Omm - GK-X Manual 2-0

Operating and Maintenance Manual GK-X
All Contents Copyright © 2021 – Appropriate Process Technologies. All Rights Reserved.
This manual being the APT GK-X and GK-X with Automation Operations and Maintenance
Manual is for use with supplied equipment only. The information in this manual is furnished for
informational use only, is subject to change without notice, and nothing contained herein shall
be construed as conferring any licence or right under any APT copyright, patent or trademark.
Although the specifications, features, illustrations, equipment and other information contained
in this manual are based upon up-to-date information, and while APT makes all reasonable
efforts to ensure that all material is correct, accuracy cannot be guaranteed and APT makes
no warranties or representations as to its accuracy and assumes no responsibility or liability
for any errors or inaccuracies that may appear in this book. Reference to non-APT products
or services are for informational purposes only and constitute neither an endorsement nor a
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Written and designed by Appropriate Process Technologies, 218 New Market Road,
Northlands Commercial Park, North Riding 2162 South Africa
Printed in South Africa
Revision Number 2.0 (05/21)
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Table of Contents
1. Introduction ............................................................................................................... 1
1.1. What is a GK-X and how does it work? ............................................................... 1
1.2. When should a GK-X be used? ........................................................................... 2
1.3. What is the GK-X Automation System? ............................................................... 2
2. Safety ............................................................................................................................................. 3
2.1. General Safety Precautions ................................................................................. 3
2.2. Transport and Hoisting ........................................................................................ 4
3. Installation ..................................................................................................................................... 5
3.1. Receiving ............................................................................................................ 5
3.2. Preparation of Foundations ................................................................................. 5
3.3. Removal from Shipping Crate.............................................................................. 5
3.4. Installation on Site ............................................................................................... 5
3.4.1. Installing Concentrator ................................................................................. 5
3.4.2. Installing Control Panel (Auto Version) ......................................................... 5
3.4.3. Removal of Shipping Locks .......................................................................... 6
3.5. Assembly of Additional Components ................................................................... 6
3.5.1. Water Supply................................................................................................ 6
3.5.2. Electrical Supply and Wiring ......................................................................... 7
3.5.3. Slurry Feed................................................................................................... 8
3.5.4. Air Piping (Auto Version) .............................................................................. 9
4. Operation ..................................................................................................................................... 11
4.1. Introduction ....................................................................................................... 11
4.1.1. Reminders and Cautions ............................................................................ 11
4.1. Checks Prior to Start-up .................................................................................... 12
4.1.2. Hardware Pre-checks ................................................................................. 12
4.1.3. Manual model Pre-checks .......................................................................... 12
4.1.4. Software Pre-checks for Auto (if fitted) ....................................................... 12
4.2. Start-up Procedure ............................................................................................ 13
4.1.5. Manual option............................................................................................. 13
4.1.6. Auto option ................................................................................................. 13
4.3. Concentrate harvesting ..................................................................................... 14
4.1.7. Concentrating Cycle Duration ..................................................................... 14
4.1.8. Manual Option ............................................................................................ 15
4.1.9. Auto Option ................................................................................................ 15
4.1.10. Parameter settings (Auto Option) ............................................................ 16
5. General Maintenance ................................................................................................................. 17
5.1. Drive Belt........................................................................................................... 17
5.2. Bearings ............................................................................................................ 17
5.3. Rotating union ................................................................................................... 17
5.4. De-silting fluidisation lines ................................................................................. 17
5.5. Cone and rotating assembly .............................................................................. 18
5.6. Feed tube liner .................................................................................................. 18
5.7. Maintenance Schedule ...................................................................................... 19
5.8. Other equipment................................................................................................ 19
5.9. Replacement Parts List ..................................................................................... 20
5.10. Long term storage .......................................................................................... 20
Appendix .............................................................................................................................................. 21
6. A1 GK-X Specification Sheet ................................................................................... 22
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About this manual

This instruction manual is intended for clients of APT who are purchasing or installing a
GK-X ® Concentrator, manual and automated versions. It is divided into 5 sections:
Section 1: Introduction
Section 2: Safety
Section 3: Installation
Section 4: Operation
Section 5: Maintenance
Document Conventions
WARNING – Indicates a source of danger in connection with the installation or
operation of the equipment.
Prohibition of an action or activity in connection with a source of danger, the

disregarding of which may result in serious accidents.
Command to perform an action or task associated with a source of danger, the

disregarding of which may result in serious accidents.
Indicates that the operator should read a specific section of the manual before
commencing work on a particular area
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1. Introduction
1.1. What is a GK-X and how does it work?
• A GK-X is a fluidized gravity concentrator for the recovery of liberated precious metals
(gold, silver, platinum) from milled ore and alluvial slurry. Nominal capacity is 10-15
tph of solids at -3mm size.
• The GK-X is designed to be economical by using modern materials. Instead of over-

engineering, the GK-X designers have allowed for easy and economical replacement
of all wearing parts. Poly plastic and fibreglass components are used extensively for
long life, lower cost and corrosion resistance.
• The GK-X incorporates several advanced features to result in a highly efficient yet
simple platform for precious metal recovery. Its design is the result of extensive
engineering and metallurgical research, testing and field trials to give you a highly
effective product.
• The incoming slurry is distributed to via a feed funnel into a specially designed cone
incorporating a centrifugal riffle which results in efficient capture even when black
sands are present. The centrifugal riffle begins the capture process at the base of the
cone. The slurry then travels up the sides of the cone over a series of inclined rings
where the higher density particles are trapped. The riffles are fluidised with water to
prevent packing. The tailings finally exit to the tailings launder over the top of the cone.
• At regular intervals the feed and the bowl rotation are stopped, and the rich gold
concentrate is washed from the riffles into the bottom of the bowl. The concentrate is
then washed down through two discharge pipes to a concentrate collection vessel.
• The GK-X is a fluidized bed concentrator, which requires the water used to be clean
and free from sediment.
• The GK-X has low power requirements.
1
1.2. When should a GK-X be used?

As a low-cost concentrator, the GK-X can be used in the following situations:
• In conjunction with an APT RG scrubbing plant in alluvial applications.

• In conjunction with a ball mill to recover fine free gold liberated in the mill.
Figure 1: The GK-X Concentrator (Auto version shown)
1.3. What is the GK-X Automation System?

GK-X Auto is the automated and secure control system that accompanies the GK-X when
specified.
The GK-X Auto system ensures there is no unauthorised access to the concentrates
generated during the run cycle. All concentrates are automatically discharged at pre-set
intervals into a locked concentrate box sitting beneath the GK-X. The security cage and
concentrates box are unlocked at end of day and the concentrate box is taken to the gold
room for upgrading and smelting of the concentrates. The run time interval is pre-set by the
mine operator and password protected. The GK-X Auto also logs run time to allow owners and
operators to see a record of daily use and total use.
Combined with APT’s alluvial and hard rock plants, small to medium scale miners are now
able to run a secure operation on a budget with the peace of mind, knowing that gold recovered
remains yours.
2
2. Safety
The GK-X is designed for operation by trained professionals in a stationary and stable
installation. This equipment must be operated in accordance with the instructions in this
manual. Any use other than described requires prior written approval from APT.
2.1. General Safety Precautions
WARNING – Attempting to operate the GK-X without reviewing the instructions

contained in this manual could result in serious personal injury and/or
equipment damage.
Never operate the GK-X without the belt guard in place.
Always disconnect the GK-X from the water system before maintenance work
Always use the “Locked Out, Tagged Out” procedure for work on the machine
to ensure that the power is off
Always wear eye protection, ear protection and a hard hat when working on or
around the GK-X
Automated machines may start up at any time and must be considered ‘live’
unless disconnected from power and locked out.
Always comply with manufacturers’ operating, maintenance and safety

manuals for OEM equipment.
3
2.2. Transport and Hoisting

The GK-X is usually shipped crated or on a wooden pallet. It can be easily transported using
a light delivery vehicle. When lifting the GK-X, use only approved lifting methods and tools.
Always lift the GK-X by the steel framework. Always use all lifting lugs with
correct chain lengths to ensure balanced lifting.
Do not attempt to lift the machine by attaching chains around the bowl, piping,
electrical or any of the plastic components or the domed launder structure.
Always disengage locking pins and lifting straps and remove lifting cables or
slings before attempting to start the system.
4
3. Installation
The GK-X and any associated equipment has been designed with the intention of making
installation as fast as possible, requiring a minimum amount of machinery and on-site
assembly. Please consult APT if you need any clarification or are unsure of the procedures.
3.1. Receiving
When removing the equipment from its packing, take care to account for all parts and check
against the packing slip. Any damage to the GK-X, associated components or shortages from
the packing list must be noted on the bill of lading before signing for delivery. This will prevent
controversy and expedite any claims for adjustment that you may need to pursue with the
carrier.
3.2. Preparation of Foundations

The GK-X requires a level base. Extensive foundations or plinths are not normally necessary,
but a brick base or thin concrete screed may be used to provide a level surface and assist
with quick installation and cleanliness of site thereafter. The GK-X must be bolted down to the
ground via the four drilled tabs on the base frame.
If you have ordered a complete Crusher/Concentrator plant from APT including the GK-X, (e.g.
RG100 wash plant) the framework will include a base for the GK-X to sit on.
3.3. Removal from Shipping Crate

The GK-X and any associated equipment are usually shipped mounted on a wooden pallet
and enclosed by a wooden frame in an almost fully assembled form. The crate can be broken
open and the equipment unscrewed from the wooden pallet.
3.4. Installation on Site
3.4.1. Installing Concentrator

The GK-X can now be installed in the prepared location. Lift the GK-X into place and orientate
it correctly. Using a spirit level across the square base frame in both directions to check the
frame is horizontal. Use small shims to pack under the corners of the frame if it needs to be
levelled. Anchor the concentrator down to the base or support frame using 4x M16 bolts or
concrete anchors
3.4.2. Installing Control Panel (Auto Version)

The Auto panel for the GK-X is supplied on a free-standing frame and must be located within
1m of the concentrator in an easily accessible position. The panel should also be located away
from extremely wet or dusty areas.
5
3.4.3. Removal of Shipping Locks

The GK-X has a wooden block inserted into the cone to hold the concentrating bowl steady
during shipping. This block must be removed before starting the concentrator.
WARNING – Attempting to operate the GK-X with the shipping block in place
can cause permanent damage to the concentrator.
3.5. Assembly of Additional Components

The GK-X is either supplied as a standalone unit or part of a complete system. For complete
systems you will either have an APT commissioning crew, or you will have been trained on
how to assemble the units. If you are buying the GK-X as a standalone unit you will require
water and slurry piping to be attached. Please consult the relevant sections for installation of
the equipment provided.
3.5.1. Water Supply

The GK-X is provided with a water supply connection which requires water at the specified
pressure and flow, see Table 1 below.
APT recommends that the water is supplied from a dedicated pump and
pipeline which supplies the concentrator only. Other off-takes on the water line
can cause the water pressure to fluctuate and affect recovery.
If the module has been supplied with a water pump(s), the client must supply water to the
tank/pond at a flow rate to meet demand plus contingency, 2 times plant requirement is
recommended.
WARNING:The water supply pressure to the GK-X feed must not exceed 3 bar.
Table 1: GK-X Water Requirements
Variable Units
Water Supply / Hose Connection mm 40mm Hose Swage
Typical water requirement* m3/h 4–6
Water pressure bar 2–3
*Water requirement is for a single GK-X only, excluding additional process equipment.
The GK-X fluidisation inlet must be fed clean water. Poor water conditions may require the
water to be cleaned (filtered) before use.
6
Connect the water feed to the inlet of the water piping on the GK-X, as shown in the figure
below
Figure 2: GK-X Water Piping (Auto version shown)
3.5.2. Electrical Supply and Wiring

