.
The maximum permissible temperature of the handled medium is 450.
Restriction of the permissible service environment

When the temperature is extremely low, the materials change their strength characteristics
and grease loses its lubricity.
The fan may only be operated when the temperature of the ambient air is at least 5 °C!
Limitation of the permissible rotating speed range
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.
Rotating speed range Limitation

0 - 120 Continuous operation is prohibited. This range must be quickly passed through
during start-up and run-down.
> 989 The maximum rotating speed must not be exceeded.
--- Continuous operation is prohibited. This range must be quickly passed through
during acceleration and slowing down.

HRV 63S-1600/K
4 Design and Method
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 constructional elements which are particularly at danger from wear (inside of
scroll plate) are made from highly resistant special steel.
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.

HRV 63S-1600/K
5 Transport
The fan must be fastened only to designated crane lugs.
Please observe the accident prevention regulations!
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.
For transport of rotor unit please

pay attention to a sufficient lifting
capacity of the lifting belts!
The weights can be seen from
the shipping documents.
The rotor unit must be lifted
equally at the shaft.
Do not fix lifting belts to impeller
or bearings!
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.
General storage conditions for machines and machine parts

The following must be noted when putting machines and their individual parts into storage:
 Check the delivery for any damage. Please contact your supplier if there is any damage, or in cases where
you are not sure.
 Check the packing and rust-proofing before putting the items into storage.
 Put the items into storage in closed, dry, vibration-free rooms that are protected against rain, snow and
flooding.
 Protected against dust
 Frost-free
 Avoid extreme variations of temperature (do not go below the dew point) and the associated formation of
condensation.
 Low relative humidity, max. 65%
 Protection against dampness from the ground

HRV 63S-1600/K
 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.

HRV 63S-1600/K
6 Installation
 Check the place of installation for

 smoothness and
 cleanness
 Please only unpack those components which are required for the assembly work which is actually being
carried out. This will help to avoid damage during assembly and as a result of incorrect storage.
Danger of injury!
Observe the operating instructions for the lifting gear which is used.
The components must only be lifted on the crane lugs provided.
Observe the Accident Prevention Regulations
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.
Screwing down the fan / baseframe on an uneven foundation warps the

material. This can negatively influence the smooth running of the fan.
Fans must be put up and secured without putting tension on them. To
guarantee this, place sheet metal underneath the frame right next to the
fastening screws. When finished check the bearings for vibration to insure
smooth running.
In certain cases it may be necessary to underpour the fan with a non
shrinking grouting compound.
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.
Follow the assembly drawings! A-301113-0, A-301542-0, A-283993-4
 Tools and accessories

Place following tools and accessories to hand:
 Set of box wrenches
 Set of torque wrenches
 Set of open-end spanners

HRV 63S-1600/K
 Set of thickness gauges (from 0.05 mm)

 Shaft level or spirit level
 Slide gauge
 Scraper / sandpaper
 Oil-stone
 Hoist gear
 Fill plates
 Permanently plastic sealing material (Curil T)
 Clean, lint-free cloths
 Lubricant according to the viscosity data
 Cleaning agent (e.g. VAVOLINE 150)
 Liquid bolt securing agent (e.g. LOCTITE 242)
 Teflon band, liquid sealing material
Attachment as in The housing must not be fixed. A clearance of at least 2.0

illustration left. mm must remain between the support claw and the of the
lower section of the housing and the plate. It must be
possible for the four contact surfaces to move in all
directions during temperature-related expansion of the
housing.
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!
Assemble the rotor (impeller, shaft, bearings and shaped inlet)
 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.

HRV 63S-1600/K
 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.
Changes in the shaft length which occur by temperature differences

are compensated by the floating bearing housing.
During installation, observe the specified axial clearance of the
floating bearing.
a= 17 mm
b= 40 mm
c= 3 mm
 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.
Setting on the upper section of the housing
 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.
Adjusting the inlet ring
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 SG2-H.
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.

HRV 63S-1600/K
 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.
Mounting of the shaft seal
 Check that the shaft is running smoothly.

 The shaft must be free of grooves and clean on the sealing faces.
 During erection ensure that the sealing discs and the steel discs are arranged alternately (labyrinth seal).
 The severance cuts of the sealing discs must not be directly next to one another, but must be radially
staggered.
 Bend the sealing discs apart at the severance cuts and push them onto the shaft. The severance points
must lie close to one another.
 Align the steel discs on the outside diameter of the sealing discs.
 Apply the sealing units to the casing, align to the shaft and screw alternately evenly all round to the fan
casing.
Mount all protective equipment!

Rotate the impeller several times by hand.
This must be repeated at least once a month until commissioning.
Locking- and regulating flap
 Tighten the flanged screws evenly in order to avoid stresses.

 Inlet and discharge pipework must be mounted so that they are stress-free.
Carefully apply the packing. Tighten the bolts evenly all the way round.
6.1 Electrical Connection
Mains Current!
Connection may only be carried out when there is not current passing through.
When connecting the electric components, please observe the following:
 Regulations according to VDE (Association of German Electro-Engineers) Guidelines 0100.

 The valid national electrical regulations.
 This work must be carried out by an authorized specialist and in accordance with the instructions of the
motor manufacturer.
 The available mains voltage and mains frequency must be the same as the values stated on the motor
nameplate.
 The mains supply cable must be protected against damage and dimensioned appropriately to the power
consumption.

HRV 63S-1600/K
 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.

HRV 63S-1600/K
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.

HRV 63S-1600/K
 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.

HRV 63S-1600/K
7.1 Checklist for maintenance, servicing and commissioning

High efficiency centrifugal fan Type: HRV 63S-1600/K Job No.: 12300051
Legend: √ = checked and correct; / = N/A; f = fault (action necessary) 

Visual check for damage or faults
No loose foreign bodies in casing and connected ducts/pipework
Access doors properly closed
All guards firmly mounted
Bearings sufficiently greased
Bearing seals
Area around the fan closed off to personal
Vibration monitor
Temperature monitor
Tightening torque for fixing bolts
bearing housing, anchor bolts, connecting flanges, guards
Shaft seal
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 = 45 mm
h = 12,5/2,5 mm
A-237284-4
Bearing temperature measured on the bearing outside ring:

Time
Non-locating bearing °C °C °C °C °C
Locating bearing °C °C °C °C °C
Vibration measurements on the bearings

Measure vibrations on the bearings veff[mm/s]
horizontally and vertically bearing vertical horizontal
1 locating bearing *
*) See layout plan
2 non-locating bearing *

HRV 63S-1600/K
Remarks:
___________ ____________________________
Date Signature

HRV 63S-1600/K
8 Operation
8.1 Switching the fan on

The fan does not possess a device to switch it on or off. This function is generally performed by a higher-level
control. This control must ensure that it is not possible to accidentally switch on the fan which could result in
serious injury or death.
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.
Throttling by the system mechanisms can likewise

put the fan at risk.
! 60
0
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).
8.2 Switching off the fan

The closed damper reduces the volume flow and thus extends the spin-out phase of the fan.
When it handles hot gas the fan must only be switched off at a temperature below the 120 °C. Provide sufficient
cooling and ensure that large differences in temperature are avoided.
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.

HRV 63S-1600/K
If hot or cold gases are flowing through the fan when it

is in no-load operation, the rotor can be unevenly
warmed up. This causes a shifting of the point of
gravity. Installation of an idling drive.
The shaft can become deformed by uneven warming The idling provides for an even temperature
or cooling. distribution.
When the fan is switched on, unbalance vibrations can

be caused..
The effect of temperature

High Temperatures often indicate that the bearing is acting abnormally. High temperatures can be detrimental to
the bearing lubricant. Overheating can sometimes be attributed to the bearing lubricant. Running for extended
periods at temperatures in excess of 125 °C (260 °F) can reduce bearing life. Causes of high bearing
temperatures include insufficient or excessive lubrication, impurities in the lubricant, overloading, bearing
damage, insufficient clearance, pinching and high friction in the seals.
It is therefore necessary to check the temperature continually, both at the bearing itself and at other vital
components. Any change in temperature can be an indication of malfunction if the running conditions have not
been altered
On the housing cap there is a blind-end bore with thread M10 x 1, which is closed off by a plastic stop. If
required, a thermometer or the feeler of a remote thermometer or of another type of temperature monitoring
device can be inserted.
The bore reaches close to the outer ring of the roller bearing so that the temperature can be measured very
close to its source. Variations in temperature can therefore be indicated with only a slight delay.
With a bearing temperature monitor we recommend following settings:
1st. warning temperature 1st alarm contact 90 °C
2nd warning temperature 2nd alarm contact 105 °C
The operator must decide whether the machine should be switched off when the 2nd alarm contact is reached.
In any case the reason for the limit temperature must be determind.
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.
The vibrations on the fan can have following causes:

Unbalance
Unbalance is caused by displacement of the mass center of gravity of a rotor system (impeller and shaft). This
mass-related unbalance is caused by wear, caking, corrosion and thermal influences.
 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.

HRV 63S-1600/K
Increased care is required when:
 the permissible bearing temperature is exceeded,

 unacceptable vibrations occur,
 unusual noises or smells occur on the bearings and
 the monitoring plant is activated.
Evaluation of the vibrations / limit values for roller bearing

Evaluation of the vibrations on machines by measurements on non-rotating components according to DIN ISO
10816-3.
Measurements are taken directly on the bearings in horizontal and vertical direction, whereby the higher value is
relevant.
shaft output > 300 kW
applied standard ISO 10816-3
fan-application category Group 1
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
Status after the commissioning / Alarm limit 5,6 8,9

operation Limit for shut-down 8,9 11*
*) Venti Oelde recommends a maximum of 11 mm / s.

HRV 63S-1600/K
9 Servicing
The Accident Prevention Regulations must be observed.
During servicing the usual engineering principles must be observed.

Maintenance and repair work may only be carried out by appropriately qualified personnel.
Electrical work may only be carried by a qualified electrician. All applicable safety regulations and guidelines
(DIN VDE 0105) must be observed.
Only lifting gear with sufficient bearing capacity may be used.
The fixing attachment must correspond with the safety regulations.
Eyebolts (e.g. in bearing housings and motors) must be tightened before use.
Before commencing work:
 Obtain information about

 Type and scope of the work
 Dangers and any safety measures which must be taken
 Ambient hazards, e.g. gases, lack of oxygen
 Measures to take in an emergency
 Switch off plant
 Wait until plant is at a standstill
 Secure so that plant cannot be switched on again
 Ensure that there can be no movement as the result of residual energy
 Shut off the work area
Before restarting plant:
 Re-fix guards
 Check that the guards are correctly functioning
 Ensure that plant is in an operational state
 Remove personnel from hazardous area
Observe the process described in the section „Commissioning“
9.1 Maintenance and Care

The smoothness of the fan must occasionally be checked when the motor is switched on. If the fan is not
running smoothly, then the impeller must be cleaned and, if necessary, re-balanced.
Before the fan casing is opened, any flanged connection loosened or protection guard removed,
the fan must be switched off and the possibility of switching it back on prevented. Make sure that
the impeller is at a standstill. Accident Prevention Regulations must be observed. All safety
devices must again be firmly fixed before the fan is switched on again.

HRV 63S-1600/K
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
 Loosen the fixing clamps

 Pull back the steel disc
 Bend the seal disc apart and pull it away from the shaft. If there is not sufficient space between fan casing
and bearing housing or motor, then the impeller must be dismantled and the shaft pulled back.
 If the seal is a multi-disc type, the other seal discs must be removed in the same way.
When re-assembling, make sure that the sealing discs and the steel discs are arranged alternately
(labyrinth seal). The slits in the sealing disc must not lie directly next to one another, but must be radially
displaced.
 Bend the seal disc apart at the notch and push it onto the shaft.
 Align the steel discs on the outside diameter of the seal discs and fix them with the fixing clamps.
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.

HRV 63S-1600/K
General
 The oil conveyor ring must be mounted

in any case and must be free movable.
Without the oil conveyor ring there will
be the risk after a short period that the
roller bearing runs without any
lubricant and therefore it will be
damaged.
 The lateral cover with the notches at
the center shoulder is to be fixed at the
casing side where the oil conveyor ring
is.
 During assembly pay attention to the Construction with end cover Construction with passing
(punch) marks at the bearing casing. through shaft
The casing halves must not be
interchanged or resp. turned round.
 The venting borehole at the oil level indicator must not be clogged, as an air padding in the view glas
causes a wrong indiction of the oil level.
 During the mounting pay attention that a thin sealing compound which remains viscous is applied on partial
surfaces between the housing upper and lower part and that the sealing is put between the cover and
housing and at the oil level indicator.
Assembly
 Check and clean the bearing seats on the shaft.

 Warm the bearings with a heater or oil bath to about 80-90 °C above the shaft temperature. However never
above 125°C.
 Push the fan-casing seal onto the shaft.
 Push the shaft seal for the bearing housing and butting ring onto the shaft
Pay attention to the arrangement of non-locating and locating bearing.
 Push the warmed roller bearing quickly and without the use of force onto the shaft up to the shoulder.
 Push on the locking disc and tighten the lock nut with a hook spanner.
Bend the locking plate tab into a slit.
 Clean and check the bearing housing.

During mounting pay attention to the markings on the bearing housing. The housing halves must not be
interchanged or mounted in a skewed position.
 Align shaft seal and put the lower bearing half onto the shaft.
 Mount the upper half of the bearing housing. Pay attention to the markings.
 Put the bearing in position and align it.
 Screw tight the binding bolts.
 Fill the pillow-block frame with the lubricant in accordance with the lubrication chart.
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.

HRV 63S-1600/K
Bearing lubrication
Always wear protective gloves, if possible, because allergies may be caused by

regular contact with oil products.
Observe the directions for use provided by the lubricant manufacturer. Your supplier
will advise you about oil waste disposal.
Lubricants for roller bearings

In principle any brand-name oil with a low tendency to foam formation and with good ageing properties.
Viscosity ISO VG 68is specified.
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.: 1,3 2,1 Liter
Oil level max.: 60 70 mm
Oil level min.: 45 50 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.

HRV 63S-1600/K
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).
Steps of Oil Change

1. Create suitable preconditions for collecting all the lubricant (see above filling volume).
2. If possible drain the lubricant under hot running condition. By doing so impurities and sump tailings are
rinsed out as well. Filter the oil so that the residues can be better judged.
If the lubricant contains residues or it has changed noticeably look for the reasons. If
necessary carry out an inspection of bearings.
3. Screw in tightly the oil drainage screw possibly with a new sealing.
4. Fill the bearing casing with the lubricant mentioned above.
5. When the maximum oil level is reached again the bearing is ready for operation.
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.
Coupling size () Pitch S [mm] Angular displacement f Radial displacement y

[mm] [mm]
RWN 360 3..6 0,5 0,5
The total of both displacements must not exceed the figure of 0,5 mm.
Check regularly torsional tolerance of both coupling halves.
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.

HRV 63S-1600/K
9.2 Inspection and Maintenance List
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
Grease bearings See servicing instructions

HRV 63S-1600/K
10 What to do first if a malfunction occurs

Please go through this check list of what to do if a malfunction occurs. If the equipment or plant is still not
working properly, please contact our Maintenance Service.
Operating Malfunction Possible Causes Remedial Action
Fan flow volume insufficient Impeller with incorrect direction of Reverse direction of rotation (see
rotation Chapter "Commissioning")
Damper equipment is not or only Check opening position on
partially opened equipment
Inlet or outlet pipework blocked Remove obstruction
Guide plates for the flexible joints Assemble flexible joint according to
have been mounted in reverse the direction of flow and to the given
position. Fabric of flexible joint is dimensions.
making the opening of the pipework
too narrow.
Sudden decrease in performance Inlet or discharge duct not airtight Seal
Fabric of flexible joint defect Replace flexible joint fabric
Fan is not reaching its rated Electrical switching devices are Check setting of motor protection
speed incorrectly set device and if necessary re-adjust.
Motor winding defect Please contact manufacturer
Drive motor has been incorrectly Please contact manufacturer for the
sized purpose of checking the starting
torque.
Motor is switched off by overload Plant resistance is too low Check that plant is airtight Increase
protection switch the plant resistance by damping the
fan until the current consumption lies
about 5 % below the rated current.
Fan is not running true Impeller is unbalanced Re-balancing by specialist
Deposits on impeller Carefully wash off deposits. If
necessary re-balancing by specialist.
Material disintegration on impeller Report to manufacturer
as result of aggressive medium.
Material erosion as a result of Report to manufacturer.
abrasive medium.
Impeller deformed as result of Please contact manufacturer.
overheating or foreign bodies
Dust egress or leakages at shaft Sealing disc or shaft sleeve worn. Replace sealing disc or shaft sleeve
passage through fan casing
Seal not suitable for this application Please report back to manufacturer
Dust egress or leakages at Flexible joint defect Replace flexible joint
flexible joints
Clamping flange or clamping ring Retighten the screws of the clamping
are not properly tightened flange or clamping ring
Noises of friction during operation Inlet pipe mounted under stress Loosen inlet pipework and re-align
or when fan is running down

HRV 63S-1600/K
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
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
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.

