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BIFFI ITALIA SGR – Spur Gear Reducer Instruction and operating manual
A© Copyright by BIFFI Italia. All right reserved MAN 685/Rev.0 Page i
MAN 685
SGR - Spur Gear Reducer
Instruction and Operating Manual
1 20/Oct/2011 General Revision G. Inzani A. Ghiadoni L. Vigliano
0 12/Dec/2008 Issue S. Orefici A.Ghiadoni L.Vigliano
Rev. Date Description Prepared Checked Approved
BIFFI ITALIA SGR – Spur Gear Reducer Instruction and operating manual
A© Copyright by BIFFI Italia. All right reserved MAN 685/Rev.0 Page ii
BIFFI ITALIA has taken every care in collecting and verifying the documentation contained in this Instruction
and Operating Manual.
The informations herein contained are reserved property of BIFFI ITALIA.
Contents may change without notice.
BIFFI ITALIA SGR – Spur Gear Reducer Instruction and operating manual
A© Copyright by BIFFI Italia. All right reserved MAN 685/Rev.0 Page i Page i
INDEX
1 GENERAL SAFETY INSTRUCTIONS ......................................................................... 3
1.1 Manufacturer 3 1.2 Machine Intended Use 3 1.3 Terms and conditions 4 1.4 Manufacturer’s Liability 4 1.5 Applicable Standards and Regulations 4 1.6 Installation in hazardous area 4 1.7 Marking for application in hazardous area 5
1.7.1 Label for ICON2000/ICON2000EC .................................................................................................................. 5
1.7.2 Extract from the Standard ................................................................................................................................ 5
2 MACHINE DESCRIPTION ......................................................................................... 6
2.1 General 6 2.2 Main Parts Description 6
3 TECHNICAL DATA ...................................................................................................... 7
3.1 Application range 8
4 TRANSPORT AND STORAGE .................................................................................... 9
picture 2 9 4.1 Transport 9 4.2 Checks to be carried out on receipt of the SGR reduction unit 10 4.3 Storage Procedure 10
5 INSTALLATION ........................................................................................................ 11
5.1 Working condition 11 5.2 Safety Instructions for installation in Hazardous Area 11
5.2.1 Instructions for the explosion-proof enclosures ..................................................................................... 11
5.2.2 Installation in ambient with explosive dusts ........................................................................................... 11
5.3 Assembling the SGR actuators onto the valve 11
6 MAINTENANCE ........................................................................................................ 13
6.1 Standard Maintenance 13 6.2 Special Maintenance 13
7 LUBRICATION .......................................................................................................... 15
8 DISMANTLING AND DEMOLITION ....................................................................... 16
BIFFI ITALIA SGR – Spur Gear Reducer Instruction and operating manual
A© Copyright by BIFFI Italia. All right reserved MAN 685/Rev.0 Page ii Page ii
9 PARTS LIST .............................................................................................................. 17
9.1 How to Order Parts List 17 9.2 SGR160 Parts List 18 9.3 SGR250 Parts List 20 9.4 SGR400 Parts List 22 9.5 SGR640 Parts List 24 9.6 SGR1000 e SGR 1600 Parts List 26
BIFFI ITALIA SGR – Spur Gear Reducer Instruction and operating manual
A© Copyright by BIFFI Italia. All right reserved MAN 685/Rev.0 Page 3 Page 3
1 GENERAL SAFETY INSTRUCTIONS
1.1 Manufacturer
Manufacturer with respect to the Machinery Directive 2006/42/EC is BIFFI ITALIA, as specified on the
machinery label.
1.2 Machine Intended Use
The machines to whose this Instruction and Operating Manual applies are the SGR series (ON-OFF type),
which are designed to operate industrial valves with rising or not rising stem (such as gate, globe and
others) for use in applications in heavy industrial, chemical, petrochemical, food, water and power
generating plants. They are designed for motor operation in conjunction with ICON 2000 electric actuators.
BIFFI ITALIA will not be liable for any possible damage or physical injury resulting from use in other than the
designated application or by lack of care during installation, operation, adjustment and maintenance of the
machinery. Such risks lie entirely with the User.