The GK-X requires a three-phase power supply to the 4 kW motor. Where the client supplies
main line electricity or a generator, the electrical connection must be carried out by suitably
qualified personnel observing local codes.
WARNING: To prevent personnel injury or equipment damage, all wiring

connections must be properly isolated. Proper safety lockouts must be
installed and observed. Electrical voltages and frequency specified for the
system must be adhered to within a 10% tolerance, otherwise any electrical
warranties will be void. All electrical connections to and within the system must
be performed by qualified and authorised persons, taking local codes into
consideration.
The voltage/frequency requirements for the system must be specified on order and is clearly
labelled on the control panel.
Standard supply is 400V, three phase, 50Hz power supply. Certain countries are provided
with 60Hz units
The motors are generally reliable units but are susceptible to variations in
current, voltage and frequency. As a result, no warranty can be given or implied
on the electric motor. APT recommends having a spare electric motor on site.
7
For manual units, the power supply must be connected to the motor terminal box and routed
through a Direct-online (DOL) contactor to control the motor ON/OFF. Follow the wiring
diagram included inside the motor terminal box to wire the motor correctly (Δ/Y) according to
the site voltage.
For units supplied with an Auto control, the power supply is connected to the control panel.
The incomer terminals are located in the bottom left of the control box and labelled for the
correct wiring.
Figure 3: Control panel wiring
3.5.3. Slurry Feed

The slurry feed to the GK-X should be screened before feeding the concentrator, to remove
any coarse material or scrap steel which can damage the cone. A 3mm screen is
recommended.
The slurry feed line to GK-X must have a means of control to turn it off or divert it during the
concentrate purge cycle.
For manual units, the slurry feed line must have a valve installed in the line, within easy reach
of the operator. The valve should be located with less than 2m of slurry line between the valve
and the concentrator to minimise the amount of material draining into the concentrator after
the valve is shut. A knife-gate or butterfly valve is recommended.
Auto units are supplied with a pneumatic knife-gate valve which is controlled by the Auto
control panel. The valve must be installed by the client by bolting it between two flanges in the
slurry feed pipeline. The valve must be close to the control panel which is fitted with a fixed
length of pneumatic air piping and control wiring to operate the valve.
8
Figure 4: GK-X Slurry Piping
If the slurry supply to the concentrator is continuous, the client must provide
piping to accommodate this flow when the GK-X valve is shut for concentrator
purges. An overflow, head tank or diversion pipe must be fitted.
3.5.4. Air Piping (Auto Version)

The Auto system controls the water and slurry valves using pneumatic air. The airlines and
solenoids to control them are connected at the control panel through a flexible trunking, but
have been disconnected from the valves for shipping. The client must also connect the
compressed air supply line. A typical workshop air compressor which meets the supply
requirements below is suitable. All electrical connections and switchgear for the control panel
must be installed by the client separate from the GK-X
Table 2: GK-X Auto Air Requirements
Variable Units GK-X

8mm OD Nylon “Festo” air
Air supply connection
pipe
Typical air requirement CFM 6 cfm (180 litres/min)
Air pressure bar 5 – 8 bar
The airline and control cable for the slurry valve is fitted with a flat mounting plate for attaching
to the valve. The cable must be connected to the solenoid by pushing the terminal block onto
the solenoid lugs, and the air pipe into the connector on the solenoid.
9
Figure 5: Slurry valve connections
The airline and control cable for the Auto water valve is fitted with an angled mounting plate
for attaching to the valve. The cable must be connected to the solenoid by pushing the terminal
block onto the solenoid lugs, and the air pipe into the connector on the solenoid.
Figure 6: Auto water valve connections
A third air line is fed through the control panel, which is for the air supply and must be
connected to the Client’s compressor outlet.
Figure 7: Auto water valve connection points
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4. Operation
4.1. Introduction
Operation of the GK-X system is relatively straightforward and should require minimal
adjustment after initial setup.
4.1.1. Reminders and Cautions
4.1.1.1. Personnel Safety
All operators of the equipment must be properly trained and knowledgeable about the
equipment
Ensure that no one is working on or around the equipment before starting up
Operators must wear Personal Protective Equipment (PPE). Hard hat, safety boots
and safety goggles are recommended. Dust masks may be required when operating in dry
conditions.
4.1.1.2. Piping
WARNING: All piping in the system carries water or slurry under elevated
pressure. All piping connections and flanges must be tight and sealed.
4.1.1.3. Wiring
WARNING: To prevent personal injury or damage to the machine:
• All wiring connections must be properly isolated.

• Be sure that voltages and wiring are correct and match nameplates on
electric motors.
• When working on the drives in the system engage proper safety lockouts
to ensure the power is off and prevent electric shocks.
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4.1. Checks Prior to Start-up
4.1.2. Hardware Pre-checks

1. Before starting the GK-X, ensure it is placed on a firm and stable foundation.
2. Check the concentrating bowl turns freely by rotating it by hand before starting the
motor.
3. Check all rotating parts are clear of obstruction.
4. Check water supply, air supply and power are available and operating.
5. Place the concentrate box in position under the GK-X.
6. Lock all necessary parts (concentrates box, concentrates cage).
4.1.3. Manual model Pre-checks

1. Turn on electrical supply to the motor.
2. Check the rotation direction of the bowl is correct, by looking through the inspection
port on the GK-X housing.
3. If the direction is incorrect, stop the motor immediately, isolate the power and change
the direction by re-wiring the motor terminals.
4. Start the water supply to the GK-X and open the Manual Pressure Valve halfway.
Check that the Fluidisation Water Pressure gauge reads 2 – 3 bar (30 – 45 psi) with
valve open.
4.1.4. Software Pre-checks for Auto (if fitted)

1. Turn on electrical supply to the control panel
2. On the GK-X interface, select ‘Manual’ on the screen. This brings up a page where
each function of the GK-X can be controlled individually to test the machine.
Figure 8: Startup Screen - Auto/Manual Selection
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Figure 9: Manual Operation Screen
3. Toggle each of the features on and off for a 5 second interval to check functionality.
4. When the motor starts, check the rotation direction of the bowl is correct, by looking
through the inspection port on the GK-X housing.
The Manual option should not be used to run the concentrator under regular
operating conditions
5. Return to the Main Menu, then select the “Auto” option. Tap on “Settings” and follow
the steps in Section 4.1.10 to set the parameters to their typical values as a starting
point.
4.2. Start-up Procedure
4.1.5. Manual option

1. Turn on the electrical supply to the motor, and the fluidisation water pump.
2. Open the manual pressure valve to three quarters position.
3. Start the motor.
4. Adjust the manual pressure valve so that the Cone Pressure Gauge shows 0.35 bar
(approx. 5 psi) water pressure into the cone.
5. Open the slurry valve slowly and begin feeding material into the concentrator.
6. After 2 minutes of feeding, re-adjust the manual pressure valve so the gauge reads
0.35 bar.
7. Run for desired cycle time. During the cycle, the Cone Pressure may increase slightly
as the cone fills with heavy material. This is normal and expected.
4.1.6. Auto option

1. Turn on the electrical supply to the control panel.
2. On the GK-X interface, select ‘Auto’.
3. Select “Settings” and check that the adjustable times parameters are correct
4. Select ‘Run’. The control panel will automatically start the motor, open the Auto water
valve, and open the slurry valve.
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5. Adjust the manual pressure valve so that the Cone Pressure Gauge shows 0.35 bar
(approx. 5 psi) water pressure into the cone.
6. After 2 minutes of feeding, re-adjust the manual pressure valve so the gauge reads
0.35 bar.
7. Run for desired cycle time. During the cycle, the Cone Pressure may increase slightly
as the cone fills with heavy material. This is normal and expected.
Figure 10: Auto control page
4.3. Concentrate harvesting
4.1.7. Concentrating Cycle Duration

During a cycle, the Cone Pressure may increase slightly as the cone fills with
heavy material. This is normal and expected. However, if pressure exceeds
0.70 bar (10 psi) this indicates blocked fluidisation nozzles, water pressure too
high, or a packed bed of solids in the cone.
Concentration of free milling gold and other precious metals is optimum for a limited period.
Beyond this it is necessary to stop the concentrator and drain the concentrate.
The period between concentrate purges depends on several factors such as:
• Feed rate of the ore/slurry to the machine
• Grind size of the ore being fed to the machine (Coarser particles fill the riffles more
readily)
• Content of gold and other heavy minerals in the ore
It is necessary to determine the optimum concentrating cycle for each ore individually. This is
easily carried out by collecting and panning a bucket sample of the tails every 10 minutes after
start-up. When free gold just begins to show up in the pan, it is an indication that the cycle is
just past optimum, so reduce by 10 minutes. A typical concentration cycle is one hour, but this
may vary.
14
For small custom milling operations or where the ore changes frequently, it is
good practice to repeat this operation daily, and for each different ore batch.
Each purge of the GK-X concentrator will produce about 10kg of concentrate, together with a
significant amount of water (approx. 50 – 100 litres). Ensure the concentrate collection vessel
has sufficient capacity to collect the material and water, and is able to drain the excess water
off once the concentrate has settled.
4.1.8. Manual Option

1. Stop the slurry feed by closing the Slurry Valve and wait about 10 seconds to allow slurry
to drain out the feed pipe and cone.
2. Turn off the GK-X motor and whilst rotation is running down simultaneously decrease the
Manual water valve so both stop at about the same time.
3. Reopen the Manual water valve fully for 10 seconds to flush concentrate out the rings.
4. Close the valve and allow 20 seconds or so for the concentrates to drain through the base.
5. Repeat steps 3 and 4 to flush the cone for a second time.
6. Re-open the Manual Pressure Valve to three-quarters position and re-start the motor.
7. Open the slurry valve slowly and begin feeding material into the concentrator.
8. After 2 minutes of feeding, re-adjust the manual pressure valve so the gauge reads 0.35
bar.
4.1.9. Auto Option

1. The concentration cycle duration (in minutes) is programmed into the control panel. Once
this time is reached, the GK-X will automatically start a concentrate flush.
2. The Slurry Valve to the GK-X will shut off, followed by the motor and Auto water valve
after a few seconds.
3. When rotation has stopped, the Auto water valve will open for a set time, usually 10
seconds, to flush the concentrates from the riffles.
4. The Auto water valve will close, then a second flush will initiate.
5. After the concentrates have drained down into the holding box, the Auto water valve will
re-open, then the cone rotation will start.
6. After 8 seconds, slurry feed may be re-started, the Auto slurry valve will open, and a new
concentration cycle begins.
There are delays programmed into the cycle time of 1 – 10 seconds between
stages. If the concentrator appears to be inactive, allow the timer to complete
before opening or inspecting. If in doubt, select “Sequence Status” from the Auto
panel to check the current stage of concentrator
15
4.1.10. Parameter settings (Auto Option)

The duration of the concentrating cycles, and flush times, can be adjusted on the control
system by accessing the “Settings” page from the Auto Menu
Figure 11: Settings screen
There are three parameters that can be set on the control system. The first column of numbers
shows the current time in the current cycle, the second column allows the values to be
changed. The settings are protected by a password to prevent unauthorised changes.
The access password is eight ones i.e. 11111111
Table 3: Parameter Values
Parameter Name Function Typical values
This is the duration