HRV 63S-1600/K
11 Technical Data
Fan Type HRV 63S-1600/K Venti- Job Number 12300051

Customer Loesche GmbH Person responsible ETT
Remarks Booster Fan Date 07.04.16
Project Bim Son Clinker Year of construction 2016
operating point 1
Volume flow, normal condition Vnorm 156.196 Nm³/h
Volume flow at fan inlet V1 300.000 m³/h
Volume flow at fan inlet Ve 300.000 m³/h
Mass flow m 201.533 kg/h
Mass flow dust mst 3.123,9 kg/h
Air pressure Δpb 101.084 Pa
Pressure increase (1-2) , static Δp1-2 2.000 Pa
Stat. press (inlet side) Δpe -2.000 Pa
Stat. press (outlet side) Δpa 0 Pa
Internal losses at fan inlet Δpie 0 Pa
Internal losses at fan outlet Δpia 0 Pa
Dynamic pressure (at fan inlet) Δpde 362 Pa
Dynamic pressure (at fan outlet) Δpda 565 Pa
Inlet velocity ce 32,83 m/s
Outlet velocity ca 40,74 m/s
Temperature (at fan inlet) te 240,00 °C
Gas constant R 287,43 Nm/kg K
Spec. flow work Yt 3.253 Nm/kg
Total pressure Δpt 2.203 Pa
Total pressure (1.205) Δpt1,205 3.951 Pa
Density (at inlet) ρ1 0,672 kg/m³
Density (at inlet) ρe 0,672 kg/m³
Density (at outlet) ρa 0,681 kg/m³
Fan speed nv 989 1/min
Impeller diameter D2 2,055 m
Efficiency tw 69,37 %
Useful power Pn 184,95 kW
Drive power fan shaft Pw 266,63 kW
Tip speed u2 106,41 m/s
Temperature (at fan outlet) ta 244,66 °C
Coefficient of flow φ 0,2361 -
Coefficient of pressure ψ 0,5746 -
The characteristic data will be determined according to DIN 24163.

The accuracy classes acc. to DIN 24166 apply to the limiting deviations.
10060670-11178986-0002 Internal: f. HRV (2-seitig gelagert - SK angeschweißt); Drehzahlregelung SK3 - VW3,63 VS0,931 LD0,15

HRV 63S-1600/K
Fan Type HRV 63S-1600/K Venti Job Number 12300051

Customer Loesche GmbH Person responsible ETT
Remarks Booster Fan Date
Project Bim Son Clinker Year of construction 2016

HRV 63S-1600/K
Sound data without/with silencing measures

A-weighted sound pressure level under free inlet and outlet duct outlet duct connected inlet duct connected
field conditions (DIN 45635) connected
distance of 1 m from fan distance of 1 m at angle of distance of 1 m at angle of
45° from the open inlet side 45° from the open outlet side
Operating point
dB(A) dB(A) dB(A)
1 83 99 103
11.1 Speed torque curve
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 300.000 m³/h
Temperature (at fan inlet) te 240,00 °C
Total pressure (E - A) Δpt 2.203 Pa
Fan speed nv =nL 989 1/min
Basic torque at ρe = 0,672 kg/m³ and te = 240,00 °C MN 2.574,45 Nm
Mass moment of inertia of the rotor J kg m²
Required power PW 266,63 kW
Recommended motor nominal power PM 315 kW
Motor basic speed nM 989 1/min

HRV 63S-1600/K
11.2 Electrical Values

The fan is designed for these standard motor values.
If the motor is not included in our scope of supply, then we must be consulted before another drive may be
used.
Motor output 315 kW

Motor speed 990 U/min
Mains voltage - V
Frequency 50 Hz
Enclosure IP55
Mounting arrangement B3
Insulation class F

HRV 63S-1600/K
12 Stocking of Spare Parts

Having the most important spare and wear parts available where the plant is installed, is an important pre-
requisite for the continued function and readiness of the plant.
We undertake a guarantee only for the original spare parts supplied by us.
We must state expressly that spare parts and accessories which have not been supplied by us, have also not
been examined and approved by us. The installation and/or use of such products can therefore in certain
circumstances have a negative influence on the construction properties of the equipment or plant and therefore
effect negatively the active and/or passive security of the plant.
Any liability or warranty on the part of manufacturer for damage which is caused by the use of non-original spare
parts and accessories, is totally excluded.
Please observe that there are often special manufacturing and supply specifications for our own parts and those
supplied by our suppliers, and that we always offer spare parts in accordance with the most recent technical
developments and the latest laws.
When placing an order for spare parts, please let us have the following information:
 Description and type of equipment/plant

 Serial number
 Description of spare part
 Article number
 Quantity required.
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

HRV 63S-1600/K
12.1 Diagram and Spare Parts List
Article No. No. Item Description kg/pce €/pce.

K_HRV_LAUFR2SG_0JR 1 1 Impeller complete
62642 4 2a Shaft sealing locating bearing side
62630 4 2b Shaft sealing non locating bearing side
72332 1 3 Pedestal bearing
72397 1 3c Bearing inset
K_V_WELLE2SGEL_0G3 1 4 Shaft
72359 1 5 Pedestal bearing
72381 1 5c Bearing inset
T_G_KUPPLELAS_0KC 1 6 Coupling
1 6a flexibles for coupling (set)
47974 1 * 16a Cooling vane locating bearing side
48026 1 * 16b Cooling vane non locating bearing side
*) special accessories

HRV 63S-1600/K
13 Appendix
13.1 Declaration of incorporation as defined by EC machinery directive
T:\AUFTRAG\12300XXX\12300051\KDOKU\VORBEREITUNG\POS_0120\12300051_120_HRV_63S-1600_K_EN.DOCX; Date: 01.09.2016

HRV 63S-1600/K
Declaration of incorporation
in accordance with EU Machinery Directive 2006/42/EC, Annex IIB
Manufacturer and representative Ventilatorenfabrik Oelde GmbH

for Technical Documentation Robert-Schuman-Ring 21
D-59302 Oelde
Telephone: +49 2522 75-0
Telefax: +49 2522 75-250
www.venti-oelde.de
Designation: High efficiency centrifugal fan

Job No. / Item: 12300051 / 120
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:
EU Machinery Directive 2006/42 EC
EU low voltage guideline 2014/35/EU
EU guideline electromagnetic compatibility 2014/30/EU
Following harmonized standards (or parts of these standards) were used:
EN ISO 12100 ; EN ISO 12499; EN ISO 13857; EN 349+A1; EN 60204-Part 1
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
Date Peter Herrmann, Technical Manager GBV

HRV 63S-1600/K
Annex to Declaration of Incorporation

Designation: High efficiency centrifugal fan
Job No. / Item: 12300051 / 120
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

HRV 63S-1600/K
Designation Remarks
applicable
complied
entirety /
ANNEX I
Number
1.4.1. General requirements

1.4.2. Special requirements for guards
1.4.2.1. Fixed guards
1.4.2.2. Interlocking movable guards
1.4.2.3. Adjustable guards restricting access
1.4.3. Special requirements for protective devices
1.5. Risks due to other hazards
1.5.1. Electricity supply
1.5.2. Static electricity
1.5.3. Energy supply other than electricity
1.5.4. Errors of fitting
1.5.5. Extreme temperatures
1.5.6. Fire
1.5.7. Explosion
1.5.8. Noise
1.5.9. Vibrations
1.5.10. Radiation
1.5.11. External radiation
1.5.12. Laser radiation
1.5.13. Emissions of hazardous materials and substances
1.5.14. Risk of being trapped in a machine
1.5.15. Risk of slipping, tripping or falling
1.5.16. Lightning
1.6. Servicing
1.6.1. Machinery maintenance
1.6.2. Access to operating positions and servicing points
1.6.3. Isolation of energy sources
1.6.4. Operator intervention
1.6.5. Cleaning of internal parts
1.7. Information
1.7.1. Information and warnings on the machinery
1.7.1.1. Information and information devices
1.7.1.2. Warning devices
1.7.2. Warning of residual risks
1.7.3. Marking of machinery
1.7.4. Operating Instructions
1.7.4.1. General principles for the drafting of instructions
1.7.4.2. Contents of the instructions
1.7.4.3. Sales literature

HRV 63S-1600/K
13.2 Operating instructions for louver damper
Transport and Assembly

Risk of injury!
Strictly observe the operating instructions for the lifting gear used.
The components must only be lifted on the crane lugs provided.
Observe the Accident Prevention Regulations
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.

HRV 63S-1600/K
1. Flange
2. Seal
1 2
The seal can be glued to the flange to prevent it from slipping.
 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.
Assembly with double-flow fans
 First align both the louver dampers, adjust

and bring into the „closed“ position
 Connect both the louver dampers with the
universal shaft and pin the shaft-hub
connections twice each.
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:
Readjusting the louver damper
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

HRV 63S-1600/K
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
Louver connection shaft has clearance Check the shaft-hub connection
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.
Two times in a year check for wear at the louver leaves.

Readjusting gland bearings or glands
It is especially important to ensure that the glands are readjusted evenly after approx. 70 operating hours (from
assumption of operation involving temperature).
If no sealing could be achieved after long operational time and several readjustments, the pressure ring (3) must
be removed to insert or replace new packing rings. Provide the bearing with heat-resistant lubricating grease.
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.

HRV 63S-1600/K
Gland nut with shaft drive side Stopfbuchse mit Welle Gegenseite
1. Packing ring
2. Gland bearing
3. Pressure ring

HRV 63S-1600/K
13.3 Operating instructions for actuator

13358811 4300202981-334013#20
Part-turn gearboxes
GS 50.3 – GS 250.3
Operation instructions Assembly, commissioning

GS 50.3 – GS 250.3
Table of contents
Read operation instructions first.

●
Observe safety instructions.
●
These operation instructions are part of the product.
●
Retain operation instructions during product life.
●
Pass on instructions to any subsequent user or owner of the product.
Purpose of the document:

This document contains information for installation, commissioning, operation and maintenance staff. It is intended
to support device installation and commissioning.
Table of contents Page

1. Safety instructions................................................................................................................. 4
1.1. Basic information on safety 4
1.2. Range of application 4
1.3. Warnings and notes 5
1.4. References and symbols 5
2. Identification........................................................................................................................... 7
2.1. Name plate 7
2.2. Short description 9
3. Transport, storage and packaging........................................................................................ 10
3.1. Transport 10
3.2. Storage 10
3.3. Packaging 11
4. Assembly................................................................................................................................ 12
4.1. Mounting position 12
4.2. Handwheel fitting 12
4.3. Multi-turn actuators for motor operation 12
4.3.1. Mounting positions Multi-turn actuators with part-turn gearboxes 13
4.3.2. Input mounting flange: mount 13
4.4. Gearbox to valve: mount 15
4.4.1. Output drive for coupling 15
4.4.1.1. Gearbox with coupling: mount to valve 15
5. Indications.............................................................................................................................. 19
5.1. Mechanical position indicator/running indication 19
6. Commissioning...................................................................................................................... 20
6.1. End stops in gearbox 20
6.1.1. End stop CLOSED: set 20
6.1.2. End stop OPEN: set 21
6.2. Seating in end positions via multi-turn actuator 22
6.2.1. Seating in end position CLOSED: set 22
6.2.2. Seating in end position OPEN: set 23
6.3. Swing angle 23
6.3.1. Swing angle: modify at gearboxes up to size 125.3 23
6.3.2. Swing angle: modify at gearboxes from size 160.3 24
6.4. Mechanical position indicator: set 25
2
GS 50.3 – GS 250.3
Table of contents
7. Servicing and maintenance................................................................................................... 27

7.1. Preventive measures for servicing and safe operation 27
7.2. Maintenance intervals 27
7.3. Disposal and recycling 27
8. Technical data......................................................................................................................... 29
8.1. Technical data Part-turn gearboxes 29
9. Spare parts............................................................................................................................. 34
9.1. Part-turn gearboxes GS 50.3 – GS 125.3 34
9.2. Part-turn gearboxes GS 160.3 – GS 250.3 36
9.3. Primary reduction gearing for GS 100.3 – GS 125.3 (126:1/160:1/208:1) 38
9.4. Primary reduction gearing for GS 160.3 (218:1/442:1) GS 200.3 (214:1/434:1) GS 250.3 40
(210:1/411:1)
9.5. Primary reduction gearing for GS 200.3 (864:1) GS 250.3 (848:1) 42
10. Certificates.............................................................................................................................. 44
10.1. Declaration of Incorporation and EC Declaration of Conformity 44
Index........................................................................................................................................ 47
Addresses............................................................................................................................... 49
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.
Operation Prerequisites for safe and smooth operation:

● Correct transport, proper storage, mounting and installation, as well as careful
commissioning.
● Only operate the device if it is in perfect condition while observing these instruc-
tions.
● Immediately report any faults and damage and allow for corrective measures.
● Observe recognised rules for occupational health and safety.
● Observe the national regulations.
● During operation, the device warms up and increased surface temperature may
occur. To prevent possible burns, we recommend checking the surface temper-
ature using an appropriate thermometer and wearing protective gloves, if re-
quired, prior to working on the device.
Protective measures The end user or the contractor are responsible for implementing required protective
measures on site, such as enclosures, barriers, or personal protective equipment
for the staff.
Maintenance To ensure safe device operation, the maintenance instructions included in this manual
must be observed.
Any device modification requires prior consent of the manufacturer.
1.2. Range of application
AUMA 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.
The following applications are not permitted, e.g.:

● Industrial trucks according to EN ISO 3691
4
GS 50.3 – GS 250.3
Safety instructions
● Lifting appliances according to EN 14502

● Passenger lifts according to DIN 15306 and 15309
● Service lifts according to EN 81-1/A1
● Escalators
● Continuous duty
● Potentially explosive atmospheres in combination with F21 lubricant type (refer
to name plate)
● Radiation exposed areas in nuclear power plants
No liability can be assumed for inappropriate or unintended use.
Observance of these operation instructions is considered as part of the device's
designated use.
1.3. Warnings and notes
The following warnings draw special attention to safety-relevant procedures in these

operation instructions, each marked by the appropriate signal word (DANGER,
WARNING, CAUTION, NOTICE).
Indicates an imminently hazardous situation with a high level of risk. Failure

to observe this warning could result in death or serious injury.
Indicates a potentially hazardous situation with a medium level of risk. Failure

Indicates a potentially hazardous situation with a low level of risk. Failure to

observe this warning may result in minor or moderate injury. May also be used
with property damage.
Potentially hazardous situation. Failure to observe this warning may result in

property damage. Is not used for personal injury.
Arrangement and typographic structure of the warnings
Type of hazard and respective source!

Potential consequence(s) in case of non-observance (option)
→ Measures to avoid the danger
→ Further measure(s)
Safety alert symbol warns of a potential personal injury hazard.