Depending on the specific working conditions, additional precautions may be required.
The SGR are produced by BIFFI ITALIA and identified on the proper label by the product designation:
SGR-XXXX.
Important
This Manual gives basic information for SGR series setting; more detailed
information for setting and control of the Electric Actuator ICON2000 are
included on the MAN 618 which form part of the mandatory instructions
documentation.
Warning
It is assumed that the installation, the setting, the commissioning and the
maintenance and repair works are carried out by qualified personnel and
checked by responsible Specialists.
Warning
Read this installation and maintenance manual carefully and completely
before attempting to store or install the operator. If an electric operator is
attached to the SGR operator, be aware of the electrical hazards and consult
the relevant electric actuator installation and maintenance manual for
guidance.
The SGR series are designed in accordance with the applicable International Rules and Specifications but in
any case the following Regulation must be observed:
the general installation and safety regulations
the plant specific regulations and requirements
the proper use of personal protective devices (glasses, clothing, gloves)
the proper use of tools, lifting and transport equipment.
BIFFI ITALIA SGR – Spur Gear Reducer Instruction and operating manual
A© Copyright by BIFFI Italia. All right reserved MAN 685/Rev.0 Page 4 Page 4
1.3 Terms and conditions
BIFFI ITALIA guarantees each single product to be free from defects and to conform with current goods
specifications and regulations as applicable. The warranty period is 12 months from the date of installation
by the first User or 18 months from the date of shipment to the first User, whichever occurs first. No
warranty is given for products, which have been subject to damages or corrosion due to the improper
storage, improper installation, misuse, or which have been modified or repaired by unauthorised personnel.
Repair work due to improper use will be charged at standard rates.
1.4 Manufacturer’s Liability
Biffi Italia declines all liability in the event of:
use of the machinery in contravention of local safety at work legislation.
incorrect installation, disregard or incorrect application of the instructions provided on the product
nameplate and in this Instruction and Operating Manual.
modification of the product without Biffi’s authorisation.
work done on the product by unqualified or unsuitable personnel.
1.5 Applicable Standards and Regulations
EN ISO 12100-1 Safety of machinery - Basic concepts, general principles for design.
Part 1-Basic terminology, methodology.
EN ISO 12100-2 Safety of machinery - Basic concepts, general principles for design.
Part 2-Technical principles and specification.
2006/42/EC Machinery Directive.
97/23/EC PED Directive.
1.6 Installation in hazardous area
Warning
In case the SGR are to be installed in HAZARDOUS AREA, as defined by the
applicable Rules, it is mandatory to check if the nameplates of the
associated ICON2000/ICON2000EC specify that the assembly is suitable to
be installed in HAZARDOUS AREA with the indication of appropriate degree
of protection.
Maintenance and repair works must carry out by qualified personnel and
checked by responsible Specialists.
BIFFI ITALIA SGR – Spur Gear Reducer Instruction and operating manual
A© Copyright by BIFFI Italia. All right reserved MAN 685/Rev.0 Page 5 Page 5
1.7 Marking for application in hazardous area
1.7.1 Label for ICON2000/ICON2000EC
The ICON 2000/ICON 2000 EC associated to the SGR, for the application in hazardous areas, has to present
a label with the following marking description:
0080 = Notified Body for ATEX
II = Group II (Surface)
2 = Category 2 apparatus
G = explosive atmosphere by gas
D = explosive atmosphere by dust
IP 66/68= degree of protection
1.7.2 Extract from the Standard
Type of Hazard Classification of Zones Categories acc. to 94/9/EC Directive
Gas, mists or vapours Zone 0 1G
Gas, mists or vapours Zone 1 2G
Gas, mists or vapours Zone 2 3G
Dust Zone 20 1D
Dust Zone 21 2D
Dust Zone 22 3D
BIFFI ITALIA SGR – Spur Gear Reducer Instruction and operating manual
A© Copyright by BIFFI Italia. All right reserved MAN 685/Rev.0 Page 6 Page 6
2 MACHINE DESCRIPTION
2.1 General
The SGR actuator is a spur gear reduction unit driven by an ICON 2000 multi-turn electric actuator in order
to increase the overall mechanical advantage. The unit is suitable to operate industrial valves with rising or
not rising stem such as gate, globe and others.