60 min
of the concentrating
T1 Run Time
cycle between
This should be determined according to
flushes
the procedure in Section 4.4.1
10 sec
This is the duration
that the Auto water
During setup, inspect the cone through
valve is open to
T2 Rinse Time the hatch after a flush cycle to check if
wash out the
the cone is clean. Increase time if the
concentrates during
cone still retains material, decrease time
a flush
to reduce water in the concentrate
hopper
This is the time

5 sec
duration after closing
T3 Drainage Time the Auto water valve
During set-up adjust this time so that the
in a concentrate flush
concentrates collection pipe runs clear
before restarting
and empties before the GK-X restarts
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5. General Maintenance
The GK-X requires minimal maintenance; however, some regular attention such as greasing
of bearings will ensure a long, trouble free life.
Observe all necessary safety precautions when carrying out maintenance on the
machine.
5.1. Drive Belt

The GK-X uses a V-belt to drive the rotor. The machine is equipped with a belt tensioner which
will maintain tension on the belt during regular operation. The condition of the belt should be
inspected to ensure it is not cracked or wearing.
5.2. Bearings
The bearings will require regular greasing intervals to keep them serviceable. They should be
greased on a weekly interval. The standard bearing grease used in all bearings is Shell Alvania
EP2 or equivalent. Give only one or two pumps of the grease gun: this will be sufficient if the
greasing interval is adhered to.
Many bearing failures occur when bearings push excess grease around the
inside of the bearing case, generating excess heat. Do not over-grease.
5.3. Rotating union

Grease very sparingly at regular intervals. Check for water leaks and replace if necessary.
Refer to the OEM User manuals for the rotating union for additional servicing
information
5.4. De-silting fluidisation lines

Over time, fine silt from the water supply or slurry enters the fluidisation lines and builds up in
the water piping and rotating union. This needs to be flushed out periodically (typically weekly),
depending on how dirty the water supply is.
1. Stop and flush the GK-X, then isolate it from the mains supply.
2. Open the valve or plug at the base of the rotating union extending out the side of the
base frame.
3. Clean out the in-line water filter basket, replace the screen if necessary.
4. Open one of the eight silt exit hole caps on the top ring.
5. Fit the flushing hose connector supplied.
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6. Back-flush the line with high pressure water for a few minutes.
7. Whilst flushing, poke out each of the four fluidisation nozzles with the tool provided.
Note they migrate down the cone in a clockwise spiral, view under the cone if
necessary to identify.
8. When the back flush water is running out of the rotating union freely and clean, turn off
the back flush water, remove the hose connector and replace the silt cap, being careful
not to over tighten.
9. Repeat on each of the other silt caps and lines.
10. Close the drain valve on the rotating union or replace cap under the rotating union.
If fluidisation nozzles become oversized or broken, remove using the tool provided to depress
the locking face of the Festo coupling and pull the nozzle out. Replace, pointing the hole
counter-clockwise (opposite to rotation). Push firmly home to lock.
5.5. Cone and rotating assembly

The cone is manufactured from glass fibre with an internal rubber wear coating. The
manufacture has been designed to be light and economical to replace.
Periodically the cone will wear and will require to be replaced. The entire cone plus bearings
and shaft is replaced as a single unit, including the fluidisation pipes plus silt nozzles. Only the
silt exit nozzles can be ordered as separate items.
5.6. Feed tube liner

The upper lid includes the feed tube, and this has a Poly liner wear insert that will need to be
replaced periodically.
18
5.7. Maintenance Schedule

A sample maintenance schedule is given below. Use this as a guide only. Depending on the
ore type processed, total operating hours and operating conditions, the maintenance intervals
can be adjusted as necessary.
Daily
Start-up
Before
Start-up
After
Hourly
Weekly
Monthly
6 Months
Lubrication or Maintenance Item
Remove dirt and spillage from around the GKX

•
frame and motor
Check tightness of all nuts and bolts •
Check electrical cable is complete and
•
terminated correctly
Check for any unusual sounds or vibrations after
•
starting. Some vibration is normal
Check feed tube wear liner, replace if necessary •
Inspect V-belt for wear and re-tension if
•
necessary
Grease bearings, incl. rotating union, check
•
union for leaks
Inspect plant 3mm feed screen. Replace mesh
•
as required
Check compressed air filter and water trap if
•
fitted
Check cone, replace assembly if necessary •
5.8. Other equipment
Refer to the OEM User manuals for other maintenance and lubrication
requirements of equipment in the plant such as the electric motor and Auto
valve
19
5.9. Replacement Parts List

Part Name Model No
Air Torque
Auto Water Valve
AT201U-D-B
Spraying Systems Co
Water Strainer
AA430SC 1½” BSP
Deublin
Rotating Union
555-000-198
22213K
Shaft Bearings SNU513 Housing
H313 Taper Sleeve
Tensioner Bearings 2x F204
Drive Belt 2x SPA 1580
5.10. Long term storage

If you are storing the GK-X for an extended period or in freezing conditions, it is recommended
that you disconnect the water supply and drain the central water piping of all water. Leave all
water taps in the open position.
Every month during storage, rotate the bowl by hand a couple of revolutions to move the
bearings and maintain their grease coatings.
20
Appendix
GK-X Specification Sheet
Electrical Wiring Diagram (for Auto Models)
Operating and Maintenance Manual – Deublin Series 55 Rotating Union
Service Guide – Deublin Series 55 Rotating Union
Operating and Maintenance Manual – AirTorque Valve (Auto Models)
21
6. A1 GK-X Specification Sheet

Edition Date
APPROPRIATE PROCESS TECHNOLOGIES 2.0 05/21
www.aptprocessing.com GK-X
info@aptprocessing.com Model: MkII
Specification Sheet
FEED CAPACITY (MAY VARY DEPENDING ON

10-15 tph
MATERIAL):
WATER REQUIREMENT: 4-6 m3/hr, 3 bar MAX
CONCENTRATES PER PURGE: APPROX. 10 kg
POWER (DRIVE MOTOR): 4 kW, 3ph
MAXIMUM FEED SIZE: 3 mm
SCREEN SIZE: PASSING -3mm
AUTOMATED ACTUATION: PNEUMATIC
OVERALL DIMENSIONS: 1000 x 1174 x 1335mm
APPROXIMATE SHIPPING DIMENSIONS:
GK-X CONCENTRATOR 375 kg (1400 x 1400 x 1590mm)
CONTROL PANEL (AUTO MODELS ONLY) 160 kg (1790 x 640 x 860mm)
NOTE:
SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE
22
Model/Series:
54, 55 & 57
O P E R ATI N GOperating
MA NUA L
Manual Number: GB

Version:

040-550
2017-07
Rotating Unions
Series
54 55 57
Model
54 55 57
154 155 157
254 255 257
354 355 357
524 525 527
554 555 557
655 657
755 857
Exception: The present Operating Manual is not applicable for the following models. Those are de-
scribed in particular Operating Manuals.
040-550-1 555-413-xxx 040-550-2 655-969-xxx 040-550-3 55-283-xxx
655-905-xxx 155-339-xxx
655-921-xxx 255-156-xxx
655-952-xxx 355-062-xxx
525-171-xxx
555-087-xxx
555-542-xxx
Rev. Hi4 Page 1 of 18 ©DEUBLIN

Model/Series:
54, 55 & 57
Operating Manual Number: GB
040-550
Version:
2017-07
Content
1 For your Safety_________________________________________________________________ 3

1.1 Intended Use___________________________________________________________________ 3
1.1.1 Application one-way version (Mono)_______________________________________________ 4
1.1.2 Application two-way version (Duo)_________________________________________________ 5
1.2 Misuse_________________________________________________________________________ 5
1.3 Safety Instructions_______________________________________________________________ 6
1.3.1 Hazards due to hot surfaces______________________________________________________ 6
1.3.2 Hazards by improper hoses_______________________________________________________ 6
1.3.3 Hazards due to the media________________________________________________________ 6
1.3.4 Hazards by faulty installation______________________________________________________ 6
1.4 Structure of Pictograms__________________________________________________________ 7
2 Information as to this Manual____________________________________________________ 7
3 Information on the Name Plate___________________________________________________ 7
4 Information on the Design _______________________________________________________ 8
4.1 Filtering of the Medium___________________________________________________________ 8
4.2 Connecting Options of the Rotating Union at the Machine Shaft_______________________ 8
4.3 Options of Hose Installation ______________________________________________________ 8
4.3.1 Connection of hose to the rotating union___________________________________________ 9
4.3.2 Hose connection in case of additional axial movement of the machine shaft____________ 9
4.3.3 Hose connection for hoses with SAE flange________________________________________ 10
4.3.4 Optional: Connection of a leakage line____________________________________________ 10
5 Installation____________________________________________________________________ 11
6 Information on the Operation____________________________________________________ 11
7 Storage______________________________________________________________________ 11
8 Maintenance__________________________________________________________________ 11
8.1 Maintenance Intervals___________________________________________________________ 11
8.2 Daily Inspection________________________________________________________________ 12
8.3 Maintenance after Operating Hours_______________________________________________ 12
8.3.1 Allowed lubricants______________________________________________________________ 13
8.3.2 Volume of grease for lubrication__________________________________________________ 13
8.3.3 Relubrication intervals for series 55 and models 857________________________________ 13
8.3.4 Relubrication intervals for 55 Hot Package series___________________________________ 15
8.3.5 Lubricate the rotating union______________________________________________________ 15
9 Trouble Shooting______________________________________________________________ 15
9.1 Potential Causes for Errors and their Elimination____________________________________ 15
9.2 Pack Rotating Union for Transport________________________________________________ 16
10 Disposal_____________________________________________________________________ 17
10.1 Dispose of Packaging___________________________________________________________ 17
10.2 Dispose of Rotating Union_______________________________________________________ 17
11 Spare Parts___________________________________________________________________ 17

Model/Series:
54, 55 & 57
040-550
Version:
2017-07
1 For your Safety

This chapter provides information on the safe handling of DEUBLIN rotating unions.
❑❑ For your own safety and the safety of other people read this operating manual carefully and
completely prior to working on or with DEUBLIN rotating unions.
❑❑ This operating manual exclusively describes the rotating unions of the manufacturer DEUBLIN.
In the further description/explanation the name “DEUBLIN” is left out for a better readability.
❑❑ This operating manual is a material part of the specified rotating unions. The operator is re-
sponsible for the personnel to take note of this manual.
❑❑ Always use the latest version of the operating manual, available under www.deublin.eu.
❑❑ The operator of the rotating unions shall not make any modifications or attachments to and
retrofitting of the rotating union without the manufacturer’s consent.
❑❑ Please follow the additional instruction „Installation“ for a secure and corrrect installation of the
rotating union. The installation instruction is included with the delivered union.
1.1 Intended Use

The rotating unions of the series 54, 55 and 57 supply the feeding of the following media: Water, steam
(not for series 55 Hot Package), thermal oil
Medium
Temperature
Series Model Steam (short-term
range (°C) Water Thermal oil
saturated steam)
54 up to 90° •
55 55 up to 655 up to 120° • • •
55 Hot Package 55 up to 655
1)
up to 160° • •
55 755 up to 120° • •
55 Hot Package1)
755 up to 160° •
57 up to 90° •
57 857 up to 120° •
1)
Hot Package models are suitable either for hot water or thermal oil.
The rotating unions referred to are designed for non-potentially explosive environments and non-
combustible media. Details on the operating range of the rotating unions are provided in the catalogue
and/or the model-specific installation drawing.
The rotating unions of the series 54, 55 and 57 can be used as one-way or two-way version depending
on the type of connection.
Please note: Several special models are available for the use of other media (e.g. air), but the present
operating manual does not apply to these models. Please contact DEUBLIN if you want to use other
media.