The signal word (here: DANGER) indicates the level of hazard.
1.4. References and symbols
The following references and symbols are used in these instructions:
Information The term Information preceding the text indicates important notes and information.
Symbol for CLOSED (valve closed)

Symbol for OPEN (valve open)
Important information before the next step. This symbol indicates what is required
for the next step or what has to be prepared or observed.
5
GS 50.3 – GS 250.3
Safety instructions
<> Reference to other sections

Terms in brackets shown above refer to other sections of the document which provide
further information on this topic. These terms are either listed in the index, a heading
or in the table of contents and may quickly be found.
6
GS 50.3 – GS 250.3
Identification
2. Identification
2.1. Name plate
Figure 1: Arrangement of name plates
[1] Gearbox name plate

[2] Additional plate, e.g. KKS plate (Power Plant Classification System)
Description of gearbox name plate

Figure 2: Gearbox name plate (example GS 250.3)
[1] Name of manufacturer

[2] Address of manufacturer
[3] Type designation - valve attachment (flange)
[4] Order number
[5] Serial number
[6] Reduction ratio
[7] Factor
[8] Max. valve torque (output torque)
[9] Type of lubricant
[10] Permissible ambient temperature
[11] Explosion-proof version (option)
[12] Can be assigned as an option upon customer request
[13] Enclosure protection
[14] Duty class
[15] Version
[16] Swing angle
[17] Data Matrix code
Type designation Figure 3: Type designation (example)
1. Type and size of gearbox
7
GS 50.3 – GS 250.3
Identification
2. Flange size for valve attachment

Type and size
These instructions apply to the following device types and sizes:
Part-turn actuators type GS, sizes 50.3 – 250.3
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.
Danger of explosion when using inappropriate lubricant in potentially explosive

atmospheres!
→ Do not use gearboxes with F21 lubricant in potentially explosive atmospheres.
→ Do not mix different lubricants.
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
Description of the four different versions (view on housing cover):
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:
2.2. Short description
AUMA worm gearboxes are part-turn gearboxes converting a rotary movement at

the input shaft into a part-turn movement at the output drive. The worm gearboxes
are driven either via electric motor (by means of a multi-turn actuator) or manually
(e.g. via a handwheel). The required input torques are reduced due to high reduction
ratios. In standard version, internal end stops limit the swing angle to 100°.
Worm gearboxes are available in different versions to implement various mounting
conditions and rotary directions.
9
GS 50.3 – GS 250.3
Transport, storage and packaging
3. Transport, storage and packaging

3.1. Transport
For transport to place of installation, use sturdy 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
1) Specified weight includes unmachined coupling
3.2. Storage
Danger of corrosion due to inappropriate storage!

→ Store in a well-ventilated, dry room (maximum humidity 70 %).
→ Protect against floor dampness by storage on a shelf or on a wooden pallet.
→ Cover to protect against dust and dirt.
→ Apply suitable corrosion protection agent to uncoated surfaces.
Long-term storage If the device must be stored for a long period (more than 6 months), the following
points must be observed in addition:
1. Prior to storage:
Protect uncoated surfaces, in particular the output drive parts and mounting
surface, with long-term corrosion protection agent.
10
GS 50.3 – GS 250.3
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.
11
GS 50.3 – GS 250.3
Assembly
4. Assembly
4.1. Mounting position

The gearboxes described here can be operated without restriction in any mounting
position.
4.2. Handwheel fitting

Gearboxes designed for manual operation are supplied with a separate handwheel.
Fitting is performed on site according to the description below.
Figure 5: Handwheel
[1] Retaining ring for input shaft (partly required)

[2] Gear input shaft
[3] Spacer (partly required)
[4] Handwheel
[5] Spacer (partly required)
[6] Retaining ring
[7] Ball handle
1. For input shafts with keyway: Place retaining ring [1] onto input shaft [2].
2. If required, fit spacer [3].
3. Slip handwheel [4] onto input shaft.
4. If required, fit spacer [5].
5. Secure handwheel [4] using the retaining ring [6] supplied.
6. Fit ball handle [7] to handwheel.
4.3. Multi-turn actuators for motor operation
Refer to the operation instructions pertaining to the multi-turn actuator for indications
on how to mount multi-turn actuators to gearboxes.
This chapter supplies basic information and instructions which should be considered
in addition to the operation instructions of the multi-turn actuator.
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
Mounting positions A – D for multi-turn actuators with part-turn gearboxes

GS versions RR and LL
A B C1) D
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
[1] Gearbox with primary reduction gearing

[2] Parallel pin
[3] Input mounting flange
2. Mount parallel pin [2].
3. Place input mounting flange [3] and fasten with screws.
14
GS 50.3 – GS 250.3
Assembly
4. Fasten screws crosswise to a torque according to table.

Table 3:
Tightening torques for screws (for mounting multi-turn actuator and input mounting flange)
Threads Tightening torque Nm]
Strength class A2-80
M8 24
M10 48
M12 82
M16 200
M20 392
5. Mount AUMA actuator in compliance with the operation instructions pertaining

to the multi-turn actuator.
4.4. Gearbox to valve: mount
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
Application ● For valves with connections according to EN ISO 5211

● For rotating, non-rising valve stem
Design Figure 7: Valve attachment via coupling
[1] Gearbox output drive shaft with internal splines

[2] Splined plug-in coupling
[3] Valve shaft (example with keyway and key)
4.4.1.1. Gearbox with coupling: mount to valve

Unbored couplings or couplings with pilot bore must be machined to match the valve
shaft prior to mounting the gearbox to the valve (e.g. with bore and keyway, two-flat
or square bore).
Information Assemble valve and gearbox in the same end position. As a standard, the gearbox
is supplied in end position CLOSED.
● Recommended mounting position for butterfly valves: End position CLOSED.
● Recommended mounting position for ball valves: End position OPEN.
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
1) Extension flange, extended coupling required
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
1) Extension flange, extended coupling required
5. Apply non-acidic grease at splines of coupling (e.g. Gleitmo by Fuchs).

6. Experience showed that it is very difficult to fasten screws or nuts of size M30
or larger at defined torques. There is a risk that the worm gearbox might shift
radially with regard to the valve mounting flange. To improve adhesion between
valve and gearbox, we recommend to apply Loctite 243 (or similar adhesive
products) to the mounting faces of screws and nuts from size M30.
7. Fit gearbox. If required, slightly turn gearbox until splines of coupling engage.
Figure 10:
Information Ensure that the spigot (if provided) fits uniformly in the recess and that the flanges
are in complete contact.
8. If flange bores do not match thread:

8.1 Slightly rotate handwheel until bores line up.
8.2 If required, shift gearbox position by one tooth on the coupling.
9. Fasten gearbox with screws.
Information: We recommend applying liquid thread sealing material to the
screws to avoid contact corrosion.
17
GS 50.3 – GS 250.3
Assembly

Table 6:
Tightening torques for screws
Threads Tightening torque Nm]
Strength class
A2-70/A4-70 A2-80/A4-80
M6 8 10
M8 18 24
M10 36 48
M12 61 82
M16 150 200
M20 294 392
M30 564 1,422
M36 2,098 2,481
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
[1] Housing cover

[2] Pointer cover
[3] Indicator mark
[4] Symbol for position OPEN
[5] Symbol for position CLOSED
19
GS 50.3 – GS 250.3
Commissioning
6. Commissioning
6.1. End stops in gearbox

The internal end stops limit the swing angle and protect the valve against overload.
End stop setting is generally performed by the valve manufacturer prior to installing
the valve into the pipework.
Exposed, rotating parts (discs/balls) at the valve!

Pinching and damage at the valve.
→ End stops should be set by suitably qualified personnel only.
→ Set end stops as to ensure that they are NOT reached during normal operation.
Information The setting sequence depends on the valve:

● Recommendation for butterfly valves: Set end stop CLOSED first.
● Recommendation for ball valves: Set end stop OPEN first.
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.
6.1.1. End stop CLOSED: set
Figure 12: End stop (left: up to size 125.3, right: from size 160.3)
[1] Screws
[2] End stop
[3] Housing
1. Remove the four screws [1] at end stop [2].
No overload protection at valve for unfastened end stop!

→ In motor operation: Stop travel before reaching the valve end position (consider
overrun).
→ The last part of the travel must be completed in manual operation mode.
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
Further settings hereafter:

● If the gearbox is equipped with a pointer cover: Check whether the mark aligns
with the symbol CLOSED. Refer to <Mechanical position indicator: set>.
● If the gearbox is mounted to a multi-turn actuator, set the seating in end position
CLOSED straight after completion of the current setting: <Seating in end posi-
tions via multi-turn actuator>.
6.1.2. End stop OPEN: set
Figure 13: End stop (left: up to size 125.3, right: from size 160.3)
[1] Screws
[2] End stop
[3] Housing
1. Remove the four screws [1] at end stop [2].
No overload protection at valve for unfastened end stop!

→ In motor operation: Stop travel before reaching the valve end position (consider
overrun).
→ The last part of the travel must be in manual operation mode.
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
1. Move valve to end position CLOSED.

Information: The last part of the travel must be in manual operation mode!
2. For limit seating in end position CLOSED:
2.1 Turn back the valve from the valve end position by an amount equal to
the overrun.
2.2 Set limit switching for the end position CLOSED according to the operation
instructions for the multi-turn actuator.
3. For torque seating in end position CLOSED:
3.1 Gearbox without primary reduction gearing: Turn handwheel in the opposite
direction of the valve end position by approx. 4 – 6 turns.
3.2 Gearbox with primary reduction gearing: Turn handwheel in the opposite
3.3 Check torque switching for end position CLOSED according to operation
instructions for multi-turn actuator and, if necessary, set to required value.
3.4 Set limit switching for signalling end position CLOSED according to oper-
ation instructions for multi-turn actuator.
22
GS 50.3 – GS 250.3
Commissioning
6.2.2. Seating in end position OPEN: set
1. Move valve to end position OPEN.

Information: The last part of the travel must be in manual operation mode!
2. For limit seating in end position OPEN:
2.1 Turn back the valve from the valve end position by an amount equal to
the overrun.
2.2 Set limit switching for end position OPEN according to the operation in-
structions for the multi-turn actuator.
3. For torque seating in end position OPEN:
3.1 Gearbox without primary reduction gearing: Turn handwheel in the opposite
3.2 Gearbox with primary reduction gearing: Turn handwheel in the opposite
3.3 Check torque switching for end position OPEN according to operation in-
structions for multi-turn actuator and, if necessary, set to required value.
3.4 Set limit switching for signalling end position OPEN according to operation
instructions for multi-turn actuator.
6.3. Swing angle

The swing angle must only be changed if the swivel range for end stop setting is not
sufficient.
Figure 14: Name plate indicating the swing angle
Versions Sizes GS 50.3 – GS 125.3 = adjustable swing angle - option

Sizes GS 160.3 – GS 250.3 = adjustable swing angle - standard
Accuracy Sizes GS 50.3 – GS 125.3 = 0.6°
Sizes GS 160.3 – GS 250.3 = 0.11° up to 0.14°
6.3.1. Swing angle: modify at gearboxes up to size 125.3
The adjustment is made in end position OPEN.

Special tools: Pin drive for spring-type straight pin
● for GS 50.3 (AUMA art. no. V001.367-Pos.003)
● for GS 63.3 – GS 80.3 (AUMA art. no. V001.367-Pos.002)
● for GS 100.3 – GS 125.3 (AUMA art. no. V001.367-Pos.001)
23
GS 50.3 – GS 250.3
Commissioning
Figure 15: End stop (figure shows size 80.3)
[1] Protective cap

[2] End stop
[3] Spring-type straight pin
[4] End stop nut
[5] Pairs of safety wedge discs (for OPEN and CLOSE)
1. Unscrew protective cap [1] at end stop [2].

2. Remove spring-type straight pin [3] with suitable pin drive (special tool).
3. Swing angle increase:
3.1 Turn end stop nut [4] counterclockwise.
Information: When turning counterclockwise the end stop nut [4] make
sure that the spring-type straight pin [3] can still be tapped within the oblong
hole.
3.2 Move valve manually to the desired end position OPEN.
3.3 Turn end stop nut [4] clockwise until it is tight to the travelling nut.
4. Swing angle reduction:
4.2 Turn end stop nut [4] clockwise until it is tight to the travelling nut.
Information: Spring-type straight pin [3] must remain completely covered
by end nut [4].
5. Drive in the spring-type straight pin [3] using the appropriate tool.
→ If the slot provided in the end stop nut [4] does not align with the bore of
the worm shaft: Turn end stop nut [4] slighty counterclockwise until the
hole is aligned; then drive in spring-type straight pin [3].
6. Check whether O-ring at protective cap is in good condition, replace if damaged.
7. Fasten protective cap [1].
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. Allow for overrun!
6.3.2. Swing angle: modify at gearboxes from size 160.3
Adjustments are generally made in end position OPEN.
24
GS 50.3 – GS 250.3
Commissioning
Figure 16: End stop (figure shows size 200.3)
[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.
4.3 Turn end stop nut [6] clockwise until it is tight to the travelling nut [7].
5. Swing angle reduction:
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.
6.4. Mechanical position indicator: set
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
2. If the mark position is not correct:

2.1 Slightly loosen screws [1] at pointer cover [two screws up to size 125.3,
four screws as from size 160.3).
2.2 Turn pointer cover to symbol for position CLOSED [5].
2.3 Fasten screws again.
End position OPEN 3. Move valve to end position OPEN and check setting.
➥ The setting is correct if the mark aligns with the symbol OPEN.
26
GS 50.3 – GS 250.3
Servicing and maintenance
7. Servicing and maintenance
Damage caused by inappropriate maintenance!

→ Servicing and maintenance must be carried out exclusively by suitably qualified
personnel having been authorised by the end user or the contractor of the plant.
Therefore, we recommend contacting our service.
→ Only perform servicing and maintenance tasks when the device is switched off.
AUMA
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).
7.1. Preventive measures for servicing and safe operation

● Before commissioning, perform visual inspection for grease leakage and paint
damage (corrosion).
● Thoroughly touch up any possible damage to paint. Original paint in small
quantities can be supplied by AUMA.
7.2. Maintenance intervals
Recommendation for plants subject to strong vibration
● For plants subject to strong vibration, 6 months after commissioning and then
once a year: Check fastening screws between actuator and gearbox/valve for
tightness. If required, fasten screws while applying the tightening torques as
indicated in chapter <Assembly>. For screws sealed and secured with e.g.
thread sealing material, this action is not required.
Recommendation for grease change and seal replacement:
● If rarely operated (typically in buried service), the gearboxes are maintenance-
free. Grease change or re-lubrication is not necessary.
● If operated frequently (typically in modulating duty), we recommend changing
both grease and seals after 4 – 6 years.
Gearing damage due to using inappropriate grease!

→ Only use original lubricants supplied by AUMA.
→ Do not mix lubricants.
Instructions for use in potentially explosive atmospheres of categories M2,

2G, 3G, 2D and 3D
● Imperatively heed the technical data, as well as the ambient temperatures, type
of duty and running times indicated on the name plate are observed.
● In potentially explosive atmospheres, in particular where combustible dust is
present, perform visual inspection for deposit of dirt or dust on a regular basis.
Clean devices if required.
● The pointer cover is only approved for use in potentially explosive atmospheres
according to ATEX II2G c IIB T4 or T3.
● When using mechanical microswitches (option), additionally observe the
mounting and wiring instructions of the manufacturer.
7.3. Disposal and recycling
Our devices have a long lifetime. However, they have to be replaced at one point in
time. The devices have a modular design and may, therefore, easily be separated
and sorted according to materials used, i.e.:
● electronic scrap
● various metals
● plastics
27
GS 50.3 – GS 250.3
● greases and oils

The following generally applies:
● Greases and oils are hazardous to water and must not be released into the
environment.
● Arrange for controlled waste disposal of the disassembled material or for sep-
arate recycling according to materials.
● Observe the national regulations for waste disposal.
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).
8.1. Technical data Part-turn gearboxes
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.
Features and functions

Worm wheel material Open-close Spheroidal cast iron
duty:
Modulating Bronze
duty:
Version Standard: Clockwise rotation RR, counterclockwise rotation LL
Option: RL or LR
Housing material Standard: Cast iron (GJL-250)
Option: Spheroidal cast iron (GJS-400-15)
Self-locking The gearboxes are self-locking when at standstill under normal service conditions; strong vibration may
cancel the self-locking effect. While in motion, safe breaking is not guaranteed. If this is required, a
separate brake must be used.
End stops Positive for both end positions by travelling nut, sensitive adjustment
Strength of end stop Guaranteed strength of end stop (in Nm) for input side operation
Type GS 50.3 GS 63.3 GS 80.3 GS 100.3

Reduction ratio 51:1 51:1 53:1 52:1 126:1 160:1 208:1
[Nm] 250 450 450 1350 625 500 250
Type GS 125.3 GS 160.3

Reduction ratio 52:1 126:1 160:1 208:1 54:1 218:1 442:1 880:1
[Nm] 1350 625 500 250 3200 900 450 250
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

Mechanical position indicator Standard: Pointer cover for continuous position indication
Options: ● Sealed pointer cover for horizontal outdoor installation (not available for GS 50.3)
● Protection cover for buried services instead of pointer cover (without mechanical pos-
ition indicator)
● Sealed pointer cover with air vent valve, not available for GS 50.3
Observe notes on Information sheet Enclosure protection IP68 for part-turn gearboxes
Input shaft Cylindrical with parallel key according to DIN 6885-1
Operation
Motor operation ● Via electric multi-turn actuator
● Input mounting flanges for mounting multi-turn actuators
Type of duty Open-close Short-time duty S2 - 15 min

duty: Class A according to EN 15714-2: OPEN-CLOSE
Class B according to EN 15714-2: Inching/positioning or positioning duty
Modulating Intermittent duty S4 - 25 %
duty: Class C according to EN 15714-2: Modulating duty
Maximum permissible input speeds Modulating duty: 215 rpm
and operating times Open-close duty:
Type GS 125.3 GS 160.3