Particular feature of the SGR unit is the remarkable reliability and high efficiency obtained by adopting a
particularly simple rugged and totally enclosed housing. All internal components are precisely machined to
yield best efficiency. Particular attention to minimize friction has been achieved by using a special grease
lubrication suitable for ambient temperatures between -30°C and +85°C, thus manufacturing a reliable
actuator even in the most severe working conditions (a special grease allows to use the SGR with ambient
temperatures between -55°C and +65°C).
2.2 Main Parts Description
Picture 1
ICON Electric Actuator
Reduction Unit
Thrust Coupling Block
Valve Stem Protection tube
BIFFI ITALIA SGR – Spur Gear Reducer Instruction and operating manual
A© Copyright by BIFFI Italia. All right reserved MAN 685/Rev.0 Page 7 Page 7
3 TECHNICAL DATA
SGR Model ICON2000
Model
Nominal Torque (100%)
[Nm]
Minimum
Torque
[Nm]
Maximum
Torque
[Nm]
SGR
Ratio
(10%)
RPM
(50 Hz)
RPM
(60 Hz)
SGR 160 ICON 30
2880 1152 4320 9 :1 8 10
16 19
2150 860 3225 6,70 :1 21 26
1750 700 2625 5,50 :1 26 31
SGR 250
ICON 30
4800 1920 7200 15,86 :1 4,5 5,5
4800 1920 7200 15,86 :1 9 11
3600 1440 5400 11,80 :1 12 15
ICON 40 4800 1920 7200 8:1 18 22
3600 1440 5400 6:1 24 29
ICON 50 4800 1920 7200 4:1 36 43
SGR 400
ICON 40 9600 3840 14400 15,86 :1 4,5 5,5
ICON 30 7500 3000 11250 24,32:1 6 7
ICON 40 9600 3840 14400 15,86 :1 9 11
7500 3000 11250 12,28:1 12 14
ICON 50 9600 3840 14400 7,90:1 18 22
7500 3000 11250 6:1 24 29
SGR 640
ICON 50 19200 7680 28800 15,86 :1 4,6 5,5
ICON 50 15000 6000 22500 24,63 :1 6 7
ICON 50
19200 7680 28800 15,86 :1 9 11
16000 3400 24000 13,20 :1 11 13
9600 3840 14400 7,90 :1 18 22
SGR 1000 ICON 50
37000 14800 55500 30,88 :1 2,3 2,8
4,7 5,6
28000 11200 42000 23,36 :1 6,2 7,4
22000 8800 33000 18,19 :1 7,9 9,5
SGR 1600 ICON 50
57000 22800 85500 48,90 :1 2,9 3,5
48000 19200 72000 40,20 :1 3,6 4,3
40000 16000 60000 33,39 :1 4,3 5,2
BIFFI ITALIA SGR – Spur Gear Reducer Instruction and operating manual
A© Copyright by BIFFI Italia. All right reserved MAN 685/Rev.0 Page 8 Page 8
3.1 Application range
SGR actuators are suitable to be motorized for applications in standard temperature range from –30°C to
+85°C. A specific version is available for most severe working conditions , with ambient temperatures
between -55°C and +65°C.
The SGR actuators have protection degree IP67 accordingly to EN 60529.
BIFFI ITALIA SGR – Spur Gear Reducer Instruction and operating manual
A© Copyright by BIFFI Italia. All right reserved MAN 685/Rev.0 Page 9 Page 9
4 TRANSPORT and STORAGE
Important
Not performing the following procedures will invalidate the product
guarantee.
Important
The actuator lifting and transportation has to be done by qualified personnel
only and in accordance to the local regulation and area classification.
Warning
The lifting method, showed in picture 2, is applicable for the actuator only
and never for the assembly valve + actuator . Lift the actuator with
appropriate slings suitable for the weight of actuator model.