Model/Series:
54, 55 & 57
040-550
Version:
2017-07
1.1.1 Application one-way version (Mono)

For the one-way version, models are available which can be installed at the machine shaft from the
outside or in the machine shaft.
Rotating union externally mounted
B A
Fig. 1: Schematic diagram one-way version (Mono – externally mounted)

One one-way version of the rotating union is mounted at each of the two ends of the roller. The rotat-
ing union (A) conveys the medium into the roller. The rotating union (B) conveys the medium into the
piping system of the machine.
Rotating union in-the-shaft-mounted
B A
Fig. 2: Schematic diagram one-way version (Mono – in-the-shaft mounted)

One one-way version of the rotating union is mounted in each of the two ends of the roller. The rotat-
ing union (A) conveys the medium into the roller. The rotating union (B) conveys the medium into the
piping system of the machine.

Model/Series:
54, 55 & 57
040-550
Version:
2017-07
1.1.2 Application two-way version (Duo)

The rotating unions of the 54, 55 and 57
series are also available as two-way
model (Duo).
The two-way rotating union is fitted

with an axial connection at the elbow.
Through this elbow the medium is con-
veyed into the machine shaft through a
supply tube.
The return medium is absorbed by the

Fig. 3: Schematic diagram two-way version (Duo) same rotating union and conveyed
into the piping system of the machine
through the radial connection.
1.2 Misuse
This chapter provides information on known misuse of rotating unions of the 54, 55 and 57 series.
The rotating unions are not suitable for the areas and applications described herein. Use in such ar-
eas or for such applications constitutes a misuse endangering people and machines and is therefore
prohibited.
Prohibition for the following areas:

❑❑ Potentially explosive areas
The rotating unions of the 54, 55 and 57 series shall not be used in potentially explosive areas,
as they are not approved for the requirements in potentially explosive areas. Operation in such
areas may cause explosions.
❑❑ Food
Food, cleaning and disinfectant residues cannot be removed from the rotating unions. People
may suffer poisoning.
Prohibition for the following applications:

❑❑ Conveying of combustible media or hydrocarbons
Combustible media or hydrocarbons may ignite or cause explosions.
Exception: Thermal oil within the admissible temperature range. Please observe the safety
data sheet of the used thermal oil.
❑❑ Connection to a piping system with excessive pressure
If excessive pressure is applied to the rotating unions, supply pipes can come off and cause
personal injury or property damage.
❑❑ Operation without lubrication
Dry operation (without media) of the rotating union causes damage to the axial face seals.
❑❑ Connection to fixed pipes
If connection is via fixed pipes, the rotating unions may leak and the ball bearings may get
damaged.
❑❑ Conveying of media which are too hot
If the media exceed the maximum admissible temperature for the rotating union, the static
seals (elastomeric seals) can be damaged which may result in leaky rotating unions and per-
sonal injury or property damage.
❑❑ For series 55 only: Conveying continuous saturated steam
Escaping steam may injure people seriously.
❑❑ For series 54 and 57 only: Conveying saturated steam
Escaping steam may injure people seriously.

Model/Series:
54, 55 & 57
040-550
Version:
2017-07
This list is not comprehensive and will be updated with results from product observation.
1.3 Safety Instructions

This chapter provides information on the hazards through rotating unions.
1.3.1 Hazards due to hot surfaces

The rotating unions are heated by the temperature of the media. Skin contact with heated rotating
unions can cause injuries.
❑❑ Use safety gloves and PPE (Personal Protective Equipment) protecting against heat when han-
dling the rotating union.
❑❑ Attach a clearly visible danger sign visibly on/next to the rotating union in order to warn of
danger.
1.3.2 Hazards by improper hoses

For the connection of the rotating union to the machine, you have to choose appropriate hoses for the
respective medium, which meet, the specifications for the application.
If you use incorrect hoses, they may become porous or burst. This can cause personal injury and/or
property damage to components of the machine.
❑❑ In case of the media water, steam and thermal oil, use hoses which are suitable for the maxi-
mum system pressure of the machine and the maximum temperature of the media.
1.3.3 Hazards due to the media

When working on the rotating union, injuries can be caused by skin or eye contact with the media.
❑❑ Observe the safety instructions for the flow media. Observe the COSHH Safety Data Sheet for
the flow media.
1.3.4 Hazards by faulty installation

If the rotating unions are installed incorrectly, hoses and connections may become leaky. The medium
can escape. Depending on the medium, personal injury or property damage to the components of the
machine may occur.
❑❑ Before installing the rotating union ensure that no feed pressure and no residual pressure is
applied to the pipeline system of the machine.
❑❑ Install the rotating union on the machine using hoses only, in order to avoid stress on the rotat-
ing union.
❑❑ Install the hoses free from stress.
❑❑ Install the rotating union in a way that the leaking medium can be carried away securely down-
ward at the lowest point and that the drain line shows a fall (min. 15°).
❑❑ Install the hoses to the rotating union prior to mounting it at the machine shaft.

Model/Series:
54, 55 & 57
040-550
Version:
2017-07
1.4 Structure of Pictograms

This chapter provides information on the meaning of the pictograms used in the manual.
Warning
Potentially dangerous situation, which may result in death or serious injury.
Warning
Note
Potentially harmful situation, in which the product or surrounding objects can be dam-
aged.
Note
Application notes
and other useful information.
Info
2 Information as to this Manual

The copyright as to this manual remains with DEUBLIN. Subject to changes!
❑❑ You can download the latest version of this manual under www.deublin.eu.
❑❑ Always use the latest version of the operating manual.
3 Information on the Name Plate
Model number
DEUBLIN‘s internal identification / date of manufacture
MADE IN <<country of manufacture>>
Fig. 4: Name plate
The coding of the model number is described in the catalogue. The model number corresponds to the
order number.

Model/Series:
54, 55 & 57
040-550
Version:
2017-07
4 Information on the Design

This chapter provides information as to which items have to be observed in the design in order to have
a positive effect on the service life of the rotating union.
You can obtain the drawings of the rotating unions from DEUBLIN in order to integrate
the rotating union in your drawing.
Info
4.1 Filtering of the Medium

Unfiltered media with a particle size of more than 60 µm result in increased wear of the rotating union.
The larger the particles in the media, the higher the wear of the rotating union is. The
higher the total of all particles (polluting load), the higher the wear is.
Info
❑❑ Insert a filter in front of the rotating union which filters particles with a size of 60 µm and larger
from the media.
4.2 Connecting Options of the Rotating Union at the Machine Shaft
A B
Fig. 5: Options for the installation on the machine shaft
The rotating unions can be fastened on the machine shaft by screwing (A) or by means of a flange (B)
depending on the rotating union.
4.3 Options of Hose Installation

The following examples show how to install the hoses at the rotating unions.
These connecting options ensure that the hoses do not transfer stress to the rotating unions when the
machine shaft moves.
❑❑ Please pay attention to the chapter “1.3 Safety Instructions” regarding the design.

Model/Series:
54, 55 & 57
040-550
Version:
2017-07
4.3.1 Connection of hose to the rotating union

The hoses must be installed without stress and bends so that they do not apply any forces to the rotat-
ing union. The following figures show examples of installation.
If the rotating unions are installed with connections posi-

tioned horizontally, connect the hoses as shown.
Fig. 6: Connect hoses horizontally
If the hoses are to be guided away from the rotating unions

vertically and bent by 90°, connect the hoses as shown.
Fig. 7: Hoses bent by 90°
4.3.2 Hose connection in case of additional axial movement of the machine shaft
If the rotating unions are installed to machine shafts with an
oscillating (axial) movement, the hoses must be stress-free in
both extreme positions.
Fig. 8: Hoses laid in a curve

Model/Series:
54, 55 & 57
040-550
Version:
2017-07
4.3.3 Hose connection for hoses with SAE flange
Only possible, if the rotating union is ordered with SAE connections.
Info
The hoses are fastened at the rotating union by means of its

SAE flanges using four screws.
Fig. 9: Flange connection
4.3.4 Optional: Connection of a leakage line
Only possible, if the rotating union is externally mounted.
Info
In order to prevent surrounding components from being damaged by escaping medium, you can con-
nect a leakage line to the rotating union, if required.
The rotating unions are equipped with leakage holes.

❑❑ When used in dirty environment, we recommend to pro-
tect the leakage holes against penetrating dirt. You can
order sealing plugs at DEUBLIN. If you close the leakage
holes, you have to provide the rotating union with ventila-
tion, if applicable by means of a second leakage connec-
tion. Without ventilation the leaking medium cannot drain
off.
❑❑ Position the rotating union in a way that you can always
connect the leakage line in 6 o’clock position (at the lowest
point) to a leakage hole.
Fig. 10: Schedule connection of leakage line

Model/Series:
54, 55 & 57
040-550
Version:
2017-07
5 Installation
The union installation is described in an additional manual which is supplied with each rotating union.
Please follow the additional instruction “Installation” for a secure and correct installation of the rotating
union. The instruction “Installation” is available online under www.deublin.eu.
❑❑ Ensure that the person installing the rotating union receives the following information:
-- Position and location of the rotating union in the machine
-- Plan for connection of hoses
-- Position of leakage line
-- Information on the media
6 Information on the Operation

Damage to components due to missing lubrication (Dry run)
The axial face seals of the rotating unions are lubricated by the medium. If the rotating
unions are operated without medium present they are not lubricated and will thus be
Note damaged.
❑❑ Ensure that the rotating unions are operated with a medium.
❑❑ Switch off the plant/machine, if the rotating unions are operated without medium.
7 Storage
Damage of component due to incorrect storage
If you store the rotating unions incorrectly, they become leaky or get damaged.
❑❑ Store the rotating unions in a dry space between 3 °C and 40 °C.
Note ❑❑ Store rotating unions for two years at the most.
8 Maintenance
This chapter provides information on how to extend the service life of the rotating unions by means of
maintenance.
8.1 Maintenance Intervals

You can avoid early wear of the rotating unions, if you adhere to the maintenance intervals described
herein.
Risk of injury due to hot or cold surfaces

The rotating unions are heated or cooled by the temperature of the medium.
Skin contact with these heated or cooled rotating unions can cause severe injuries.
Warning
❑❑ Before starting to work on the rotating union, allow the machine to cool down.
❑❑ Use safety gloves and PPE (Personal Protective Equipment) protecting against heat
or cold depending on the application of the rotating unions.

Model/Series:
54, 55 & 57
040-550
Version:
2017-07
8.2 Daily Inspection

Check the rotating unions for tightness.
Risk of injuries due to applied line pressure

If you have to work on the rotating union and feed pressure of the medium is applied
or there is residual pressure in the piping system of the machine, the medium can es-
Warning cape under pressure when releasing the connections. You and other people may suffer
severe injuries.
❑❑ Ensure that no feed pressure is applied.
❑❑ Ensure that there is no residual pressure in the piping system.
During operation of the machine, leakages may occur at the

connections and hoses depending on the requirements to
the rotating unions.
1. Carry out daily visual inspections in order to check wheth-

er leakages occurred at the connections (see arrows).
If you detect leakage:

1. Stop the machine.
2. Replace the defective hoses with new ones.
3. Seal leaking connections.
Fig. 11: Inspect visually 4. If the rotating union is worn and leaks, replace it with a
new one. Repair kits for various models can be obtained
from DEUBLIN.
8.3 Maintenance after Operating Hours

This chapter describes how to relubricate the rotating unions.
The maintenance operations described below have to be executed in case of series 55

and 55 Hot Package only. Rotating unions of the series 54 and 57 are lubricated in the
factory for the entire service life.
Info ❑❑ The rotating unions are already lubricated in the factory and delivered ready-to-be-
installed.
The indicated volumes of grease and intervals for relubrication are based on experi-
ence resulting from the information of the manufacturer of the lubricant and the operat-
ing parameters of the rotating unions. The information given herein refers to operating
Info hours depending on the respective speed.
❑❑ In case of doubt, consult DEUBLIN.
Lubricate the ball bearings of the rotating unions at the stated lubricating intervals using the listed
volume of grease suitable for the operating conditions. If you do not adhere to these instructions, the
service life of the ball bearings is reduced.