Reduction ratio 52:1 126:1 160:1 208:1 54:1 218:1 442:1 880:1
Max. permissible
108 216 108 216
input speed [rpm]
Fastest operating 1350 625 500 250 3200 900 450 250
time for 90° [s]
Type GS GS 63.3 GS 80.3 GS 100.3

50.3
Reduction ratio 51:1 51:1 82:1 53:1 82:1 52:1 107:1 126:1 160:1 208:1
Max. permissible
108 108 108 108 216
input speed [rpm]
Fastest operating 7 7 11 7 11 7 15 9 11 19
time for 90° [s]
Type GS 200.3 GS 250.3

Reduction ratio 53:1 214:1 434:1 864:1 1752:1 52:1 210:1 411:1 848:1 1718:1
Max. permissible in-
108 216 108 216
put speed [rpm]
Fastest operating 7 15 30 60 122 7 15 29 59 119
time for 90° [s]
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
Calculation of the operating time for a 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
Option: ● Handwheel made of GJL-200 with electrophoretic coating and painting

● Handwheel lockable
● WSH for signalling position and end positions
Available handwheel diameters according to EN 12570, selection according to output torque:
Type GS GS GS GS 100.3 GS 125.3

50.3 63.3 80.3
Reduction ratio 51:1 51:1 53:1 52:1 126:1 160:1 208:1 52:1 126:1 160:1 208:1
Handwheel Ø [mm] 160 500
250 315 400 315 250 400 315
200 630
315 400 500 400 315 500 400
250 800
Type GS 160.3 GS 200.3

Reduction ratio 54:1 218:1 442:1 880:1 53:1 67:1 214:1 434:1 864:1 1752:1
Handwheel Ø [mm] 630 500
400 315 250 – 800 400 315 250
800 630
Type GS 250.3
Reduction ratio 52:1 210:1 411:1 848:1 1718:1
Handwheel Ø [mm] 500
– 800 400 315
630
Deflection of the input shaft

90° deflection of the input shaft
Combination with GK bevel gearbox directly mounted on GS or on planetary stage possible, refer to Mounting positions Part-turn gearboxes
with multi-turn actuators
Version with base and lever

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
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.
Type GS 80.3 GS 100.3 GS 125.3 GS 160.3

Flange according to
F12 F14 F14 F16 F16 F25 F30 F25 F30 F35
EN ISO 5211
Housing material GJS GJS GJS GJS GJL GJL GJL GJL GJL GJL
Type GS 200.3 GS 250.3

Flange according to
F30 F35 F40 F35 F40 F48
EN ISO 5211
Housing material GJL GJL GJL GJL GJL GJL
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:
For modulating duty with worm wheel made of bronze:

A start consists of one movement of minimum 1 % in both directions at a load of 35 % of the maximum
valve torque (modulating torque).
Lifetime for motor operation in ac- For open-close duty with worm wheel made of spheroidal cast iron:
cordance with AUMA load profile Duty class 1: Lifetime for 90° swivel movement Meets the lifetime requirement of EN 15714-2
Gearbox size GS 50.3/GS 63.3 GS 80.3/GS100.3 GS 125.3 – GS GS 250.3

200.3
Number of cycles
10,000 5,000 2,500 1,200
for max. torque
Duty class 2: Lifetime for 90° swivel movement for valves which are infrquently operated.
Gearbox size GS 50.3/GS 63.3 GS 80.3/GS100.3 GS 125.3 – GS GS 250.3

200.3
Number of cycles
1,000
for max. torque
Lifetime for larger swing angles on request

For modulating duty with worm wheel made of bronze:
1.2 million modulating steps
Lifetime for manual operation Duty class 3: Meets the lifetime requirement of EN 1074-2
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.
Ref. no. Designation Type

512.0 Input mounting flange Sub-assembly
517.0 Housing Sub-assembly
518.0 Housing cover Sub-assembly
519.1 Worm wheel
520.0 Worm shaft Sub-assembly
521.0 Travelling nut with two pairs of safety wedge discs Sub-assembly
521.1 Travelling nut
521.12 Pair of safety wedge discs
522.0 Bearing cover Sub-assembly
523.0 End stop Sub-assembly
524.0 Pointer cover Sub-assembly
525.0 Coupling Sub-assembly
526.0 End stop nut Sub-assembly
527.0 Protection cover Sub-assembly
534.0 Drive shaft Sub-assembly
538.0 Bearing cover with drive shaft Sub-assembly
595.0 Screw kit for manual gearbox Sub-assembly
619.1 Extension flange Sub-assembly
S1 Seal kit Set
35
GS 50.3 – GS 250.3
Spare parts
9.2. Part-turn gearboxes GS 160.3 – GS 250.3
36
GS 50.3 – GS 250.3
Spare parts

513.1 Grub screw
519.1 Worm wheel
521.0 Travelling nut with two pairs of safety wedge discs
521.2 Pair of safety wedge discs Sub-assembly
524.0 Pointer cover Sub-assembly
525.0 Coupling Sub-assembly
536.0 Protective cap Sub-assembly
537.0 Lock nut Sub-assembly
619.1 Extension flange Sub-assembly
S1 Seal kit Set
37
GS 50.3 – GS 250.3
Spare parts
9.3. Primary reduction gearing for GS 100.3 – GS 125.3 (126:1/160:1/208:1)
38
GS 50.3 – GS 250.3
Spare parts

003.0 Housing cover with drive shaft Sub-assembly
022.0 Planet carrier Sub-assembly
045.0 Internal geared wheel Sub-assembly
S1 Seal kit Set
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

006.0 Planetary gearing first stage (GS 160.3) Sub-assembly
588.1 Blanking plugs
S1 Seal kit Set
41
GS 50.3 – GS 250.3
Spare parts
9.5. Primary reduction gearing for GS 200.3 (864:1) GS 250.3 (848:1)
42
GS 50.3 – GS 250.3
Spare parts

006.0 Planetary gearing first stage Sub-assembly
007.0 Planetary gear second stage (GS 200.3) Sub-assembly
008.0 Planetary gear second stage (GS 250.3) Sub-assembly
010.0 Intermediate housing Sub-assembly
011.1 Pinion
588.1 Blanking plugs
S1 Seal kit Set
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
Europe IBEROPLAN S.A. AUMA Polska Sp. z o.o.

ES 28027 Madrid PL 41-219 Sosnowiec
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Tel +511444-1200 / 0044 / 2321 www.auma.co.jp mainbox@sunnyvalves.co.th
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KR 153-702 Gasan-dong, GeumChun-Gu,, Top Advance Enterprises Ltd.
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50
AUMA worldwide
51
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Tel +49 7631 809 - 0
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Y003.822/003/en/1.15
For detailed information on AUMA products, refer to the Internet: www.auma.com

Multi-turn actuators
SA 07.2 – SA 16.2/SAR 07.2 – SAR 16.2
AUMA NORM (without controls)
Operation instructions Assembly, operation, commissioning

SA 07.2 – SA 16.2/SAR 07.2 – SAR 16.2
Table of contents
Read operation instructions first.

●
Observe safety instructions.
●
These operation instructions are part of the product.
●
Retain operation instructions during product life.
●
Pass on instructions to any subsequent user or owner of the product.
Purpose of the document:

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

1. Safety instructions................................................................................................................. 4
1.1. Basic information on safety 4
1.2. Range of application 4
1.3. Applications in Ex zone 22 (option) 5
1.4. Warnings and notes 5
1.5. References and symbols 6
2. Identification........................................................................................................................... 7
2.1. Name plate 7
2.2. Short description 8
3. Transport, storage and packaging........................................................................................ 9
3.1. Transport 9
3.2. Storage 9
3.3. Packaging 9
4. Assembly................................................................................................................................ 10
4.1. Mounting position 10
4.2. Handwheel fitting 10
4.3. Multi-turn actuator: mount to valve/gearbox 10
4.3.1. Output drive types B, B1 – B4 and E 10
4.3.1.1. Multi-turn actuator (with output drive types B1 – B4 or E): mount to valve/gearbox 11
4.3.2. Output drive type A 11
4.3.2.1. Stem nut: finish machining 12
4.3.2.2. Multi-turn actuator (with output drive type A): mount to valve 13
4.4. Accessories for assembly 14
4.4.1. Stem protection tube for rising valve stem 14
5. Electrical connection............................................................................................................. 15
5.1. Basic information 15
5.2. Connection with AUMA plug/socket connector 16
5.2.1. Terminal compartment: open 16
5.2.2. Cable connection 17
5.2.3. Terminal compartment: close 19
5.3. Accessories for electrical connection 19
5.3.1. Parking frame 19
5.3.2. Protection cover 20
5.3.3. Double sealed intermediate frame 20
5.3.4. Earth connection, external 20
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.
Operation Prerequisites for safe and smooth operation:

● Correct transport, proper storage, mounting and installation, as well as careful
commissioning.
● Only operate the device if it is in perfect condition while observing these instruc-
tions.
● Immediately report any faults and damage and allow for corrective measures.
● Observe recognised rules for occupational health and safety.
● Observe the national regulations.
● During operation, the housing warms up and surface temperatures > 60 °C may
occur. To prevent possible burns, we recommend checking the surface temper-
ature using an appropriate thermometer and wearing protective gloves, if re-
quired, prior to working on the device.
Protective measures The end user or the contractor are responsible for implementing required protective
measures on site, such as enclosures, barriers, or personal protective equipment
for the staff.
Maintenance To ensure safe device operation, the maintenance instructions included in this manual
must be observed.
Any device modification requires prior consent of the manufacturer.
1.2. Range of application
AUMA multi-turn 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.
The following applications are not permitted, e.g.:

● Industrial trucks according to EN ISO 3691
● Lifting appliances according to EN 14502
● Passenger lifts according to DIN 15306 and 15309
● Service lifts according to EN 81-1/A1
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
The following warnings draw special attention to safety-relevant procedures in these

operation instructions, each marked by the appropriate signal word (DANGER,
WARNING, CAUTION, NOTICE).
Indicates an imminently hazardous situation with a high level of risk. Failure

5
SA 07.2 – SA 16.2/SAR 07.2 – SAR 16.2
Safety instructions
Indicates a potentially hazardous situation with a medium level of risk. Failure

Indicates a potentially hazardous situation with a low level of risk. Failure to

observe this warning may result in minor or moderate injury. May also be used
with property damage.
Potentially hazardous situation. Failure to observe this warning may result in

property damage. Is not used for personal injury.
Arrangement and typographic structure of the warnings
Type of hazard and respective source!

Potential consequence(s) in case of non-observance (option)
→ Measures to avoid the danger
→ Further measure(s)
Safety alert symbol warns of a potential personal injury hazard.

The signal word (here: DANGER) indicates the level of hazard.
1.5. References and symbols
The following references and symbols are used in these instructions:
Information The term Information preceding the text indicates important notes and information.
Symbol for CLOSED (valve closed)

Symbol for OPEN (valve open)
Important information before the next step. This symbol indicates what is required
for the next step or what has to be prepared or observed.
<> Reference to other sections
Terms in brackets shown above refer to other sections of the document which provide
further information on this topic. These terms are either listed in the index, a heading
or in the table of contents and may quickly be found.
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
[1] Motor name plate

[2] Actuator name plate
[3] Additional plate, e.g. KKS plate (Power Plant Classification System)
Description of actuator name plate

Figure 2: Actuator name plate (example)
[1] Name of manufacturer

[2] Address of manufacturer
[3] Type designation
[4] Order number
[5] Serial number
[6] Speed
[7] Torque range in direction CLOSE
[8] Torque range in direction OPEN
[9] Type of lubricant
[10] Enclosure protection
[11] Permissible ambient temperature
[14] Data Matrix code
7
SA 07.2 – SA 16.2/SAR 07.2 – SAR 16.2
Identification
Type designation Figure 3: Type designation (example)
1. Type and size of actuator

2. Flange size
Type and size
These instructions apply to the following devices types and sizes:
Multi-turn actuators for open-close duty: SA 07.2, 07.6, 10.2, 14.2, 14.6, 16.2
Multi-turn actuators for modulating duty: SAR 07.2, 07.6, 10.2, 14.2, 14.6, 16.2
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:
2.2. Short description
Multi-turn actuator Definition in compliance with EN ISO 5210:

A multi-turn actuator is an actuator which transmits to the valve a torque for at least
one full revolution. It is capable of withstanding thrust.
AUMA multi-turn actuators are driven by an electric motor and are capable of
withstanding thrust in combination with output drive type A. For manual operation,
a handwheel is provided. Switching off in end positions may be either by limit or
torque seating. Controls are required to operate or process the actuator signals.
Actuators without controls can be equipped with AUMA actuator controls at a later
date. For more information, please state our order number (refer to actuator name
plate).
8
SA 07.2 – SA 16.2/SAR 07.2 – SAR 16.2
3. Transport, storage and packaging

3.1. Transport
For transport to place of installation, use sturdy 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
Danger of corrosion due to inappropriate storage!

→ Store in a well-ventilated, dry room.
→ Protect against floor dampness by storage on a shelf or on a wooden pallet.
→ Cover to protect against dust and dirt.
→ Apply suitable corrosion protection agent to uncoated surfaces.
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
4.1. Mounting position
AUMA actuators can be operated without restriction in any mounting position.
4.2. Handwheel fitting

Information For transport purposes, handwheels from a diameter of 400 mm are supplied separ-
ately.
Figure 5: Handwheel
[1] Spacer
[2] Input shaft
[3] Handwheel
[4] Circlip
1. If required, fit spacer [1] onto input shaft [2].

2. Slip handwheel [3] onto input shaft.
3. Secure handwheel [3] using the circlip [4] supplied.
4.3. Multi-turn actuator: mount to valve/gearbox
Danger of corrosion due to damage to paint finish and condensation!

→ Touch up damage to paint finish after work on the device.
→ After mounting, connect the device immediately to electrical mains to ensure
that heater minimises condensation.
4.3.1. Output drive types B, B1 – B4 and E

Application ● For rotating, non-rising valve stem
● Not capable of withstanding thrust
Design Output drive bore with keyway:
● Types B1 – B4 with bore according to EN ISO 5210
● Types B and E with bore according to DIN 3210
● Later change from B1 to B3, B4, or E is possible.
10
SA 07.2 – SA 16.2/SAR 07.2 – SAR 16.2
Assembly
Figure 6: Output drive
[1] Output drive types B, B1 – B4, E and C

[2] Output drive sleeve/output drive plug sleve with bore and keyway
[3] Circlip
Information Spigot at flanges should be loose fit.
4.3.1.1. Multi-turn actuator (with output drive types B1 – B4 or E): mount to valve/gearbox
1. Check if mounting flanges fit together.

2. Check whether bore and keyway match the input shaft.
3. Apply a small quantity of grease to the input shaft.
4. Place multi-turn actuator.
Information: Ensure that the spigot fits uniformly in the recess and that the
mounting faces are in complete contact.
5. Fasten multi-turn actuator with screws according to table.
Information: We recommend applying liquid thread sealing material to the
screws to avoid contact corrosion.
Table 2: Tightening torques for screws

Screws Tightening torque TA [Nm]
Threads Strength class 8.8
M8 25
M10 51
M12 87
M16 214
M20 431
4.3.2. Output drive type A

Application ● Output drive for rising, non-rotating valve stem
● Capable of withstanding thrust
Information To adapt the actuators to output drive types A available on site with flanges F10 and
F14 (year of manufacture: 2009 and earlier), an adapter is required. The adapter
can be ordered from AUMA.
11
SA 07.2 – SA 16.2/SAR 07.2 – SAR 16.2
Assembly
4.3.2.1. Stem nut: finish machining
✔ This working step is only required if stem nut is supplied unbored or with pilot
bore.
Figure 7: Design of output drive type A
[1] Stem nut

[2] Bearing
[2.1] Bearing race
[2.2] Bearing rim
[3] Spigot ring
1. Remove spigot ring [3] from output drive.