Model/Series:
54, 55 & 57
040-550
Version:
2017-07
8.3.1 Allowed lubricants

Series allowed lubricants Series allowed lubricants
54 / 55 / 57 TEXACO CHEVRON SRI 2 55 Hot Package DUPONT KRYTOX XHTRUF
GREASE NLGI 2 KLÜBER BARRIERTA L55/0, L55/2
LUBCON TURMOTEMP II/400
8.3.2 Volume of grease for lubrication

Damage to the component due to excessive grease
If you put too much grease in the ball bearings, the latter can be damaged.
❑❑ Adhere to the stated volumes of grease for lubrication.
Note
Damage of part by loss of grease quality

If e.g. the grease for relubrication is supplied by a central lubrication system to the
rotating unions, the grease may lose its essential characteristics. The bearings of the
Note rotating unions will be damaged.
❑❑ Make sure only fresh new grease is fed to the bearings.
❑❑ Comply with the specifications for sevice life of the grease manufacturer.
Series Model Volume of grease (g) Series Model Volume of grease (g)
55 55 3.5 55 Hot Package 55 7
155 5.5 155 12
255 10 255 19
355 10 355 24
525 12 525 29
555 18 555 40
655 18 655 47
755 42
57 857 42
8.3.3 Relubrication intervals for series 55 and models 857

The intervals for relubrication depend on the operating conditions of the rotating unions.

Model/Series:
54, 55 & 57
040-550
Version:
2017-07
Relubrication intervals for light duty operating conditions

Light duty operating conditions are:
❑❑ Medium with a temperature of max. 75 °C
❑❑ Few vibrations
❑❑ Little humidity
❑❑ Hardly polluted environment
755/857
Model
Operating hours
Speed
Relubrication intervals for medium-heavy duty operating conditions

Medium-heavy duty operating conditions are:
❑❑ Medium with a temperature of 75 ° to 120 °C
❑❑ many vibrations
❑❑ much humidity
❑❑ extremely polluted environment
755/857
Model
Operating hours
Speed
Relubrication intervals for extreme operating conditions

If the operating conditions exceed the easy and medium-heavy operating conditions, the lubrication
interval, volume of grease and grease type have to be adapted to the application.
❑❑ Please consult your lubricant supplier.
Model/Series:
54, 55 & 57
040-550
Version:
2017-07
8.3.4 Relubrication intervals for 55 Hot Package series

Lubrication interval after commissioning
Lubricate the rotating union with the stated volume of grease and grease type after 1,000 operating
hours for the first time.
Subsequent lubrication interval

If you convey media with a temperature below 100 °C through the rotating union, you
do not have to relubricate the rotating union.
Info
Operating Conditions Subsequent lubrication intervals

from 100 ° to 150 °C after 6,000 operating hours
from 150 ° to 160 °C after 3,000 operating hours
8.3.5 Lubricate the rotating union

The following paragraphs describe how to place the grease
gun and inject the stated volume of grease into the ball bear-
ing.
1. Attach the grease gun to the lubricating nipple (see arrow).

2. Ensure that the connector of the grease gun is placed cor-
rectly on the lubricating nipple.
3. Actuate the grease gun in order to inject the stated volume
of grease into the ball bearing.
4. Count the operating hours for the following lubrication in-
terval.
Fig. 12: Attach grease gun for relubrica-
tion
9 Trouble Shooting
This chapter provides the following information:
1. Which problem may occur?
2. What can be the cause of the problem?
3. How can you eliminate this problem?
9.1 Potential Causes for Errors and their Elimination

Risk of injuries due to applied line pressure
If you have to work on the rotating union and feed pressure of the medium is applied or
there is residual pressure in the piping system of the machine, the medium can escape
Warning under pressure when releasing the connections. You and other people may suffer seri-
ous injuries.
❑❑ Ensure that no feed pressure is applied.
❑❑ Ensure that there is no residual pressure in the piping system.

Model/Series:
54, 55 & 57
040-550
Version:
2017-07
Error Potential causes Elimination

Rotating union is Incorrect installation 1. Stop the machine.
leaky after installation 2. Ensure that the connections are sealed ac-
cording to the manual “Installation”.
3. Ensure that all hoses are installed without
stress.
4. Ensure that all seal faces are clean.
Seal faces of the rotating 1. Pack rotating union.
union are damaged 2. Send rotating union to DEUBLIN for overhaul/
service.
Rotating union is defec-
tive
Rotating union leaks Medium is contaminated 1. Stop the machine.
before the end of the 2. Drain medium.
expected service life 3. Send rotating union to DEUBLIN for overhaul/
service, if required.
4. Mount new filter.
5. Flush the piping system of the machine.
6. Fill in new medium.
Rotating union is not de- 1. Ensure that the correct DEUBLIN Rotating
signed for the respective Union is used.
application 2. Contact DEUBLIN if required.
Rotating union runs Thread and/or concen- 1. Stop the machine.
untrue or wobbles tricity outside the admis- 2. Remove rotating union.
sible tolerance. 3. Manufacture new thread or flange.
4. Install rotating union.
Rotating union is mount-
ed incorrectly.
9.2 Pack Rotating Union for Transport

The rotating union has to be protected against mechanical impact and humidity during transport to
ensure that the rotating union will arrive at DEUBLIN without being damaged.
1. Dismount the rotating union in reverse order of the installation (see Installation).
2. Ensure that the rotating union is free from the respective media.
3. Use a cardboard box which is suitable for the weight of the rotating union.
4. Cushion the base of the cardboard box with a soft material, e.g. air bubble film.
5. Wrap the rotating union with a soft material, e.g. air bubble film.
6. Ensure that no packing material or dirt can penetrate the opening of the rotating union.
7. Position the rotating union in the middle of the cardboard box.
8. Fill the free space around the rotating union with newspaper or another suitable material.
9. Close the cardboard box by means of tape.

Model/Series:
54, 55 & 57
040-550
Version:
2017-07
10 Disposal
10.1 Dispose of Packaging
❑❑ Dispose of the packaging (cardboard box and plastics) according to the national standards,
regulations and directives.
10.2 Dispose of Rotating Union

Mainly, the rotating unions consist of metals, which can be reused within the reclamation of scrap.
Decontaminate unions / parts and dispose of in an “Environmentally Friendly” way.
❑❑ Dismount the rotating union in reverse order to the installation (see Installation).
❑❑ Flush the rotating union.
❑❑ Collect the dirty flushing media.
❑❑ Dispose of the collected flushing media according to the national standards, regulations and
directives.
❑❑ If you use thermal oil, please observe the instructions of the thermal oil manufacturer.
❑❑ Dispose of the rotating union according to the national standards, regulations and directives.
In case of repair, DEUBLIN disposes of all used parts.
11 Spare Parts
The rotating unions have a limited service life and include wearing parts. Wearing parts are excluded
from the warranty. All static and dynamic sealing elements of a component are considered wearing
parts, as well as ball bearings.
Repair kits are available for several models of the rotating unions and can be obtained from DEUBLIN.
Please ask your DEUBLIN Service.
You need special tools and repair instructions for repair of the rotating unions which can be obtained
from DEUBLIN as well.
Note
If you do not want to repair your rotating union on your own, DEUBLIN will be pleased
to help you. If requested, DEUBLIN will exchange all wearing parts and clean all com-
Info ponents of the rotating union. Before repaired rotating unions leave the premises, they
will be subjected to an operational check. The repaired rotating union is returned with
a standard “DEUBLIN Warranty” valid for 12 months.

Reliability
Many years’ experience, ongoing liaison with customers, innovations sourced

inhouse and from suppliers place DEUBLIN in a position providing
reliable Rotating Unions at the highest level.
When it comes to concrete applications, maximum service life is guaranteed
by matching the sealing to the respective medium.
The service life is also equally maximized by maintaining cleanliness when
storing and handling the Rotating Union and by adhering to the guidelines issued
by DEUBLIN in respect of the conditions on the customer’s premises.
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GB
IMAT 4thGU-E ISSUE: 05/11
INSTALLATION, MAINTENANCE AND OPERATING INSTRUCTION

MANUAL FOR 4TH GENERATION Upgrade Series ACTUATORS
For AIR TORQUE ACTUATORS Model/Type:

“AT045U” ➛ ”AT801U”
Double acting “D” and Spring return “S”
“90°” ➛ “180° Stroke”
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IMAT 4thGU-E
CONTENTS
1) GENERAL ......................................................................................... pag. 3
2) WARNING ......................................................................................... pag. 3
3) WORKING CONDITIONS AND TECHNICAL DATA ....................................... pag. 3
4) OPERATING FUNCTION AND DIRECTION OF ROTATION ............................ pag. 4
5) INSTALLATION INSTRUCTIONS ............................................................. pag. 4
6) MAINTENANCE INSTRUCTIONS ............................................................ pag. 5
7) STORAGE INSTRUCTIONS ................................................................... pag. 11
8) LIFTING AND HANDLING ..................................................................... pag. 11
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IMAT 4thGU-E
1) GENERAL sure that the rotation direction and the position

This instruction manual contains important information indicator are in the correct position.
regarding the installation, operation, maintenance and • If the actuator is incorporated in a system or used
storage for AIR TORQUE rack and pinion pneumatic actuators. within safety devices or circuits, the customer shall
Please read these instructions carefully and keep them ensure that the national and local safety laws and
for future reference. It is important that the use and regulations are observed.
maintenance of the actuator is made only by properly
trained personnel. 3) WORKING CONDITIONS AND TECHNICAL DATA
• Operating media:
 2) WARNING Dry or lubricated air or inert gases, provided that they
• Do not operate the actuator using inflammable, are compatible with the actuator internal parts and
oxidizing, corrosive, explosive or unstable gases lubricant. The operating media must have a dew point
or liquids (use only not dangerous fluids - group 2 equal to –20°C (-4°F) or at least 10°C below the ambient
according to 97/26/EC directive). Moreover, for temperature. The maximum particle size contained into
actuators installed in potentially explosive zones, the operating media must not exceed 30 µm.
make sure that the internal parts of the actuator do • Supply pressure:
not come into contact with the external atmosphere. The maximum supply pressure is 8 bar (116 Psi), only
• Referring to the Machinery Directive 2006/46/EC, for AT801U it is 7 bar (101,5 Psi).
the actuators can be classified as “PARTLY For double acting and spring return actuators the working
COMPLETED MACHINERY” (see the DECLARATION pressure is from 2.5 bar (36 Psi) to 8 bar (116 Psi).
OF INCORPORATION). Therefore the actuator can • Operating temperature:
not put into service until the machinery and/or the ==> “Standard” actuators from -40°C (-40°F) to +80°C
system, where the actuator is incorporated, will be (+176°F)
declared in compliance with the requirements of the ==> Actuators for high temperature “HT” from -15°C
Directive 2006/42/EC. (+5°F) to +150°C (+300°F)
• Air Torque actuators are designed, produced and ==> Actuators for extreme low temperature “LLT” from
classified according to the ATEX Directive 94/9/EC -55°C (-67°F) to + 80°C (+176°F)
(see actuator label and safety instructions). The use Caution: for low and high temperature service, special
of the actuators in potential explosive atmosphere grease and special components are required. Please
zones has to comply with the ATEX classification contact AIR TORQUE. Working at high or low temperature
indicated on the actuator label and according to the can affect the life and the output torque of the actuator.
ATEX safety instructions. • Operating time (see technical data sheet):
• The use, the installation and the maintenance of Caution: the operating time depends on several factors
the Air Torque actuators must be made by adequately such as supply pressure, supply system capacity (pipe
trained personnel. For the use, installation and diameter, flow capacity of pneumatic accessories), valve
maintenance of Air Torque actuators it is recom- type, valve torque and figures, applied safety factor,
mended to comply to the safety notice and to cycle frequency, temperature, etc.
use proper equipment to protect health and prevent • Rotation and stroke adjustment (see technical data
accidents. sheet):
• It is important that the actuator is used only within For standard actuators (90° rotation), 120° actuators
the working limits indicated in the technical specifi- (120° rotation), 135° actuators (135° rotation) and 180°
cations. actuators (180° rotation).
• Do not operate the actuator over temperature limits: Stroke adjustment at 0°(closed pistons): +15°max/ - 5°.
this could damage internal and external components Stroke adjustment at 90°, 120°, 135° and 180°(open
(disassembly of spring return actuator may become pistons): +5°/-15°max. For actuator AT045U the stroke
dangerous). adjustment at 90° (open pistons) is available only on
• Do not operate the actuator over pressure limits: this request.
could damage internal parts as well as cause damage • Lubrication:
to the housing and end-caps. The actuators are factory lubricated for the life of the
• Do not use the actuator in corrosive environments actuator in normal working conditions.
with incorrect protection: this could damage the The standard lubricant type GSTD is suitable for use
internal and external parts. from -40°C (-40°F) to +80°C (+176°F).
• Do not disassemble individual spring cartridges, this For extreme low temperature (LLT) and high temperature
may result in personal injury. If maintenance to (HT) service, special grease is required: please contact
springs is necessary, send them to AIR TORQUE. Air Torque.
• Close and disconnect all air supply lines and make • Construction: rack and pinion actuator design suitable
sure that air connections are vented during mainte- for both indoor or outdoor installations.
nance and installation on valve. • Protection and corrosion resistance:
• Do not disassemble the actuator or remove end All the actuators are supplied with corrosion protection
caps while the actuator is pressurized. for normal environments. For corrosion resistance of the
• The 4TH GENERATION Upgrade Series actuators are different types of protection see technical data sheet.
designed to be used only on valves. Before installing the actuator in aggressive environment,
• Before installing the actuator onto the valve make ensure that the selected protection level is suitable.
3
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IMAT 4thGU-E
• Actuator designation and marking (see technical data

SINGLE ACTING OPERATION FUNCTION
sheets): (STANDARD ROTATION TYPE “ST”) TOP VIEW
The actuator type, size, operating pressure, output
torque, direction of rotation, spring action, operating
temperature and type of connections/interfaces are
determined by designation.
• All AIR TORQUE actuators are supplied with an identifi-
cation label showing the serial number and all necessary
information on use, service, operation and product
designation. Where applicable, the label indicates the
classification according to ATEX Directive 94/9/EC.
4) OPERATING FUNCTION AND DIRECTION OF

ROTATION Air supplied to Port “2” forces the pistons toward the actuator end caps,
The actuator is a pneumatic device for remote opera- compressing the springs.
A counter-clockwise rotation is achieved. Exhaust air exits from Port 4.
tion of industrial valves. The operation (90°,120°,135° or
180° rotation) may be activated by different methods:
• Direct mounting of solenoid valve (5/2 for double acting,
3/2 for spring return) to pressure connections 2 and 4,
connected to supply and control lines.
• Screwed connection (to pressure connections 2 and 4)
with air lines from separate control cabinet.
The standard rotation (when port 4 is pressurized or
for spring action) is clockwise to close. When port 2 is
pressurized, counter-clockwise rotation is obtained.
Air Torque actuators can be supplied with different types
of assembly/rotation direction depending on the type of
required operation and/or installation, see technical data
sheets. The loss of air pressure (air or electric failure) at Port “2” allows the springs
to force the pistons inward.
A clockwise rotation is achieved.
DOUBLE ACTING OPERATION FUNCTION Exhaust air exits from Port 2.
(STANDARD ROTATION TYPE “ST”) TOP VIEW
5) ACTUATOR INSTALLATION INSTRUCTIONS
The Air Torque actuator is a pneumatic device for the remote
operation of industrial valves. The actuator will operate through
90°,120°,135° and 180° rotation permitting the opening and
closing of many types of valves up to 180° rotation.
All the necessary technical information to install the actuator
correctly and safely onto a valve i.e.:
Dimensions, Output torque, Supply pressure, Air volume,
Stroke adjustment, Operating time, Operating temperature,
Direction of rotation and Weight is stated clearly on the
Actuator label, in the catalogue and technical data sheets.
Please read all technical information before proceeding with
Air supplied to port 2 forces the pistons towards the actuator end caps. the actuator installation.
A counter-clockwise rotation is achieved.
 5.1) Important safety notice!

Exhaust air exits from Port 4.
• For safety reasons, the actuator must not be pressurized

at any time during installation as injury may result.
• The utmost cleanliness is required during air supply
connection to the actuator i.e. the connecting pipe
thread, fittings and seals must be clean and dirt-free.
• When fitting accessories onto the actuators, assemble
them in such a way that the emergency control of the
solenoid valve and the top of the drive shaft are easily
accessible, should emergency manual operations be required.
• Before fitting onto the valve, make sure that the actuator/
valve are correctly orientated, depending upon which
direction of rotation is required.
• For spring return actuators, avoid that dangerous and/or
Air supplied to Port 4 forces the pistons inward. corrosive substances in the working environment enter
A clockwise rotation is achieved. into the external chambers by using adequate filters
Exhaust air exits from Port 2.
and/or solenoid valves.
4
GB
IMAT 4thGU-E
• Remove plugs from actuator air connections during 5.4) Assembly of valve figure C:
installation and operation. Protect the air connections of Before proceeding with the assembly of the actuator onto
actuators not being used immediately. the valve, be sure that the actuator operates in the desired
5.2) Interfaces for actuator control and connections, figure A: direction of rotation when pressurised and both actuator/
valve are in the correct position.
Fig. A Fig. C
Important: when using a spring return actuator for a fail
safe operation, ensure that when air or electricity failure
5.3) Assembly of accessories: solenoid valves and occurs the direction of rotation is correct for your application.
switchboxes, figure B: Fit the actuator 3 onto the valve 5. It is possible to assemble
the valve onto the actuator in two ways:
• Direct-mount: fit the stem of the valve 5 directly into the
female connection of the actuator 3 and bolt together
through the valve ISO pad (max. tightening torque see table).
• Bracket-mount: mounting with a bracket 6 and coupling
7, the bracket is bolted to the actuator / valve to join
them together and the coupling is used to connect the
actuator output drive to the valve stem (max. tightening
torque see table).
M.. Nm
M5 5 →6
M6 10 → 11
M8 23 → 25
M10 48 → 52
Tightening torque table: M12 82 → 86
M14 132 → 138
M16 200 → 210
M20 390 → 410
M24 675 →705
Fig. B M30 1340 →1400
6) MAINTENANCE INSTRUCTION
• Solenoid valve mounting: With the information given below, AIR TORQUE provides
Before mounting a solenoid valve, ensure that the the end user with all the required information necessary
actuator is in its normal position (closed position) with for maintenance. Under normal conditions, the actuator
pistons inwards. requires only periodic observation to ensure proper operation.
For standard rotation type “ST” (clockwise to close) Maintenance (disassembly, maintenance and rebuilding)
assembly: the groove on the drive shaft or on the position of AIR TORQUE actuators is allowed only to AIR TORQUE
indicator 2 must be horizontal to the longitudinal axis of personnel or properly instructed personnel. In case of
the actuator in closed position. controversy the product guarantee will expire!
Fit the solenoid valve 4 onto the actuator 3 using the Spare kits for maintenace are available to replace all
provided screws (max. tightening torque see table). seals and bearings (soft parts indicated into the table),
• Switchbox mounting: that may be necessary between 300.000 and 1.000.000
Fit the switchbox and bracket 1 onto the actuator 3 using cycles depending on operating and environmental
four provided screws (max. tightening torque see table). conditions and actuator size.
5
GB
IMAT 4thGU-E
6.1) DRAWING WITH ITEMIZED COMPONENTS AND RECOMMENDED SPARE PARTS
60.1
Model Ex1 mm Ex2 mm d mm

AT045U / 8 13
AT051U 10 8 14
AT101U 10 10 16
AT201U 13 10 22
AT251U 13 10 25
AT301U 17 13 26
AT351U 19 13 36
AT401U 19 17 38
AT451U 22 17 45
AT501U 22 19 48
AT551U 24 19 52
AT601U 30 22 58
AT651U 30 24 68
AT701U 36 22 80
AT751U 46 24 85
AT801U 46 24 90
6
GB
IMAT 4thGU-E
PART N° UNIT Q.TY NOTE PART DESCRIPTION
01 1 NA for AT045U OCTI-CAM (Stop arrangement)

02 2 NA for AT045U STOP CAP SCREW
03 2 NA for AT045U WASHER
04 2 NA for AT045U NUT (Stop screw)
05* 2 BEARING (Piston back)
06* 1 BEARING (Pinion top)
07* 1 BEARING (Pinion bottom)
08* 2 1 Pcs. for model AT045U THRUST BEARING (Pinion)
09* 2 NA for AT801U P L UG
09.1* 2 "O" RING (For AT801U)
10 1 THRUST WASHER (Pinion)
11* 2 NA for AT045U "O" RING (Stop screw)
12 2 NA for AT045U PISTON GUIDE
13 8/12/16 (A) CAP SCREW (End cap)
14* 2 "O" RING (End cap)
15* 2 BEARING (Piston head)
16* 2 "O" RING (Piston)
17 min.5/max.12 for AT101U ÷ AT801U SPRING (Cartridge)
17.1 NA for AT101U ÷ AT801U SPRING (For AT045U ÷ AT051U)

max. 2 for AT045U
max. 4 for AT051U
18 1 SPRING CLIP (Pinion)
19 1 POSITION INDICATOR (For AT045U AT101U)
19.0 1 GRADUATED RING
19.1 1 NA for AT045U ÷ AT101U POSITION INDICATOR
19.5 1 NA for AT045U ÷ AT101U TOP ADAPTOR
19.6 2 NA for AT045U ÷ AT101U HEX. SOCKET SCREW (Top Adaptor)
20* 1 "O" RING (Pinion bottom)
21* 1 "O" RING (Pinion top)
30 2 END CAP
39 1 CAP SCREW (Indicator)
40 2 PISTON
41 1 ACTUATOR IDENTIFICATION LABEL
42 2 only for AT045U, AT751U END CAP LABEL
43 1 SPIGOT (Only on request)
50 1 BODY
60 1 DRIVE SHAFT
60.1 1 only for protec. level "E"and "F" INTEGRAL DRIVE SHAFT
65 1 PLASTIC INSERT
* Suggested SPARE PARTS for maintenance
Notes: A) 12 Pcs. for models AT701U / AT751U, 16 Pcs. for models AT801U
7
GB
IMAT 4thGU-E
6.2) DISASSEMBLY Fig. 03