2. Remove stem nut [1] together with bearings [2].
3. Remove bearing races [2.1] and bearing rims [2.2] from stem nut [1].
4. Drill and bore stem nut [1] and cut thread.
Information: When fixing in the chuck, make sure stem nut runs true!
5. Clean the machined stem nut [1].
6. Apply sufficient Lithium soap EP multi-purpose grease to bearing rims [2.2] and
bearing races [2.1], ensuring that all hollow spaces are filled with grease.
7. Place greased bearing rims [2.2] and bearing races [2.1] onto stem nut [1].
8. Re-insert stem nut [1] with bearings [2] into output drive.
Information: Ensure that dogs or splines are placed correctly in the keyway of
the hollow shaft.
9. Screw in spigot ring [3] until it is firm against the shoulder.
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
Figure 8: Assembly with output drive type A
[1] Valve stem

[2] Output drive type A
[3] Screws to actuator
[4] Valve flange
[5] Screws to output drive
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.
Table 3: Tightening torques for screws

Screws Tightening torque TA [Nm]
Threads Strength class 8.8
M6 11
M8 25
M10 51
M12 87
M16 214
M20 431
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
4.4. Accessories for assembly
4.4.1. Stem protection tube for rising valve stem

— Option —
Figure 9: Assembly of the stem protection tube
[1] Cap for stem protection tube

[2] Stem protection tube
[3] Sealing ring
1. Seal thread with hemp, Teflon tape, or thread sealing material.

2. Screw stem protection tube [2] into thread and tighten it firmly.
3. Push down the sealing ring [3] onto the housing.
4. Check whether cap for stem protection tube [1] is available and in perfect con-
dition.
14
SA 07.2 – SA 16.2/SAR 07.2 – SAR 16.2
Electrical connection
5. Electrical connection
5.1. Basic information
Danger due to incorrect electrical connection

Failure to observe this warning can result in death, serious injury, or property damage.
→ The electrical connection must be carried out exclusively by suitably qualified
personnel.
→ Prior to connection, observe basic information contained in this chapter.
→ After connection but prior to applying the voltage, observe the <Commissioning>
and <Test run> chapters.
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).
Valve damage for connection without controls!

→ NORM actuators require controls: Connect motor via controls only (reversing
contactor circuit).
→ Observe the type of seating specified by the valve manufacturer.
→ Observe wiring diagram.
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
Figure 10: Motor name plate (example)
[1] Type of current

[2] Mains voltage
[3] Mains frequency (for 3-ph and 1-ph AC motors)
Connecting cables ● For device insulation, appropriate (voltage-proof) cables must be used. Specify
cables for the highest occurring rated voltage.
● Use connecting cable with appropriate minimum rated temperature.
● For connecting cables exposed to UV radiation (outdoor installation), use UV
resistant cables.
5.2. Connection with AUMA plug/socket connector
Cross sections AUMA plug/socket connector:
● 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
Figure 11: Connection AUMA plug/socket connector, version S
[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
Hazardous voltage!
Risk of electric shock.
→ Disconnect device from the mains before opening.
1. Loosen screws [2] and remove cover [1].

2. Loosen screws [4] and remove socket carrier [5] from cover [1].
3. Insert cable glands [8] suitable for connecting cables.
➥ The enclosure protection IP... stated on the name plate is only ensured if suitable
cable glands are used.
Figure 12: Example: Name plate shows enclosure protection IP68
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
✔ Observe permissible cross sections.
Danger of motor damage if PTC thermistors or thermoswitches are not con-

nected!
Our warranty for the motor will lapse if the motor protection is not connected.
→ Connect PTC thermistors or thermoswitches to external controls.
Danger of corrosion: Damage due to condensation!

→ After mounting, commission the device immediately to ensure that heater min-
imises condensation.
1. Remove cable sheathing.

2. Strip wires.
3. For flexible cables: Use end sleeves according to DIN 46228.
4. Connect cables according to order-related wiring diagram.
17
SA 07.2 – SA 16.2/SAR 07.2 – SAR 16.2
In case of a fault: Hazardous voltage while protective earth conductor is NOT

connected!
Risk of electric shock.
→ Connect all protective earth conductors.
→ Connect PE connection to external protective earth conductor of connecting
cables.
→ Start running the device only after having connected the protective earth con-
ductor.
5. Tighten PE conductors firmly to PE connection using ring lugs (flexible cables)

or loops (rigid cables).
Figure 13: PE connection
[1] Socket carrier

[2] Screw
[3] Washer
[4] Lock washer
[5] Protective earth with ring lugs/loops
[6] PE connection, symbol:
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
5.2.3. Terminal compartment: close
Figure 14: Example: Version S
[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)
Short-circuit due to pinching of cables!

Risk of electric shock and functional failures.
→ Carefully fit socket carrier to avoid pinching the cables.
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
Figure 15: Parking frame
5.3.2. Protection cover

Protection cover for plug compartment when plug is removed.
The open terminal compartment can be closed using a protective cover (not
illustrated).
5.3.3. Double sealed intermediate frame
When removing the electrical connection or due to leaky cable glands, ingress of
dust and water into the housing may occur. This is prevented effectively by inserting
the double sealed intermediate frame [2] between the plug/socket connector [1] and
the housing of the device. The enclosure protection of the device (IP68) will not be
affected, even if the electrical connection [1] is removed.
Figure 16: Electrical connection with double sealed intermediate frame
[1] Electrical connection

[2] Double sealed intermediate frame
[3] Actuator housing
5.3.4. Earth connection, external

As an option, the housing is equipped with an external earth connection (U-bracket)
to connect the device to the equipotential earth bonding.
Figure 17: Earth connection
20
SA 07.2 – SA 16.2/SAR 07.2 – SAR 16.2
Operation
6. Operation
6.1. Manual operation

For purposes of setting and commissioning, in case of motor failure or power failure,
the actuator may be operated manually. Manual operation is engaged by an internal
change-over mechanism.
6.1.1. Manual operation: engage
Damage at the motor coupling due to faulty operation!

→ Engage manual operation only during motor standstill.
1. Press push button.
2. Turn handwheel in desired direction.

→ To close the valve, turn handwheel clockwise:
➥ Drive shaft (valve) turns clockwise in direction CLOSE.
6.1.2. Manual operation: disengage
Manual operation is automatically disengaged when motor is started again. The

handwheel does not rotate during motor operation.
6.2. Motor operation
Valve damage due to incorrect setting!

→ Perform all commissioning settings and the test run prior to motor operation.
Controls are required to operate an actuator during motor operation. If the actuator
is to be operated locally, additional local controls are required.
1. Switch on power supply.

2. To close the valve, switch on motor operation in direction CLOSE.
➥ Valve shaft turns clockwise in direction CLOSE.
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.
Feedback signal Type and designation in wiring diagram

End position OPEN/CLOSED Setting via limit switching
reached Switches: 1 NC and 1 NO (standard)
LSC Limit switch, closing, clockwise rotation
LSO Limit switch, opening, counterclockwise rotation
Intermediate position reached Setting via DUO limit switching
(option) Switches: 1 NC and 1 NO (standard)
LSA DUO limit switch, clockwise rotation
LSB DUO limit switch, counterclockwise rotation
Torque OPEN/CLOSED Setting via torque switching
reached Switches: 1 NC and 1 NO (standard)
TSC Torque switch, closing, clockwise rotation
TSO Torque switch, opening, counterclockwise rotation
Motor protection tripped Thermoswitches or PTC thermistors, depending on the version
F1, Th Thermoswitches
R3 PTC thermistors
Running indication (option) Switches: 1 NC (standard)
S5, BL Blinker transmitter
Valve position (option) Depending on version either with potentiometer or electronic position transmitter EWG/RWG
R2 Potentiometer
R2/2 Potentiometer in tandem arrangement (option)
B1/B2, 3-wire or 4-wire system (0/4– 20 mA)
EWG/RWG
B3/B4, 2-wire system (4 – 20 mA)
EWG/RWG
Manual operation active (op- Switches
tion)
23
SA 07.2 – SA 16.2/SAR 07.2 – SAR 16.2
Commissioning
9. Commissioning
9.1. Switch compartment: open
The switch compartment must be opened to perform the following settings (options).
1. Loosen screws [2] and remove cover [1] from the switch compartment.
2. If indicator disc [3] is available:

Remove indicator disc [3] using a spanner (as lever).
Information: To avoid damage to paint finish, use spanner in combination with
soft object, e.g. fabric.
9.2. Torque switching: set

Once the set torque is reached, the torque switches will be tripped (overload protection
of the valve).
Information The torque switches may also trip during manual operation.
Valve damage due to excessive tripping torque limit setting!

→ The tripping torque must suit the valve.
→ Only change the setting with the consent of the valve manufacturer.
24
SA 07.2 – SA 16.2/SAR 07.2 – SAR 16.2
Commissioning
Figure 19: Torque measuring heads
[1] Torque switching head black in direction CLOSE

[2] Torque switching head white in direction OPEN
[3] Lock screws
[4] Torque dials
1. Loosen both lock screws [3] at the indicator disc.

2. Turn torque dial [4] to set the required torque (1 da Nm = 10 Nm). Example:
- Black torque switching head set to approx. 25 da Nm ≙ 250 Nm for direction
CLOSE
- White torque switching head set to approx. 20 da Nm ≙ 200 Nm for direction
OPEN
3. Fasten lock screws [3] again.
Information: Maximum tightening torque: 0.3 – 0.4 Nm
➥ The torque switch setting is complete.
9.3. Limit switching: set

The limit switching records the travel. When reaching the preset position, switches
are operated.
Figure 20: Setting elements for limit switching
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
9.3.1. End position CLOSED (black section): set
1. Engage manual operation.

2. Turn handwheel clockwise until valve is closed.
25
SA 07.2 – SA 16.2/SAR 07.2 – SAR 16.2
Commissioning
3. Turn handwheel by approximately half a turn (overrun) in the opposite direction.

4. Press down and turn setting spindle [1] with screw driver in direction of the
arrow and observe the pointer [2]: While a ratchet click is felt and heard, the
pointer [2] moves 90° every time.
5. If the pointer [2] is 90° from mark [3]: Continue turning slowly.
6. If the pointer [2] moves to mark [3]: Stop turning and release setting spindle.
➥ The end position CLOSED setting is complete.
7. If you override the tripping point inadvertently (ratchet click is heard after the
pointer has snapped): Continue turning the setting spindle in the same direction
and repeat setting process.
9.3.2. End position OPEN (white section): set
1. Engage manual operation.

2. Turn handwheel counterclockwise until valve is open.
3. Turn handwheel by approximately half a turn (overrun) in the opposite direction.
➥ The end position OPEN setting is complete.
9.4. Intermediate positions: set
— Option —
Actuators equipped with DUO limit switching contain two intermediate position
switches. One intermediate position may be set for each running direction.
Figure 21: Setting elements for limit switching
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
1. Move valve in direction CLOSE to desired intermediate position.

2. If you override the tripping point inadvertently: Turn valve in opposite direction
and approach intermediate position again in direction CLOSE.
Information: Always approach the intermediate position in the same direction
as in later electrical operation.
➥ The intermediate position setting in running direction CLOSE is complete.
9.4.2. Running direction OPEN (white section): set
1. Move valve in direction OPEN to desired intermediate position.

2. If you override the tripping point inadvertently: Move valve in opposite direction
and approach intermediate position again in direction OPEN (always approach
the intermediate position in the same direction as in later electrical operation).
➥ The intermediate position setting in running direction OPEN is complete.
9.5. Test run
Perform test run only once all settings previously described have been performed.
9.5.1. Direction of rotation: check
Valve damage due to incorrect direction of rotation!

→ If the direction of rotation is wrong, switch off immediately.
→ Correct phase sequence.
→ Repeat test run.
1. Move actuator manually to intermediate position or to sufficient distance from

end position.
2. Switch on actuator in running direction CLOSE and observe the direction of
rotation:
with indicator disc: step 3
without indicator disc: step 4 (hollow shaft)
→ Switch off before reaching the end position.
27
SA 07.2 – SA 16.2/SAR 07.2 – SAR 16.2
Commissioning
3. With indicator disc:

→ Observe direction of rotation.
➥ The direction of rotation is correct, if actuator runs in direction CLOSE
and indicator disc turns counterclockwise.
4. Without the indicator disc:

→ Unscrew threaded plug [1] and seal [2] or cap for stem protection tube [4]
and observe direction of rotation at hollow shaft [3] or the stem [5].
➥ The direction of rotation is correct, if actuator runs in direction CLOSE and
hollow shaft or stem turn clockwise.
Figure 22: Hollow shaft/stem
[1] Threaded plug

[2] Seal
[3] Hollow shaft
[4] Cap for stem protection tube
[5] Stem
[6] Stem protection tube
9.5.2. Limit switching: check
1. Move actuator manually into both end positions of the valve.

➥ The limit switching is set correctly if:
- LSC switch trips in end position CLOSED
- LSO switch trips in end position OPEN
- the switches release the contacts after turning back the handwheel
2. If the end position setting is incorrect: Reset limit switching.
3. If the end position setting is correct and no options (e.g. potentiometer, position
transmitter) are available: Close switch compartment.
28
SA 07.2 – SA 16.2/SAR 07.2 – SAR 16.2
Commissioning
9.6. Electronic position transmitter EWG 01.1

— Option —
The electronic position transmitter EWG 01.1 signals the remote position or the valve
position. On the basis of the actual valve position sensed by hall sensor, a current
signal between 0 – 20 mA or 4 – 20 mA is generated.
Technical data
Table 4: EWG 01.1
Data 3-wire or 4-wire system 2-wire system
Output current Ia 0 – 20 mA, 4 – 20 mA 4 – 20 mA
Power supply UV 1) 24 V DC (18 – 32 V) 24 V DC (18 – 32 V)
Max. current consumption LED off = 26 mA, LED on = 27 20 mA
mA
Max. load RB 600 Ω (UV – 12 V)/20 mA
Impact of power supply 0.1 %
Load influence 0.1 %
Temperature impact < 0.1 ‰/K
Ambient temperature2) –60 °C to +80 °C
1) Power supply possible via: AC, AM controls or external power supply
2) Depending on temperature range of the actuator: Refer to name plate
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
[S1] Push button: Set 0/4 mA

[S2] Push button: Set 20 mA
LED Optical aid for setting
[1] Measuring point (+) 0/4 – 20 mA
[2] Measuring point (–) 0/4 – 20 mA
The output current (measuring range 0 – 20 mA) can be checked at measuring points
[1] and [2].
Table 5: Short overview on push button functions

Push but- Function
tons
[S1] + [S2] → press simultaneously for 5 s: Activate setting mode
[S1] → press in setting mode for 3 s: Set 4 mA
→ press in setting mode for 6 s: Set 0 mA
→ press in operation for 3 s: Switch on/off LED end position signalling.
→ touch in end position: Reduce current value by 0.02 mA
[S2] → press in setting mode for 3 s: Set 20 mA
→ press in operation for 3 s: Switch on/off LED end position signalling.
→ touch in end position: Increase current value by 0.02 mA
29
SA 07.2 – SA 16.2/SAR 07.2 – SAR 16.2
Commissioning
9.6.1. Measuring range: set
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 .
until LED is blinking fast .
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
→ Operate valve in desired end position (OPEN/CLOSED).

→ Reduce current value: Press push button [S1]
(the current is reduced by 0.02 mA every time the push button is
pressed)
→ Increase current value Press push button [S2]
(the current is increased by 0.02 mA every time the push button is
pressed)
9.6.3. LED end position signalling: switch on/off
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.
Table 6: LED behaviour when end position signalling is switched on

Set output current LED behaviour in end position
4 mA
LED is blinking slowly
0 mA
LED is blinking fast
20 mA
LED is illuminated
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
9.7.1. Potentiometer setting
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.
31
SA 07.2 – SA 16.2/SAR 07.2 – SAR 16.2
Commissioning
2. Turn potentiometer [1] clockwise to the stop.

➥ End position CLOSED corresponds to 0 %
➥ End position OPEN corresponds to 100 %
3. Turn potentiometer [1] slightly in opposite direction.
4. Perform fine-tuning of the zero point at external setting potentiometer (for remote
indication).
9.8. Electronic position transmitter RWG
— Option —
The electronic position transmitter RWG records the valve position. On the basis of
the actual position value measured by the potentiometer (travel sensor), it generates
a current signal between 0 – 20 mA or 4 – 20 mA.
Technical data
Table 7: RWG 4020
Data 3-wire or 4-wire system 2-wire system
Output current Ia 0 – 20 mA, 4 – 20 mA 4 – 20 mA
Power supply UV 1) 24 V DC (18 – 32 V) 14 V DC + (I x RB), max. 30 V
Max. current consumption 24 mA at 20 mA output current 20 mA
Max. load RB 600 Ω (UV – 14 V)/20 mA
Impact of power supply 0.1 %/V 0.1 %/V
Load influence 0.1 %/(0 – 600 Ω) 0.1 %/100 Ω
Temperature impact < 0.3 ‰/K
Ambient temperature2) –60 °C to +80 °C
Transmitter potentiometer 5 kΩ
1) Power supply possible via: AC, AM controls or external power supply
2) Depending on temperature range of the actuator: Refer to name plate
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
[1] Potentiometer (travel sensor)

[2] Potentiometer min. (0/4 mA)
[3] Potentiometer max. (20 mA)
[4] Measuring point (+) 0/4 – 20 mA
[5] Measuring point (–) 0/4 – 20 mA
The output current (measuring range 0 – 20 mA) can be checked at measuring points
[4] and [5].
9.8.1. Measuring range: set
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
2. Connect measuring equipment for 0 – 20 mA to measuring points [4] and ]5].