When disassembly of actuator is required for maintenance,
firstly remove the actuator from the valve. Before
performing any disassembly operations it is important
to verify that the actuator is not pressurised.
Always use caution and double check that the ports 2 and
4 are vented and are free from any accessory and/or
device. When the actuator is a spring return unit, make
sure that the actuator is in the failed position and with
pistons completely inwards before disassembling.
A) Removal of position indicator and graduated ring

(Part N° 19,19.0,19.1), figure 01:
• Remove the o-rings (14) using a screwdriver. Discard soft
• Remove cap screw (39) if Fig. 01 parts if replacing.
fitted. • Only for actuators with adjustment 50% or 100%, remove
• Lift position indicator (19 the nut 04R, the washers 03R and o-rings 11R and
or 19.1) off shaft, it may discard soft parts if replacing.
be necessary to pry gently
with a screwdriver. D) Pistons disassembly (Part N° 40), figure 04:
• Lift, if necessary, the • Holding the body (50) in a vice or similar device, rotate the
graduated ring (19.0) drive shaft (60) until the pistons (40) are released. Caution:
off the body, it may be air pressure should not be used to remove the pistons from
necessary to pry gently the body.
with a screwdriver. • Remove o-rings (16) using a screwdriver. Remove the
piston back (05) and piston head (15) bearings.
• Discard bearings when replacing all soft components.
Fig. 04
B) Removal of stop cap screws (Part N° 02), figure 02:
• Remove both stop cap Fig. 02
screws together with nut
(04) and washer (03).
• Remove stop screw
o-rings (11) and discard if
replacing all soft parts.
E) Drive shaft disassembly (Part N° 60), figure 05:

• If necessary, remove the graduated ring (19.0) with a
screwdriver, remove the spring clip (18) using snap-ring
pliers or screwdriver for spiral rings, remove the thrust
washer (10) and the external thrust bearing (08). Apply
C) End caps disassembly (Part N° 30), figure 03:
downward force to top of drive shaft (60), until it is partially
• End caps disassembly for spring return actuators
out of the bottom of the body when it is possible to
(disassemble one end cap at a time).
remove the internal thrust bearing (08) and the octi-cam
Unscrew the end cap bolts (13) in the sequence shown in
(01), then push the pinion (60) completely out of the
figure 03, until the end-caps are free from springs force
body. If pinion is not easily removed, gently tap the top
(for AT045U and AT051U 20-23 turns of the screws, for
of the shaft with a plastic hammer.
AT101U to AT801U 4-5 turns of the screws).
Then completely unscrew the screws and remove the Fig. 05
end-cap and the springs.
If there is still force on the end-caps after unscrewing as
indicated above, this may indicate that spring cartridge is
damaged or that the pistons are not completely closed,
so any further disassembly should be discontinued.
Further disassembly of the end caps may result in injury.
• End caps disassembly for double acting actuators
(disassemble one end cap at a time)
Unscrew the end cap bolts (13) in the sequence shown in
figure 03, until the screws are completely unscrewed and
the end caps are free.
8
GB
IMAT 4thGU-E
• Remove top (06) and bottom (07) pinion bearings and top Fig. 07A
(20) and bottom (21) pinion o-rings.
• Discard bearings (06) and (07), internal and external thrust
washer (08) and o-rings (20) and (21) if replacing the soft
components.
All the components disassembled and not replaced will

have to be cleaned and inspected for wear and before
reassembly, if necessary, also replace the plugs (09).
6.3) ASSEMBLY:
Prior to assembly, ensure that:
• all the components are perfectly clean and in good
condition. • Fit external thrust bearing (08), thrust washer (10) and then
• the spare parts and the lubricant used are suitable for the external spring clip (18) using snap ring pliers or screwdriver
operating temperature of the actuator (see Air Torque for spiral rings.
technical data sheets).
• Note: The lubricants suitable for the various operating B) Pistons assembly (Part N° 40), figures 08, 09, 10 and 11:
temperatures (Standard, HT and LLT actuators) are • Grease and install o-rings (16), piston back (05) and
available in Air Torque. piston head (15) bearings.
Only for “standard” actuators, for temperature from -40°C • Grease the internal surface of the body (50) and the
(-40°F) to +80°C (+176°F), it is possible to use lubricant piston (40) rack teeth.
Dow Corning type Molykote® G-2003. • Insert the female connection of the drive shaft (60) in a
properly fixed coupling.
A) Drive shaft assembly (Part N° 60), figures 06, 07 • Ensure that the octi-cam is in the right position as shown
and 07A: in figure 09.
• Install top (06) and Fig. 06 Fig. 08 Fig. 09

bottom (07) bearings,
grease and insert the
bottom (20) and top
(21) pinion o-rings
onto the shaft.
• Grease the outside
surface of the drive
shaft as shown in figure
06.
• For standard rotation assembly type “ST” (clockwise to

close), rotate the body (50) about 40-45° clockwise from
top view, as shown in figure 10.
• Insert partially the drive shaft (60) in the body (50),
install octi-cam (01) in the correct position (for standard
Fig. 10
assembly or for lock-out) as shown in figures 07 and
07A, related to the bottom and top of the drive shaft and
the rotation of the actuator when energised. Install the
internal thrust bearing (08). Insert completely the drive
shaft in the body.
Fig. 07
• Insert and press the two pistons (40) simultaneously

inside the body (50) until the pistons are engaged, then
rotate the body anticlockwise from top view until the
stroke is completed.
• Ensure that with pistons completely closed, the rotation
obtained referred to the axis of the body is about over 0°
9
GB
IMAT 4thGU-E
for models AT051U→AT801U (0,5° over 0° for AT045U) SPRING SET CONFIGURATION
and that the dimension “A” on both sides is the same as
shown in figure 11. AT045U configuration:
Fig. 11 Side B Side A

Spring Set AT045U AT045U
Spring type Spring type
S1-1 1 (green) 1 (green)
S1-2 1 (green) 2 (red)
S2-2 2 (red) 2 (red)
S2-3 2 (red) 3 (black)
S3-3 3 (black) 3 (black)
C) End cap (Part N° 30) assembly, figures 12, 13 and 14: AT051U configuration:
• Assemble one end cap at a time.
• Lubricate the body. Side B Side A
• For spring return actuators, insert the springs in each AT051U AT051U AT051U AT051U
Spring
end cap according to the desired configuration, as shown
in figure 12 and related tables. For models Set Internal External Internal External
AT101U→AT801U insert spring cartridges as shown in Spring type Spring type Spring type Spring type
figure 13. S1 1(green) ------------ ------------ 2 (black)
S2 ------------ 2 (black) ------------ 2 (black)
S3 ------------ 2 (black) ------------ 3 (red)
S4 ------------ 3 (red) ------------ 3 (red)
S5 ------------ 3 (red) 1 (green) 2 (black)
S6 1 (green) 2 (black) 1 (green) 2 (black)
S7 1 (green) 2 (black) 1 (green) 3 (red)
S8 1 (green) 3 (red) 1 (green) 3 (red)
Fig. 12
• Fit end cap o-ring seal (14) into the groove on both end caps.
Fig. 13 Fig. 14
10
GB
IMAT 4thGU-E
• Fit end caps onto the body (50), verifying that the o-ring Fig. 17
remains in the groove.
• Only for actuators with 50% or 100% stroke adjustment,
ensure that the adjustment screws 221G/222G are
completely screwed into the end-cap.
• Insert the cap screws (13) and tighten each only partially.
Complete tightening by making 1-2 turns for each screw
in the sequence shown in figure 14 until tightening is
completed. See the table for screw tightening torque.
D) Assembly of stop cap screws (Part 02) and stroke

adjustment for models AT051U→AT801U, figures 15
and 16:
• Insert on both stop screws (02) the nut (04), the washer Fig. 18 Fig. 19
(03) and the o-ring (11).
• Fit the stop cap screws (02) in the body.
• Stroke adjustment for actuators with standard type “ST”
rotation / assembly (clockwise to close).
Stroke adjustment in close position: with the actuator in
close position 0°, screw or unscrew the right (from top
view) stop cap screw until the desired stop position is
achieved. Then tighten the stop adjustment nut (04) to
lock it in place.
Stroke adjustment in open position: with the actuator in
open position 90°, screw or unscrew the left (from top
view) stop cap screw until the desired stop position is
achieved. Then tighten the stop adjustment nut (04) to 7) STORAGE INSTRUCTIONS
lock it in place. If the actuator is not for immediate use, the following
For spring return actuators, it could be necessary to precaution must be taken for storage:
make rotation tests to verify the correct stroke adjust- • Store the actuator in a clean and dry environment and at
ment in open position. temperature between –20°C (-4°F) and +40°C (+104°F).
• Only for actuators with adjustment 50% or 100%, fit on • It is recommended that the actuator be stored in its
end-cap adjustment screws 221G/222G the o-rings original box.
11R, the washers 03R and the nuts 04R. To adjust the • Do not remove the plastic plugs on air supply ports.
stroke in open position: with the actuator in partially or
totally open position, screw or unscrew the end-cap ad- 8) LIFTING and HANDLING
justment screw 221G/222G until the desired position is It is recommended to lift the actuators with proper, adequate
achieved. It is important that the two end-cap adjust- and permitted systems in relation to the actuator weight and
ment screws are both in contact with the pistons. by following the ruling laws in terms of safety and health
Then lock the nuts 04R. protection. The weight of the actuators is indicated on the Air
Torque catalogue and on the related technical data-sheets.
During the lifting and the handling of the actuators, it is
Fig. 15 Fig. 16 recommended to avoid clashes and/or accidental falls in
order to avoid irreparable damages to the actuators and to
compromise the functionality.
Contact Air Torque for any information and technical
data-sheets.
E) Assembly of graduated ring and position indicator

(Part N° 19,19.0,19.1), figures 17,18 and 19:
• Fix the graduated ring (19.0) to the body.
• If necessary, correctly position the “Top Adaptor” (19.5)
and lock it with the proper screws (19.6).
• Insert the indicator (19 or 19.1) making sure that it indicates
the correct actuator position.
• Screw the indicator screw (39) if assembled.
11
se obtiene cuando se presuriza la entrada 2. - Connessione con raccordi (alle connessioni 2 e 4) della linea di controllo da cabina di comando.
Los actuadores marcados LF giran al contrario de las agujas del reloj para cerrar, se obtiene giro en sentido La rotazione standard è chiusura in senso orario, si ottiene rotazione antioraria pressurizzando la
de las agujas del reloj cuando se presuriza la entrada 2. connessione 2. Per attuatori marcati LF la rotazione è chiusura in senso antiorario, si ottiene rotazione oraria
pressurizzando la connessione 2.
dard rotation)Top View/ Funktionsprinzip des einfachwirkenden Antriebs (Standarddrehrichtung) Draufsicht/ Manœuvre en simple effet (rotation standard) Vue de Dessus/
andard) Vista Inferior/ Funzionamento semplice Effetto (Rotazione standard) Visto da sopra.
uluft auf Anschluß "2" bewegt die L’air alimentant l’orifice 2 pousse les On loss of air pressure (air or electric Druckverlust (Luftausfall) an Anschluß Sur perte de pression à l’orifice 2
Kolben in Richtung der pistons en position extrême, comprimant failure) at Port 2 allow the springs to "2" ermöglicht den Kolben die (manque d’air ou de courant), les
ndlagen, die Federn werden les ressorts avec échappement d’air à force the pistons to the centre position Ausgangsstellung anzufahren, Abluft ressorts repoussent les pistons en
komprimiert, Abluft über Anschluß "4", l’orifice 4. Le sens de rotation est du with exhaust air exiting at Port 2, a clock- über Anschluß "2", eine Drehrichtung im position centrale avec échappement
ine Drehrichtung im Gegenuhrzeigersinn type anti-horaire. wise rotation is obtained. Uhrzeigersinn wird erzielt. d’air à l’orifice 2. Le sens de rotation est
du type horaire.
’aria fornita alla connessione “2” porta i A pérdida de presión de aire (fallo de La caduta di pressione (Per mancanza
pistoni verso l’esterno, comprimendo le aire o electricidad) en la entrada "2" los aria o elettricità) alla connessione “2”
molle con l’aria esausta alla connessione muelles empujan los pistones hacia consente alle molle di portare i pistoni
dentro, expulsando el aire por la entrada verso il centro, con l’aria esausta alla
4”, si ottiene una rotazione antioraria. "2", se obtiene un giro en sentido de las connessione “2”, si ottiene una rotazione
agujas del reloj. oraria.
5) INSTRUCCIONES DE MONTAJE: 5) ISTRUZIONI PER L’INSTALLAZIONE