If no value can be measured:
→ Check whether external load is connected to customer connection XK
(for standard wiring: terminals 23/24). Consider maximum load RB.
→ Or connect link across customer connection XK (for standard wiring:
terminals 23/24).
3. Turn potentiometer [1] clockwise to the stop.
4. Turn potentiometer [1] slightly in opposite direction.
5. Turn potentiometer [2] clockwise until output current starts to increase.
6. Turn potentiometer [2] in opposite direction until the following value is reached:
- for 0 – 20 mA approx. 0.1 mA
- for 4 – 20 mA approx. 4.1 mA
➥ This ensures that the signal remains above the dead and live zero point.
7. Move valve to end position OPEN.
8. Set potentiometer [3] to end value 20 mA.
9. Approach end position CLOSED again and check minimum value (0.1 mA or
4.1 mA). If necessary, correct the setting.
Information If the maximum value cannot be reached, the selection of the reduction gearing must
be checked.
9.9. Mechanical position indicator: set

— Option —
1. Place indicator disc on shaft.

3. Turn lower indicator disc until symbol (CLOSED) is in alignment with the
mark on the cover.
4. Move actuator to end position OPEN.

5. Hold lower indicator disc in position and turn upper disc with symbol (OPEN)
until it is in alignment with the mark on the cover.
6. Move valve to end position CLOSED again.

7. Check settings:
If the symbol (CLOSED) is no longer in alignment with mark on the cover:
7.1 Repeat setting procedure.
7.2 Check whether the appropriate reduction gearing has been selected, if
required.
33
SA 07.2 – SA 16.2/SAR 07.2 – SAR 16.2
Commissioning
9.10. Switch compartment: close
Danger of corrosion due to damage to paint finish!

→ Touch up damage to paint finish after work on the device.
1. Clean sealing faces of housing and cover.

2. Check whether O-ring [3] is in good condition, replace if damaged.
3. Apply a thin film of non-acidic grease (e.g. petroleum jelly) to the O-ring and
insert it correctly.
4. Place cover [1] on switch compartment.

5. Fasten screws [2] evenly crosswise.
34
SA 07.2 – SA 16.2/SAR 07.2 – SAR 16.2
Corrective action
10. Corrective action
10.1. Faults during commissioning
Table 8: Faults during commissioning

Fault Description/cause Remedy
Mechanical position indicator Reduction gearing is not suitable for Exchange reduction gearing.
cannot be set. turns/stroke of the actuator.
In spite of correct setting of limit The overrun was not considered when setting ● Determine overrun: Overrun = travel
switching, actuator operated into the limit switching. covered from switching off until complete
the valve end position. The overrun is generated by the inertia of standstill.
both the actuator and the valve and the delay
time of the controls. ● Set limit switching again considering the
overrun (turn handwheel back by the
amount of the overrun).
No value can be measured at Current loop across RWG is open. ● Connect link across RWG to XK (terminals
measuring points of the RWG. (Position feedback 0/4 – 20 mA is only pos- 23/24)
sible if the current loop is closed across the
RWG.)
● Connect external load to XK, e.g. remote
indication.
● Observe maximum load RB.
Measuring range 0/4 – 20 mA or Reduction gearing is not suitable for Exchange reduction gearing.
maximum value 20 mA at position turns/stroke of the actuator.
transmitter cannot be set or sup-
plies an incorrect value.
The measuring range 0/4 – 20 The LED on the EWG either flashes in setting Call AUMA service.
mA at EWG position transmitter mode a) single flash or b) triple flash:
cannot be set.
a) EWG is not calibrated.

b) Magnet positions of EWG are not aligned.
Limit and/or torque switches do Switch is defective or switch setting is incor- ● Check setting, if required, reset end posi-
not trip. rect. tions.
● Refer to <Check switches> and replace
the switches if required.
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
11. Servicing and maintenance
Damage caused by inappropriate maintenance!

→ Servicing and maintenance must be carried out exclusively by suitably qualified
personnel having been authorised by the end user or the contractor of the plant.
Therefore, we recommend contacting our service.
→ Only perform servicing and maintenance tasks when the device is switched off.
AUMA
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).
11.1. Preventive measures for servicing and safe operation
The following measures are required to ensure safe device operation:

6 months after commissioning and then every year
● Carry out visual inspection:
Cable entries, cable glands, blanking plugs, etc. have to be checked for correct
tightness and sealing.
Respect torques according to manufacturer's details.
● Check fastening screws between actuator and gearbox/valve for tightness. If
required, fasten screws while applying the tightening torques as indicated in
chapter <Assembly>.
● When rarely operated: Perform test run.
● For devices with output drive A: Press in Lithium soap EP multi-purpose grease
on mineral oil base at the grease nipple with a grease gun.
● Lubrication of the valve stem must be done separately.
Figure 26: Output drive type A
[1] Output drive type A

[2] Grease nipple
Table 9: Grease quantities for bearing of output drive type A

Output drive A 07.2 A 10.2 A 14.2 A 16.2
Quantity [g] 1) 1.5 2 3 5
1) For grease at density r = 0.9 kg/dm³
For enclosure protection IP68
After continuous immersion:

● Check actuator.
● In case of ingress of water, locate leaks and repair, dry device correctly and
check for proper function.
11.2. Maintenance
Lubrication ● In the factory, the gear housing is filled with grease.
37
SA 07.2 – SA 16.2/SAR 07.2 – SAR 16.2
● Grease change is performed during maintenance

- Generally after 4 to 6 years for modulating duty.
- Generally after 6 to 8 years if operated frequently (open-close duty).
- Generally after 10 to 12 years if operated rarely (open-close duty).
● We recommend exchanging the seals when changing the grease.
● No additional lubrication of the gear housing is required during operation.
11.3. Disposal and recycling
Our devices have a long lifetime. However, they have to be replaced at one point in
time. The devices have a modular design and may, therefore, easily be separated
and sorted according to materials used, i.e.:
● electronic scrap
● various metals
● plastics
● greases and oils
The following generally applies:
● Greases and oils are hazardous to water and must not be released into the
environment.
● Arrange for controlled waste disposal of the disassembled material or for sep-
arate recycling according to materials.
● Observe the national regulations for waste disposal.
38
SA 07.2 – SA 16.2/SAR 07.2 – SAR 16.2
Technical data
12. Technical data

Information The following technical data includes 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 at www.auma.com
in both German and English (please state the order number).
12.1. Technical data Multi-turn actuators

Type of duty Standard:
Short-time duty S2 - 15 min (multi-turn actuators for open-close duty)
Intermittent duty S4 - 25 % (multi-turn actuators for modulating duty)
Option: Short-time duty S2 - 30 min (multi-turn actuators for open-close duty)
S5 - 25 % only in combination with insulation class H
For nominal voltage and 40 °C ambient temperature and at average load with 35 % of the
max. torque
Motors Standard: 3-ph AC asynchronous motor, type IM B9 according to IEC 60034
Option: 1-phase AC motor, type IM B9 according to IEC 60034
DC shunt motor, type IM B14 according to IEC 60034
DC compound motor, type IM B14 according to IEC 60034
Mains voltage, mains frequency Refer to motor name plate
Permissible variation of mains voltage: ±10 %
Permissible variation of mains frequency: ±5 % (for 3-phase AC and 1-phase AC current)
Overvoltage category Category III according to IEC 60364-4-443
Insulation class Standard: F, tropicalized
Option: H, tropicalized
Motor protection Standard: 3-phase and 1-phase AC motors: Thermoswitches (NC)
DC motors: Without
Option: PTC thermistors (according to DIN 44082)1)
Self-locking Self-locking: Output speeds up to 90 rpm (50 Hz), 108 rpm (60 Hz)
NOT self-locking: Output speeds up to 125 rpm (50 Hz), 150 rpm (60 Hz)
Multi-turn actuators are self-locking, if the valve position cannot be changed from standstill
while torque acts upon the output drive.
Motor heater (option) Voltages: 110 – 120 V AC, 220 – 240 V AC or 400 V AC (externally supplied)
Power depending on the size 12.5 – 25 W
Manual operation Manual drive for setting and emergency operation, handwheel does not rotate during elec-
trical operation.
Option: Handwheel lockable
Handwheel stem extension
Power tool for emergency operation with square 30 mm or 50 mm
Indication for manual operation Indication whether manual operation is active/not active via single switch (1 change-over
(option) contact)
Electrical connection Standard: AUMA plug/socket connector with screw-type connection
Motor connection for some DC motors via separate motor terminal board
Option: Terminals or crimp connection
Gold-plated control plug (sockets and plugs)
Threads for cable entries Standard: Metric threads
Option: Pg-threads, NPT-threads, G-threads
Terminal plan Terminal plan according to order number enclosed with delivery
Valve attachment Standard: B1 according to EN ISO 5210
Option: A, B2, B3, B4 according to EN ISO 5210
A, B, D, E according to DIN 3210
C according to DIN 3338
Special output drive types: AF, AK, AG, B3D, ED, DD, IB1, IB3
A prepared for permanent lubrication of stem
1) PTC thermistors additionally require a suitable tripping device within the controls
39
SA 07.2 – SA 16.2/SAR 07.2 – SAR 16.2
Technical data
Electromechanical control unit

Limit switching Counter gear mechanism for end positions OPEN and CLOSED
Turns per stroke: 2 to 500 (standard) or 2 to 5,000 (option)
Standard: Single switches (1 NC and 1 NO) for each end position, not galvanically isolated
Options: Tandem switches (2 NC and 2 NO) for each end position, switches galvanically
isolated
Triple switches (3 NC and 3 NO) for each end position, switches galvanically
isolated
Intermediate position switch (DUO limit switching), adjustable for any position
Torque switching Torque switching adjustable for directions OPEN and CLOSE
Standard: Single switches (1 NC and 1 NO) for each direction, not galvanically isolated
Options: Tandem switches (2 NC and 2 NO) for each direction, switches galvanically
isolated
Position feedback signal, ana- Potentiometer or 0/4 – 20 mA (EWG/RWG)
logue (option)
Mechanical position indicator Continuous indication, adjustable indicator disc with symbols OPEN and CLOSED
(option)
Running indication Blinker transmitter (option for modulating actuators)
Heater in switch compartment Standard: Self-regulating PTC heater, 5 – 20 W, 110 – 250 V AC/DC
Options: 24 – 48 V AC/DC or 380 – 400 V AC
A resistance type heater of 5 W, 24 V AC is installed in the actuator in combination with AM
or AC actuator controls.
Technical data for limit and torque switches

6
Mechanical lifetime 2 x 10 starts
Silver plated contacts:
U min. 24 V AC/DC
U max. 250 V AC/DC
I min. 20 mA
I max. AC current 5 A at 250 V (resistive load)
3 A at 250 V (inductive load, cos phi = 0.6)
I max. DC current 0.4 A at 250 V (resistive load)
0.03 A at 250 V (inductive load, L/R = 3 µs)
7 A at 30 V (resistive load)
5 A at 30 V (inductive load, L/R = 3 µs)
Gold plated contacts
U min. 5V
U max. 30 V
I min. 4 mA
I max. 400 mA
Technical data for blinker transmitter

7
Mechanical lifetime 10 starts
U min. 10 V AC/DC
U max. 250 V AC/DC
I max. AC current 3 A at 250 V (resistive load)
2 A at 250 V (inductive load, cos phi ≈ 0.8)
I max. DC current 0.25 A at 250 V (resistive load)
40
SA 07.2 – SA 16.2/SAR 07.2 – SAR 16.2
Technical data
Technical data for handwheel activation switches

6
Mechanical lifetime 10 starts
U min. 12 V DC
U max. 250 V AC
I max. AC current 3 A at 250 V (inductive load, cos phi = 0.8)
I max. DC current 3 A at 12 V (resistive load)
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
13. Spare parts

13.1. Multi-turn actuators SA 07.2 – SA 16.2/SAR 07.2 – SAR 16.2
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
Europe IBEROPLAN S.A. AUMA Polska Sp. z o.o.

ES 28027 Madrid PL 41-219 Sosnowiec
AUMA Riester GmbH & Co. KG Tel +34 91 3717130 Tel +48 32 783 52 00
iberoplan@iberoplan.com biuro@auma.com.pl
Plant Müllheim www.auma.com.pl
DE 79373 Müllheim AUMA Finland Oy
Tel +49 7631 809 - 0 FI 02230 Espoo AUMA-LUSA Representative Office, Lda.
riester@auma.com Tel +358 9 5840 22 PT 2730-033 Barcarena
www.auma.com auma@auma.fi Tel +351 211 307 100
www.auma.fi geral@aumalusa.pt
Plant Ostfildern-Nellingen
DE 73747 Ostfildern AUMA France S.A.R.L. SAUTECH
Tel +49 711 34803 - 0 FR 95157 Taverny Cedex RO 011783 Bucuresti
riester@wof.auma.com Tel +33 1 39327272 Tel +40 372 303982
info@auma.fr office@sautech.ro
Service-Center Bayern www.auma.fr
DE 85386 Eching OOO PRIWODY AUMA
Tel +49 81 65 9017- 0 AUMA ACTUATORS Ltd. RU 141402 Khimki, Moscow region
Riester@scb.auma.com GB Clevedon, North Somerset BS21 6TH Tel +7 495 221 64 28
Tel +44 1275 871141 aumarussia@auma.ru
Service-Center Köln mail@auma.co.uk www.auma.ru
DE 50858 Köln www.auma.co.uk
Tel +49 2234 2037 - 900 OOO PRIWODY AUMA
Service@sck.auma.com D. G. Bellos & Co. O.E. RU 125362 Moscow
GR 13673 Acharnai, Athens Tel +7 495 787 78 21
Service-Center Magdeburg Tel +30 210 2409485 aumarussia@auma.ru
DE 39167 Niederndodeleben info@dgbellos.gr www.auma.ru
Tel +49 39204 759 - 0
Service@scm.auma.com APIS CENTAR d. o. o. ERICHS ARMATUR AB
HR 10437 Bestovje SE 20039 Malmö
AUMA-Armaturenantriebe Ges.m.b.H. Tel +385 1 6531 485 Tel +46 40 311550
AT 2512 Tribuswinkel auma@apis-centar.com info@erichsarmatur.se
Tel +43 2252 82540 www.apis-centar.com www.erichsarmatur.se
office@auma.at
www.auma.at Fabo Kereskedelmi és Szolgáltató Kft. ELSO-b, s.r.o.
HU 8800 Nagykanizsa SK 94901 Nitra
AUMA BENELUX B.V. B. A. Tel +36 93/324-666 Tel +421 905/336-926
BE 8800 Roeselare auma@fabo.hu elsob@stonline.sk
Tel +32 51 24 24 80 www.fabo.hu www.elsob.sk
office@auma.be
www.auma.nl Falkinn HF Auma Endüstri Kontrol Sistemleri Limited
IS 108 Reykjavik Sirketi
ProStream Group Ltd. Tel +00354 540 7000 TR 06810 Ankara
BG 1632 Sofia os@falkinn.is Tel +90 312 217 32 88
Tel +359 2 9179-337 www.falkinn.is info@auma.com.tr
valtchev@prostream.bg
www.prostream.bg AUMA ITALIANA S.r.l. a socio unico AUMA Technology Automations Ltd
IT 20023 Cerro Maggiore (MI) UA 02099 Kiev
OOO “Dunkan-Privod” Tel +39 0331 51351 Tel +38 044 586-53-03
BY 220004 Minsk info@auma.it auma-tech@aumatech.com.ua
Tel +375 29 6945574 www.auma.it
belarus@auma.ru Africa
www.zatvor.by AUMA BENELUX B.V.
LU Leiden (NL) Solution Technique Contrôle Commande
AUMA (Schweiz) AG Tel +31 71 581 40 40 DZ Bir Mourad Rais, Algiers
CH 8965 Berikon office@auma.nl Tel +213 21 56 42 09/18
Tel +41 566 400945 stcco@wissal.dz
RettichP.ch@auma.com NB Engineering Services
MT ZBR 08 Zabbar A.T.E.C.
AUMA Servopohony spol. s.r.o. Tel + 356 2169 2647 EG Cairo
CZ 250 01 Brandýs n.L.-St.Boleslav nikibel@onvol.net Tel +20 2 23599680 - 23590861
Tel +420 326 396 993 contactus@atec-eg.com
auma-s@auma.cz AUMA BENELUX B.V.
www.auma.cz NL 2314 XT Leiden SAMIREG
Tel +31 71 581 40 40 MA 203000 Casablanca
GRØNBECH & SØNNER A/S office@auma.nl Tel +212 5 22 40 09 65
DK 2450 København SV www.auma.nl samireg@menara.ma
Tel +45 33 26 63 00
GS@g-s.dk SIGUM A. S. MANZ INCORPORATED LTD.
www.g-s.dk NO 1338 Sandvika NG Port Harcourt
Tel +47 67572600 Tel +234-84-462741
post@sigum.no mail@manzincorporated.com
www.manzincorporated.com
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
AUMA ACTUATORS INC. Al-Arfaj Engineering Co WLL AUMA Vietnam Hanoi RO

US PA 15317 Canonsburg KW 22004 Salmiyah VN Hanoi
Tel +1 724-743-AUMA (2862) Tel +965-24817448 +84 4 37822115
mailbox@auma-usa.com info@arfajengg.com chiennguyen@auma.com.vn
www.auma-usa.com www.arfajengg.com
Australia
Suplibarca TOO “Armaturny Center”
VE Maracaibo, Estado, Zulia KZ 060005 Atyrau BARRON GJM Pty. Ltd.
Tel +58 261 7 555 667 Tel +7 7122 454 602 AU NSW 1570 Artarmon
suplibarca@intercable.net.ve armacentre@bk.ru Tel +61 2 8437 4300
info@barron.com.au
Asia Network Engineering www.barron.com.au
LB 4501 7401 JBEIL, Beirut
AUMA Actuators UAE Support Office Tel +961 9 944080
AE 287 Abu Dhabi nabil.ibrahim@networkenglb.com
Tel +971 26338688 www.networkenglb.com
Nagaraj.Shetty@auma.com
50
AUMA worldwide
51
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
For detailed information on AUMA products refer to the Internet: www.auma.com

Part-turn gearboxes
GS 50.3 – GS 250.3
with base and lever
To be used in combination with the operation instructions only!

● The present short instructions do NOT replace the operation instructions!
● They are only intended for persons already familiar with the operation instructions
where safety instructions, assembly, operation and commissioning are already described
in detail!
● The operation instructions must always be available!
Short instructions Assembly

Table of contents

1. Short description................................................................................................................... 3
2. Assembly................................................................................................................................ 4
2.1. Gearbox: mount and secure 4
2.2. Lever position: adjust 5
2.3. Lever arrangement: mount 6
3. Technical data......................................................................................................................... 8
3.1. Features and functions 8
4. Spare parts............................................................................................................................. 9
4.1. Part-turn gearbox GS 50.3 – GS 125.3 with base and lever 9
4.2. Part-turn gearbox GS 160.3 – GS 250.3 with base and lever 11
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
Description of the four different versions (view on housing cover):
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
2.1. Gearbox: mount and secure
Danger of jamming due to moving parts!

→ Prior to mounting, check whether there are no space constraints. The actuator
or other parts must be outside of the lever swivel range.
→ Provide protective equipment.
Modification of lever range caused by vibration!

→ Mount the lever gearbox on a firm, rigid, and vibration-free surface in such a
way as to prevent any relative movements between the base and the fixing
element.
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
[1] Tube to valve

[2] Swing lever
2. Thoroughly clean and degrease mounting surfaces.
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
2.2. Lever position: adjust

By re-placing the lever, the lever position may be changed in steps if required.
Information For more precise (adjustable) setting, the lever position can also be changed by
changing the swing angle via the gearbox end stop. Refer to operation instructions.
Figure 2: Lever position adjustment
[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
3. Secure swing lever with circlip [1].
5
Assembly
2.3. Lever arrangement: mount

Ball joints suitable for swing lever including lock nuts and welding nuts are available
on special order with AUMA.
Figure 3: Lever arrangement with ball joints
[1] Ball joint

[2] Lock nut
[3] Welding nut
[4] Tube
[5] Valve lever
[6] Swing lever
[7] Crown nut
[8] Cotter pin
1. Insert ball joint [1] into bore at swing lever [6], fix with crown nut [7] and secure
against removal using cotter pin [8].
2. Insert the second ball joint [1] into bore at valve lever [5], fix with crown nut [7]
and secure against removal using cotter pin [8].
3. Fasten both welding nuts [3] on ball joints [1] until half the thread length.
Information: Respect minimum thread engagement (Xmin = 1 x thread diameter).
4. Move lever gearbox and valve into the same end position.
5. Ensure that valve lever [5] and swing lever [6] are perpendicular.
6. Measure tube length required and shorten the tube to the length needed.
7. Unscrew welding nut [3] from both ball joints and weld to the tube.
Information: Apply corrosion protection after welding work.
8. Tighten lock nut [2] and tube [4] into ball joint at swing lever.
9. Remove second ball joint [1] from valve lever [5], tighten lock nut [2] and screw
ball joint into tube.
10. Insert the second ball joint [1] into valve lever [5], fix with crown nut [7] and se-
cure against removal using cotter pin [8].
6
Assembly
11. Adjust suitable length by turning the tube.

Information: When using the ball joints supplied, one ball joint has a
right-handed thread, the other a left-handed thread.
Information: When adjusting the length, make sure that angle α min. or α max.
are neither undercut nor exceeded.
Figure 4: Permissible angle deflection
α Angle deflection
β Angle depending on valve
➥ The limits for angle β must be defined by the valve manufacturer.

Table 3:
Permissible angle deflection
Type α min. α max.
GS 50.3 – GS 100.3 30° 150°
GS 125.3 37° 143°
GS 160.3 – GS 250.3 (small clearance M1) 45° 135°
GS 160.3 – GS 250.3 (large clearance M2) 33° 147°
12. Tighten both lock nuts [2] at tube [4].
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).
3.1. Features and functions
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

513.1 Grub screw
519.1 Worm wheel
546.0 Base flange Sub-assembly
547.0 Swing lever
S1 Seal kit Set
10
Spare parts
4.2. Part-turn gearbox GS 160.3 – GS 250.3 with base and lever
11
Spare parts

513.1 Grub screw
519.1 Worm wheel
536.0 Protective cap Sub-assembly
537.0 Lock nut Sub-assembly
546.0 Base flange Sub-assembly
547.0 Swing lever
S1 Seal kit Set
12
13
14
15
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
For detailed information on AUMA products, refer to the Internet: www.auma.com

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
order13358811
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 : 32 32 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 : 52,0 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-regulating 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 : DE-AL German, aluminium
Oper. instructions : DE German
Inspect. accord. KV: 01.03.200.01 inspect. record/decl.of
compl.
Motormerkmale
Article number : Z100.831
Type designation : AD0R063-4-0,20
Type of current : 3ph-AC
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
Nominal voltage [V]: 380

Nominal freq. [Hz]: 50
Nominal power [kW]: 0,200
Nominal speed [rpm]: 1.400
Power factor : 0,420
Nominal current [A]: 1,600
Starting current[A]: 4,600
Type of service : S4-25%ED
Type enclosure IP: 68
Insulation class : F
Thermal protection : 1T-140
Motorart : 9
pos 2
article GS. 125.3
description AUMA worm gearbox
Produktmerkmale
Mounted to : 1:SAR 07.6
Explosion protect. : 0 not suitable for use in
poten-tially explosive
atmospheres
Duty classes : DC1 motor operation: DC1,
accord. to EN15714-2
Version : GF 125.3-208:1 lever gearbox with primary
reduction gearings
Mounting position : A
Version : LR input shaft clockwise: clock-
wise rotation of valve shaft
Reduction ratio : 208:1
Swing angle [*]: 92 degrees, 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 : 5600 5600 Nm output torque
Max. mod. torque : 2000 2000 Nm
Max. input torque : 73 73 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 : DE-AL German, aluminium
Oper. instructions : DE German
Inspect. acc. to KV: 02.03.014.01 inspect. record/works certif.
Technical data sheet Page: 2 of 2

HRV 63S-1600/K
13.4 Operating instructions for coupling
Coupling type RUPEX
Coupling size () RWN 360

FLENDER RUPEX®
couplings
Types RWN, RWS, RWB, RBS
and RFN, RFS
Operating instructions
BA 3600 en 02/2016
FLENDER couplings
Technical data 1
FLENDER RUPEX® 2
Notes
couplings
Fitting 3
Types RWN, RWS, RWB, RBS Start-up

and RFN, RFS and operation 4
Faults, causes
and remedy 5
Operating instructions
Maintenance
Translation of the original operating instructions and repair 6
Stocking spare parts 7
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.
WARNING! Imminent personal injury!
The notes indicated by this symbol are given to prevent personal injury.
Disregarding these notes may result in serious injury or death.
WARNING! Imminent damage to the product!
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.
WARNING! Hot surfaces!
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.
Note on the EC Machinery Directive 2006/42/EC

Siemens couplings in the "FLENDER couplings" product range must be treated as "components" in the sense
of the EC Machinery Directive 2006/42/EC.
Therefore, Siemens needs not issue a declaration of incorporation.
Information on safe fitting, safe startup and safe operation can be found in this instructions manual; in addition
the "warningnote concept" therein must be observed.
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.
1.1 Speeds, geometric data and weights
U2
S
P U1
1 2
NL1 NL2
∅ND2
∅ND1
∅DA
∅D1
∅D2
Fig. 1: Types RWN and RWS
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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
1) Maximum bore with keyway to DIN 6885/1.
2) Weights are valid for maximum bores.
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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
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1 S 20
P U1
L1
∅DFN
∅ND1
∅DFA
∅DFK
NL1
∅D1
∅DA
ZF x ∅DFB
FB
Fig. 3: Types RFN and RFS
Table 3: Types RFN and RFS

Maximum
Speed Weight 2)
bore 1)
Size nmax. D1 DA ND1 NL1 P S U1 DFA B FB DFN L1 DFK ZF DFB m m
RFN RFS RFN RFS H7 RFN RFS
1/min 1/min mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm kg kg
105 7000 10000 32 32 105 53 45 30 2 ... 4 13 158 23 10 142 6 9 2.3 2.3
125 6000 9000 40 42 125 65 50 35 2 ... 4 16 180 28 13 160 6 11 4.2 4.2
144 5250 7800 45 50 144 76 55 35 2 ... 4 16 200 28 13 180 7 11 5 5
162 4650 6900 50 55 162 85 60 40 2 ... 5 20 220 34 13 200 8 11 7.3 7.3
178 4200 6300 60 70 178 102 70 40 2 ... 5 20 248 34 16 224 8 14 10 10
198 3750 5600 70 80 198 120 80 40 2 ... 5 20 274 34 16 250 8 14 13 13
228 3300 4900 80 85 228 129 90 50 2 ... 5 26 314 42 20 282 8 18 20 20
252 3000 4400 90 100 252 150 100 50 2 ... 5 26 344 42 20 312 8 18 25 25
285 2650 3900 100 110 285 164 110 60 3 ... 6 32 380 51 22 348 9 18 38 38
320 2350 3500 110 125 320 180 125 60 3 ... 6 32 430 51 25 390 9 22 50 50
360 2100 3100 120 135 360 200 140 75 3 ... 6 42 480 66 25 440 10 22 76 76
400 2050 2800 140 150 400 230 160 75 3 ... 6 42 520 70 50 380 4 480 10 22 125 125
450 1800 2500 160 170 450 260 180 90 4 ... 7 52 575 80 45 428 6 528 12 26 170 175
500 1600 2200 180 190 500 290 200 90 4 ... 7 52 620 80 45 475 6 570 12 26 205 210
140 165 250 330 330
560 1450 2000 180 200 560 300 220 120 4 ... 8 68 700 100 65 532 8 650 16 26 330 340
200 210 320 340 340
140 165 250 390 390
630 1280 1800 180 200 630 300 240 120 4 ... 8 68 785 100 60 602 8 725 16 33 400 400
220 235 355 420 420
160 190 290 550 550
710 1150 1600 200 220 710 330 260 140 5 ... 9 80 875 120 80 675 10 815 18 33 550 560
240 250 385 570 580
180 210 320 680 690
800 1000 1400 220 240 800 360 290 140 5 ... 9 80 1000 120 70 765 10 930 16 39 690 710
260 280 420 710 730
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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.
Table 4: RUPEX buffer
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
2.1 Safety instructions and general notes

All persons involved in the installation, operation, maintenance and repair of the
coupling or clutch must have read and understood these instructions and must
comply with them at all times. Disregarding these instructions may cause damage to
the product and material and/or injury to persons. Damage caused by disregard of
these instructions will result in exclusion of liability.
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
Tel.: +49 (0)2871 / 92-0

Fax: +49 (0)2871 / 92-2596
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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
Coupling part 2 bears the marking .

Coupling part 3 is manufactured without a marking. Coupling part 3 is part of the Brake module and must
be certified by the manufacturer of the brake.
The marking is in one or two lines.
If, in addition to the CE mark, the letter "U" together with the Siemens order number has been stamped
on, the coupling part has been delivered by Siemens un or prebored.
Siemens supplies unbored and prebored couplings with CE marking only under the
condition that the customer assumes the responsibility and liability for correct
refinishing in a declaration of exemption.
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
• Equipment group I (underground applications) of the category M2.

• Explosion group IIA or IIB in case of electrically insulating flexible elements.
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.
The machines connected by the coupling must be earthed by an earth leakage

resistance < 106 Ω.
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)
Fig. 4: Machining the finished bore

1) Coupling part 1 and coupling part 2
2) Coupling part 3
Table 6: Fit recommendation for bores with parallelkey connection
Push fit Press fit Interference fit
Description
not suitable for reversing operation suitable for reversing operation
Shaft tolerance j6 h6 h6 k6 m6 n6 h6
Bore tolerance H7 J7 K7 H7 H7 H7 M7
The fit assignment m6 / H7 is particularly suitable for many applications.
Failure to observe these instructions may result in breakage of the coupling.
Danger from flying fragments!
The coupling then becomes an explosion hazard.
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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).
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!
Demount buffers (5).

Protect seals for the input and output side against damage and heating to over + 80 °C.
(Use heat shields to protect against radiant heat.)
The coupling parts (1; 2; 3) must be fitted in hot condition and, depending on the shrink dimension, heated
to the temperature indicated on the dimensioned drawing.
Heating may be done inductively, in a stove or with a burner.
Burner an heated coupling parts form an explosion hazard, therefor there must not be
an explosible atmosphere when fitting the coupling parts.
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.
3.8 Possible misalignments
Smax. Smax.
ΔKr
ΔKa
ΔKw
Smin. Smin.
1) 2) 3)
Fig. 5: Possible misalignments

1) Axial misalignment (ΔKa)
2) Angular misalignment (ΔKw)
3) Radial misalignment (ΔKr)
3.8.1 Axial misalignment

The gap dimension ΔKa should be set within the deviation permitted for the dimension "S" (see section 1).
3.8.2 Angular misalignment
The angular misalignment ΔKw can be measured as difference of the gap dimension (ΔS = Smax. – Smin.)
ΔSperm., see table 8.
If required, the permissible angular misalignment ΔKw can be calculated as follows:
ΔKwperm. in RAD = ΔSperm. / DA ΔSperm., see table 8.
ΔKwperm. in GRAD = ΔSperm. / DA x 180 / π "DA" in mm, see section 1.
3.8.3 Radial misalignment
The permissible radial misalignment ΔKrperm. can be found in table 8 (depending on the operating speed).
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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.
BA 3600 en 02/2016
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3.11 Assignment of the tightening torques and wrench widths
The use of an impact screwdriver is not permissible!
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.
4. Startup and operation
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.
If it is to be used below ground in potentially explosive areas, the coupling, which is

made of cast iron or steel, must be provided with a robust casing to preclude the risk
of ignition from e.g. friction, impact or friction sparks.
The depositing of heavy metal oxides (rust) on the coupling must be precluded by the
casing or other suitable precautions.
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.
BA 3600 en 02/2016
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5. Faults, causes and remedy
5.1 Possible cause of fault

Change in alignment:
─ Rectify the cause of the change in alignment (e.g. loose foundation bolts).
─ Align the coupling.
─ Check the axial fastening and, if necessary, adjust.
─ Wear check, procedure as described in section 6.
Buffers (5) worn:
─ Check wear of the buffers (5) as described in section 6; if necessary replace the buffers (5).
5.2 Incorrect use

Through incorrect use the coupling may become an explosion hazard.
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.
BA 3600 en 02/2016
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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
6.1 Maintenance interval

The torsional backlash between the two coupling parts must be checked after three
months, then at least once a year.
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.