El actuador Air Torque es un operador neumático para la actuación remota de válvulas industriales. La L’attuatore AT è un dispositivo pneumatico per il comando a distanza di valvole. La manovra (rotazione di 90°,
peración (rotación a 90º, aunque también es posible a 120º o 180º) permite abrir y cerrar diferentes tipos de 120° e 180°) consente l’apertura e la chiusura dei diversi tipi di valvole a 1/4 di giro.
válvulas de un cuarto de vuelta. Tutte le informazioni tecniche necessarie per un’installazione corretta dell’attuatore sulla valvola come
Toda la información técnica necesaria para instalar correctamente el actuador en la válvula es: dimensiones, Dimensioni, Coppia prodotta, Volume aria, Regolazione corsa, Tempo di manovra, Temperatura di esercizio,
par de arranque, volumen de aire, ajuste de recorrido, duración del ciclo, temperatura de trabajo, sentido de Senso di rotazione e Peso sono riportate su targhetta, catalogo e schede tecniche. Leggere tutte le infor-
rotación y peso. Toda esta información está incluida en la etiqueta del actuador, el catálogo y las hojas de mazioni tecniche prima di procedere all’installazione dell’attuatore.
datos técnicos. Lea atentamente esta información técnica antes de proceder a la instalación del actuador.
5.1) Importante!
Importante ! • Per ragioni di sicurezza l’attuatore non deve essere pressurizzato durante l’installazione, potrebbe causare
or motivos de seguridad el actuador no debe estar presurizado durante la instalación ya que puede causar lesioni personali.
• E’ richiesta la massima pulizia durante la connessione con tubi e raccodi, tubi, raccordi e guarnizioni devono
e requiere la más estricta limpieza durante la conexión. El tubo, la conexión roscada y las juntas deben essere puliti.
estar limpias de suciedad. • Qualora si installano accessori sull’attuatore assicurarsi siano installati in modo che il comando di emergen
ontar la unidad de tal manera que el mando manual de la electroválvula y la parte superior del eje del actu za dell’elettrovalvola e la parte superiore del pignone siano facilmente accessibili per le operazioni manuali.
ador sean accesibles. • Prima dell’installazione sulla valvola assicurarsi che l’attuatore e la valvola siano correttamente orientati,
Observe la posición de la válvula dependiendo en el sentido que esté montada y el sentido de rotación que in relazione alla direzione della rotazione richiesta.
5.2) Connessioni e controllo, Figura A

5.2 Piezas de control y conexiones, figura A.
5.3) Assemblaggio di accessori come elettrovalvole e scatole finecorsa, Figura B:
T his manual is property of AIR TOR QUE S .p.a. - C os ta di Mezzate - Italy and all rights of us e and reproduction are res erved - S ubject change without notice
5.3 Montaje de accesorios como electroválvulas y cajas de finales de carrera, figura B : • Montaggio Elettrovalvola:
* Montaje de la electroválvula: Prima di montare l’elettrovalvola assicurarsi che l’attuatore sia nella sua posizione normale
ntes del montaje de la electroválvula, asegúrese de que el actuador está en su posición normal (posición (posizione di chiusura) pistoni al centro:
- Assemblaggio e rotazione tipo Standard (chiusura in senso Orario): la cava sull’indicatore 2 deve
Montaje y rotaciónTipo Standard, (cerrar, en el sentido de las agujas del reloj): la ranura en el indicador 2 essere ortogonale all’asse longitudinale dell’attuatore in posizione chiusa.
iene que estar en diagonal al eje longitudinal del actuador en posición cerrado. Sole agents and major regional stockists F issare l’elettrovalvola 4 sull’attuatore 3 usando le apposite viti (Coppia massima di serraggio vedi
coplar la electroválvula 4, en el actuador 3 utilizando tornillos suministrados (máx. par de apriete, ver tabella).
* Montaje de caja de finales de carrera:

Global Supply Line (Australia) • Montaggio scatola finecorsa:
Posizionare la scatola finecorsa 1 con relativa staffa sull’attuatore 3 e fissarla usando le apposite quattro viti
Acoplar el final de carrera y adaptador 1 en el actuador 3 utilizando los cuatro tornillos
suministrados (máx. par de apriete, ver tabla ).
www.globalsupplyline.com.au (Coppia massima di serraggio vedi tabella).
5.4) Montaggio Valvole Figura C:

5.4 Montaje de válvula figura C : Prima di procedere all’assemblaggio della valvola sull’attuatore assicurarsi che l’attuatore esegua la
Antes de proceder al montaje de la válvula en el actuador, asegúrese de que el actuador opera en la rotazione nel senso desiderato quando viene pressurizzato e che l’attuatore più la valvola siano in
rotación deseada cuando se presurice y de que ambos, actuador y válvula, están en la posición correcta. posizione corretta.
Importante: en caso de actuador de simple efecto asegúrese de que en caso de pérdida de aire o Importante: in caso di attuatore semplice effetto per manovra di emergenza, assicurarsi che in caso di
electricidad la dirección de rotación es la correcta. mancanza aria e/o elettricità la direzione della rotazione sia corretta. Fissare la valvola 5 sull’attuatore 3.
Monte la válvula 5 en el actuador 3. Asegúrese de que el actuador está en posición normal Assicurarsi che l’attuatore sia in posizione normale (chiusa).
(posición cerrada ). Es posible montar el actuador de dos formas distintas en la válvula: E’ possibile avere due tipi di assemblaggio della valvola sull’attuatore:
- Montaje-directo: Ajustar el cuadrado de la válvula directamente en el cuadrado del actuador - Montaggio diretto: inserire il quadro della valvola 5 direttamente nel quadro dell’attuatore 3 e fissare la
usando tornillos o espárragos ( máx. par de apriete, ver tabla ). valvola direttamente alla foratura ISO con viti o prigionieri (Coppia massima di serraggio vedi tabella).
- Montaje con torreta y acoplamiento: la torreta 6 se atornilla al actuador y a la válvula para unirlos - Montaggio con staffa: il montaggio con staffa 6 e giunto 7 richiede che la staffa sia fissata tra attuatore
y el acoplamiento 7 va en medio uniendo ejes. (máx. par de apriete: ver tabla). e valvola con viti o prigionieri (Coppia massima di serraggio vedi tabella) e che il giunto faccia da
collegamento tra la connessione dell’attuatore e lo stelo della valvola.
5.4.1.Posibilidades de montaje.
5.4.2.Montaje de la válvula con el actuador tipo STANDARD ( cerrar en el sentido de las agujas del reloj ) 5.4.1) Possibilità di montaggio:
Figura D: 5.4.2) Montaggio valvola con attuatore tipo Standard (chiusura in senso Orario) Figura D:
5.4.3.Montaje de la válvula con el actuador tipo LF ( abrir en el sentido de las agujas del reloj) Figura E: 5.4.3) Montaggio valvola con attuatore tipo LF (apertura in senso Orario) Figura E:
M.. Nm
• Tightening torque table: M5 5 6
• Tabelle der Anzugsdrehmomente: M6 10 11
• Table de couple serrage: M8 23 25
• Tabla de par de apriete: M10 48 52
• Tabella coppia di serraggio: M12 82 86
M14 132 138
M16 200 210
M20 390 410
M24 675 705
M30 1340 1400
Head office Works:

Head office Works: AIR TORQUE S.p.A.
AIR TOR QUE S .p.A. Via Alla Campagna, 1
società uninominale
società uninominale 24060 COSTA DI MEZZATE (BG) Italy

Via Alla C ampagna, 1 - 24060 C OS TA DI ME ZZATETel.:+39
(B G) - 035
Italy682299 - Fax: +39 035 687791
Tel.:+39 035 682299 - Fax: +39 035 687791 info@airtorque.it www.airtorque.it
F ig. D F ig. E
info@airtorque.it - www.airtorque.it

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Omm - GK-X Manual 2-0

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Operating and Maintenance Manual GK-X

Printed in South Africa

Revision Number 2.0 (05/21)

About this manual

Prohibition of an action or activity in connection with a source of danger, the

Command to perform an action or task associated with a source of danger, the

• The GK-X is designed to be economical by using modern materials. Instead of over-

• The GK-X has low power requirements.

1.2. When should a GK-X be used?

• In conjunction with an APT RG scrubbing plant in alluvial applications.

Figure 1: The GK-X Concentrator (Auto version shown)

1.3. What is the GK-X Automation System?

2.1. General Safety Precautions

WARNING – Attempting to operate the GK-X without reviewing the instructions

Never operate the GK-X without the belt guard in place.

Always comply with manufacturers’ operating, maintenance and safety

2.2. Transport and Hoisting

3.2. Preparation of Foundations

3.3. Removal from Shipping Crate

3.4. Installation on Site

3.4.1. Installing Concentrator

3.4.2. Installing Control Panel (Auto Version)

3.4.3. Removal of Shipping Locks

3.5. Assembly of Additional Components

3.5.1. Water Supply

Table 1: GK-X Water Requirements

Water Supply / Hose Connection mm 40mm Hose Swage

Typical water requirement* m3/h 4–6

Water pressure bar 2–3

Figure 2: GK-X Water Piping (Auto version shown)

3.5.2. Electrical Supply and Wiring

WARNING: To prevent personnel injury or equipment damage, all wiring

Figure 3: Control panel wiring

3.5.3. Slurry Feed

Figure 4: GK-X Slurry Piping

3.5.4. Air Piping (Auto Version)

Table 2: GK-X Auto Air Requirements

Variable Units GK-X

Typical air requirement CFM 6 cfm (180 litres/min)

Air pressure bar 5 – 8 bar

Figure 5: Slurry valve connections

Figure 6: Auto water valve connections

Figure 7: Auto water valve connection points

4.1.1. Reminders and Cautions

4.1.1.1. Personnel Safety

Ensure that no one is working on or around the equipment before starting up

WARNING: To prevent personal injury or damage to the machine:

• All wiring connections must be properly isolated.

4.1. Checks Prior to Start-up

4.1.2. Hardware Pre-checks

4.1.3. Manual model Pre-checks

4.1.4. Software Pre-checks for Auto (if fitted)

Figure 8: Startup Screen - Auto/Manual Selection

Figure 9: Manual Operation Screen

4.2. Start-up Procedure

4.1.5. Manual option

4.1.6. Auto option

Figure 10: Auto control page

4.3. Concentrate harvesting

4.1.7. Concentrating Cycle Duration

• Feed rate of the ore/slurry to the machine

• Content of gold and other heavy minerals in the ore

4.1.8. Manual Option