6.2 Replacement of wearing parts

Loosen and remove the heaxagonhead nuts (7) and demount bolts (4) and buffers (5) through the buffer
bores (up to coupling size 400).
Loosen and remove the heaxagonhead nuts (11) and demount bolts (4) and buffers (5) and disks (8)
through the buffer bores (from coupling size 450 on).
After removing the locking ring (12) and the washer (6) the buffers (5) can be removed through the buffer
holes (from coupling size 710 upwards without removing the bolts).
Pull off the buffers (5) and carefully clean the bolts (4) and fitting holes.
The buffers (5) must be replaced in sets. Only identical buffers (5) may be used.
After replacing the buffers (5), assembly is carried out in the reverse order, the screws (11) being resecured
with threadlocking medium "mediumfirm" (e.g. Loctite 243). The selflocking hexagon nuts (7) must be
replaced with new hexagon nuts (7) of the same quality.
For reassembly, the instructions in sections 3 and 4 must be observed.
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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.
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.
BA 3600 en 02/2016
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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).
Observe manufacturer's instructions for using forcingoff/detaching device and

pumps.
Fit the detaching device.

Secure coupling part (1; 2; 3) and detaching device, using suitable lifting equipment!
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.
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7. Stocking spare parts
7.1 Spare parts

For ordering spare parts state the following data, as far as possible:
• Siemens order number and position
• Drawing number
• Coupling type and coupling size
• Part numer (see spareparts list)
• Bore, bore tolerance, keyway and balancing as well as particular characteristics such as
flangeconnection dimensions, intermediateshaft length, brakedrum dimensions.
• Any special details such as temperature, electrically insulating.
Table 12: Spareparts list
Type RWN, RWS Type RWB, RBS Type RFN, RFS

Part Part Part
num Designation num Designation num Designation
ber ber ber
1 Coupling part 1 1 Coupling part 1 1 Coupling part 1
2 Coupling part 2 3 Coupling part 3 4 Bolt
4 Bolt 4 Bolt 5 Buffer
5 Buffer 5 Buffer 6 Washer
6 Washer 6 Washer 7 Hexagon nut, selflocking
7 Hexagon nut, selflocking 7 Hexagon nut, selflocking 8 Washer
8 Washer 101 Screw plug 1) 11 Hexagonhead bolt
11 Hexagonhead bolt 301 Screw plug 1) 12 Locking ring
12 Locking ring 20 Coupling part 20
101 Screw plug 1) 101 Screw plug 1)
201 Screw plug 1)
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
Fig. 7: Screw plug
BA 3600 en 02/2016
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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)
Fig. 8: Spareparts drawing

1) Types RWN, RWS
2) Types RWB, RBS
3) Types RFN, RFS
4) Screw connection with bolts in case of sizes 105 to 400
Up to size 360 the buffers are arranged on one side in coupling part 1. From size 400 onwards
the buffers are located within coupling parts 1 and 2.
BA 3600 en 02/2016
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8. Declarations
8.1 EU declaration of conformity
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
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Further Information:
"FLENDER gear units" on the Internet
www.siemens.com/gearunits
"FLENDER couplings" on the Internet

www.siemens.com/couplings
Service & Support:

http://support.automation.siemens.com/WW/view/en/10803928/133300
Lubricants:
http://support.automation.siemens.com/WW/view/en/42961591/133000
Siemens AG Subject to modifications

Industry Sector
Mechanical Drives © Siemens AG 2012
Alfred-Flender-Straße 77
46395 Bocholt
GERMANY
www.siemens.com/drivetechnologies
HRV 63S-1600/K
13.5 Operating instructions for temperature sensor

rt rt ws ws
PT 100
rt = red
ws = white
Kinds of connections of the resistance thermometer

 Two-core circuit
The connection has to be made via one red and one white care lead each. The two other care leads
have to be cut off.
 Three-core circuit
The connection has to be made via two red and one white core lead each. The second white core lead
has to be cut off. The two red core leads are bridged at the precision resistance for measurement
purposes.
 Four-core circuit
The connection has to be made via all four core leads whereas the two white as well as the two red
care leads are bridged at the precision resistance for measurement purposes.

HRV 63S-1600/K
13.6 Erection drawing

A-301113-0
A-301542-0
A-283993-4

Ausführen Anlage Plannummer Abteilung Zeichnung Nr.
Stückliste Blatt
1/5 A-301542-0
bill of material Page
manufacture plant number department drawing number
Komm. Nr / Kunde Projekt Zeichnungs Benennung Änderungsstand
Loesche GmbH Düsseldorf Mounting schema - Rotor unit 0

12300051/120 Montagezeichnung - Läufereinheit
Bim Son Clinker drawing discription revision
Änderung / revision bearbeitet / prepared
order no. / purchaser project Zeile Rev. Datum Name geprüft Datum / date Name / name
ges. Masse line rev. date name checked
( kg ) 08.07.2016 JAN
total weight geprüft / checked
Datum / date Name / name
13346
Lieferung bei
Pos. Nr. supplied by Rev. Menge Benennung / Gegenstand / BxHxL Masse Werkstoff / Norm Bemerkung/ id. Nr.
( kg )
Oelde
Client
pos. no. rev. Quant. designation / subject / BxHxL weight material / norm remarks/ id. Nr.
Venti
Fan casing 7693,0 1.0425

10 X 1 4551x3214x4921 1.0038 A-301509-0
Gehäuse . 7693,0 1.8974
Hexagon head screw 0,21
20 X 164 M20x65-8.8 Cs/galv. ISO 4017
Sechskantschraube . 33,95
Washer 0,02
30 X 328 B20 Cs/galv. ISO 7090
Scheibe . 5,64
Hexagon nut 0,06
40 X 164 M20-8 Cs/galv. ISO 4032
Sechskantmutter . 10,56
Sealing cord 0,02
50 X 109 d=8 Isoglas braided cord A-301542-0
m Dichtschnur . 2,18
Non located bearing 100,30
60 X 1 430x650x250 1.0038 A-301538-3
Loslagerbock . 100,30 (S235 JRG2)
Located bearing 167,90
70 X 1 755x850x300 1.0038 A-302418-3
Festlagerbock . 167,90 (S235 JRG2)
Rotor unit complete 2485
80 X 1 2070x3422 lg.
Läufereinheit komplett . 2485
Inlet nozzle part 1 108,80
90 X 1 D=1733/1579x350 1.0425 A-301523-4
Einströmdüse Teil 1 . 108,80 (P265GH)
Inlet nozzle part 2 129,00
100 X 1 D=1576/1244x456 1.8928 A-250200-3
Einströmdüse Teil 2 . 129,00 (S690QL)
110 X 20 M16x40-8.8 Cs/galv. ISO 4017
Washer 0,04
120 X 20 A17 Cs/galv. DIN 9021
Scheibe . 0,82
Shaft passage 15° 36,00
130 X 1 DW=105-135 1.0425 A-212063-3
Wellendurchführung 15° 36,00 1.0038
Shaft passage 0° 35,60
140 X 1 DW=165-180 1.0425 A-216893-3
Wellendurchführung 0° 35,60 1.0038
Hexagon nut 0,02
150 X 32 M12-8 Cs/galv. ISO 4032
Washer 0,02
160 X 32 A13 Cs/galv. DIN 9021
Scheibe . 0,71
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170 X 8 M12x35-8.8 Cs/galv. ISO 4017
Washer 0,01
180 X 8 B12 Cs/galv. ISO 7090
Scheibe . 0,05
Hexagon nut 0,02
190 X 8 M12-8 Cs/galv. ISO 4032
200 X 8 M12x50-8.8 Cs/galv. ISO 4017
Washer 0,01
210 X 8 B12 Cs/galv. ISO 7090
Scheibe . 0,05
Protection cone 7,20
220 X 2 D=105-135 Zincor A-221278-2
Schutzkonus . 14,40
Perforated guard plate 1,20
230 X 2 D=606, t=2 1.0226 A-221314-4
Lochblech zum Schutzkonus . 2,40 (DX51D+Z)
Protection cone 9,60
240 X 2 D=165-180 Zincor A-221375-2
Schutzkonus . 19,20
Perforated guard plate 1,70
250 X 2 D=750, t=2 1.0226 A-221397-4
Lochblech zum Schutzkonus . 3,40 (DX51D+Z)
260 X 22 M8x20-8.8 Cs/galv. ISO 4017
Washer 0,00
270 X 44 B8,4 Cs/galv. ISO 7090
Scheibe . 0,08
Hexagon nut 0,01
280 X 22 M8-8 Cs/galv. ISO 4032
290 X 8 M12x20-8.8 Cs/galv. ISO 4017
Washer 0,01
300 X 8 B12 Cs/galv. DIN 7090
Scheibe . 0,05
Coupling protection hood 9,90
310 X 1 480x320x462 1.0226 A-302417-3
Kupplungsschutzhaube . 9,90 (DX51D+Z)
Shaft protection hood 4,30
320 X 1 380x80x367 1.0226 A-301535-3
Wellenschutzhaube . 4,30 (DX51D+Z)
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Bracket for proximity sensor 0,70

330 X 1 260x50x100 1.0038 A-283225-4
Konsole für Nährungsschalter . 0,70 (S235 JRG2)
340 X 8 M8x25-8.8 Cs/galv. ISO 4017
Washer 0,00
350 X 16 B8,4 Cs/galv. ISO 7090
Scheibe . 0,03
Hexagon nut 0,01
360 X 8 M8-8 Cs/galv. ISO 4032
Inductive sensor 0,50
370 X 1 NI15U-M18M-VP44X-H1141 Fa. Turck
Nährungsschalter . 0,50
Switch vane 0,20
380 X 1 D=60/150 1.0038 A-214232-4
Schaltfahne . 0,20 (S235 JRG2)
390 X 4 M20x130-8.8 Cs/galv. ISO 4014
Washer 0,02
400 X 4 B20 Cs/galv. ISO 7090
Scheibe . 0,07
Hexagon nut 0,06
410 X 8 M20-8 Cs/galv. ISO 4032
Mounting plates for bearing SNOE 218 0,09
420 X 4 pl.8x45x40 1.0038 A-259643-4
Montageplatten für SNOE 218 . 0,35 (S235 JRG2)
set Shims for SNOE 218 pedestal bearing housing 10,80 Cs/galv.
430 X 1 pl.430x170 1.0038 A-223744-4
Satz Unterlegbleche für SNOE 218 Lagergehäuse . 10,80 (S235 JRG2)
440 X 2 M20x120-8.8 Cs/galv. ISO 4014
Hexagon nut 0,06
450 X 2 M20-8 Cs/galv. ISO 4032
460 X 4 M30x160-8.8 Cs/galv. ISO 4014
Washer 0,05
470 X 4 B30 Cs/galv. ISO 7090
Scheibe . 0,21
Hexagon nut 0,22
480 X 8 M30-8 Cs/galv. ISO 4032
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Mounting plates for bearing SNOE 224 0,13

490 X 4 pl.8x60x50 1.0038 A-259644-4
Montageplatten für SNOE 224 . 0,54 (S235 JRG2)
set Shims for SNOE 224 pedestal bearing housing 15,30 Cs/galv.
500 X 1 pl.570x185 1.0038 A-285166-4
Satz Unterlegbleche für SNOE 224 Lagergehäuse . 15,30 (S235 JRG2)
510 X 2 M20x100-8.8 Cs/galv. ISO 4014
Hexagon nut 0,06
520 X 2 M20-8 Cs/galv. ISO 4032
Resistance thermometer 0,50
530 X 2 PT-100 TMT 80 Endress & Hauser
Widerstandsthermometer . 1,00
Motor 0
540 X 1
Motor . 0
Motor base plate 492,00
550 X 1 1200x1000x60 1.0038 A-301750-2
Motorsohlplatte . 492,00 (S235 JRG2)
set Filling plates for motor 5,30
560 X 4 240x170 1.0038 A-299990-4
Satz Ausgleichsbleche für Motor . 21,20 (S235 JRG2)
570 X 4 M30x120-8.8 Cs/galv. ISO 4017
Washer 0,05
580 X 4 B30 Cs/galv. ISO 7090
Scheibe . 0,21
590 X 8 M20x110-8.8 Cs/galv. ISO 4014
Hexagon nut 0,06
600 X 8 M20-8 Cs/galv. ISO 4032
Actuator 125,00
610 X 1 SAR07.6-32/GF125.3/VZ4.3 AUMA
Stellantrieb . 125,00
Linkage assembly for actuator 18,60 Cs/galv.
620 X X 1 lg.=3100 1.0038 A-302421-3
Verstellgestänge für Stellantrieb . 18,60 (S235 JRG2)
Bracket for actuator 30,80
630 X 1 300x450x120 1.0038 A-286368-3
Konsole für Stellantrieb . 30,80 (S235 JRG2)
640 X 4 M16x80-8.8 Cs/galv. ISO 4017
A-301542-0.xlsx
Stückliste Blatt
5/5 A-301542-0

( kg ) 08.07.2016 JAN
13346
Lieferung bei
( kg )
Oelde
Client
Venti
Washer 0,01
650 X 8 B16 Cs/galv. ISO 7090
Scheibe . 0,09
Hexagon nut 0,03
660 X 8 M16-8 Cs/galv. ISO 4032
Anchoring for actuator 0,47
670 X 4 M20 HILTI
Verankerung für Stellantrieb . 1,88
Louver damper 911,00
680 X 1 NW 1600 A-301542-0
Regelklappe . 911,00
Anchoring center guide 56,70 Cs/galv.
690 X X 1 M20x500 1.0038 A-275024-2
Verankerung Mittenführung . 56,70 (S235 JRG2)
Anchoring M30x630 37,60 Cs/galv.
700 X X 8 with thermal expansion 1.0038 A-190638-4
Verankerung M30x630 . 300,80 (S235 JRG2)
710 X 4 M30x100-8.8 Cs/galv. ISO 4017
720 X X 8 without thermal expansion 1.0038 A-283993-4
730 X 8 M20x80-8.8 Cs/galv. ISO 4017
740 X X 6 without thermal expansion 1.0038 A-269398-4
750 X 4 M30x120-8.8 Cs/galv. ISO 4017
A-301542-0.xlsx

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High efficiency centrifugal fan

Assembly and Operating instructions

Project: Bim Son Clinker

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1 Fundamental safety instructions ...................................................................3

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1 Fundamental safety instructions

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1.1 Special Safety Information

Caution, hot surfaces!

Warning of danger. Be sure to read and observe this information first.

Useful information and supplementary information

Attention! Electrical voltage

Attention! Automatic start of rotating parts

Attention! Hot surfaces

Secure against reactivation during repair

Information on explosion protection.

Observe the operating instructions!

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3 Area of Application and Correct Use

Gas handled: Air

Type of dust: Cooler Exhaust Air

Mass flow of dust: 3124 kg/h

Max. dust concentration: g/m³

The maximum permissible temperature of the handled medium is 450.

Restriction of the permissible service environment

Limitation of the permissible rotating speed range

Rotating speed range Limitation

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4 Design and Method

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Use only hoists with adequate lifting capacity!

For transport of rotor unit please

General storage conditions for machines and machine parts

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 Check the place of installation for

Screwing down the fan / baseframe on an uneven foundation warps the

Follow the assembly drawings! A-301113-0, A-301542-0, A-283993-4

 Tools and accessories

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 Set of thickness gauges (from 0.05 mm)

Attachment as in The housing must not be fixed. A clearance of at least 2.0

Assemble the rotor (impeller, shaft, bearings and shaped inlet)

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Changes in the shaft length which occur by temperature differences

Setting on the upper section of the housing

Adjusting the inlet ring

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Mounting of the shaft seal

 Check that the shaft is running smoothly.

Mount all protective equipment!

Locking- and regulating flap

 Tighten the flanged screws evenly in order to avoid stresses.

6.1 Electrical Connection

When connecting the electric components, please observe the following:

 Regulations according to VDE (Association of German Electro-Engineers) Guidelines 0100.

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7.1 Checklist for maintenance, servicing and commissioning