Warning
The actuator weight is reported on the transportation documents.
picture 2
4.1 Transport
Transport the spur gear reduction unit to place of installation in strong packing.
If the spur gear reduction unit is mounted together with the electric actuator, lift it by hoist with ropes or
hooks attached only to the spur gear reduction unit and not to the actuator.
BIFFI ITALIA SGR – Spur Gear Reducer Instruction and operating manual
A© Copyright by BIFFI Italia. All right reserved MAN 685/Rev.0 Page 10 Page 10
4.2 Checks to be carried out on receipt of the SGR reduction unit
Carefully remove the spur gear reduction unit from shipping carton or skid. Check that it has not been
damaged during transportation. If damaged, immediately report the damage to the transport company.
Check first of all if the information written on the nameplate (Model, Nominal torque, Degree of
protection,…) correspond with the data of the product which is expected.
Check that the model, the serial number of the spur gear reduction unit and the performance data
written on the data-plate are in accordance with those described on the order acknowledgement, test
certificate and delivery note.
Check that the fitted accessories comply with those listed in the order acknowledgement and the delivery
note.
4.3 Storage Procedure
Important
The following is the requested storage procedure to maintain maximum SGR
integrity during storage; failure to comply with recommended procedure will
invalidate the warranty.
The spur gear reduction units leave the factory in excellent working conditions and with an excellent finish
(these conditions are guaranteed by an individual inspection); in order to maintain these characteristics until
it is installed on the plant, it is necessary to observe a few rules and take appropriate measures during the
storage period.
Store in well-ventilated, protected, dry room.
Store the spur gear reduction units on wooden skids or on shelf to protect the machined mounting
flange.
If the SGR are supplied separately from the valves, they must be placed onto a wooden pallet. In case of
long-term storage (over six months), the spur gear reduction unit must be covered to protect it against
dust and dirt, and it is necessary to apply suitable corrosion protection agent to bare surfaces, and in
particular to the output drive parts and mounting surfaces.
In case of long-term storage, it is advisable to keep the spur gear reduction units in a clean, dry place in
order to provide at least some means of weather protection.
If the spur gear reduction units have to be stored outside, they must be protected adequately (for
example covered in polyethylene protection with silica gel crystals to absorb moisture).
For the storage of the Electric Actuator supplied together with the SGR reduction unit, please refer to the
storage instructions included in the actuator’s IOM (MAN 618).
BIFFI ITALIA SGR – Spur Gear Reducer Instruction and operating manual
A© Copyright by BIFFI Italia. All right reserved MAN 685/Rev.0 Page 11 Page 11
5 INSTALLATION
5.1 Working condition
The standard SGR reduction units are suitable for the following ambient temperatures:
from -30°C to +85°C (from -22°F to +185°F)
The low temperature version is suitable for temperature ranges from -55°C to +65°C
Important
Check the "temperature ambient range" embossed on the nameplate, for the
correct utilisation with respect to the ambient temperature.
Installation in ambient with temperature range outside the specified values
will invalidate the warranty.
5.2 Safety Instructions for installation in Hazardous Area
5.2.1 Instructions for the explosion-proof enclosures
Important
For the installation of the assembly SGR - Electric Actuator in hazardous
areas, please refer to the instructions included in the Electric Actuator IOM
(MAN 618).
5.2.2 Installation in ambient with explosive dusts
Important
For the installation of the assembly SGR - Electric Actuator in ambient with
explosive dusts, please refer to the instructions included in the Electric
Actuator IOM (MAN 618).
5.3 Assembling the SGR actuators onto the valve
The SGR is provided with a stem nut (machined or not machined, based on Customer requirements) for the
coupling to the valve or with a bush for valve stem key insert. The assembly position (orientation) of the
valve/actuator (gearbox) package must comply with the plant requirements.
BIFFI ITALIA SGR – Spur Gear Reducer Instruction and operating manual
A© Copyright by BIFFI Italia. All right reserved MAN 685/Rev.0 Page 12 Page 12
To assemble the actuator onto the valve proceed as follows:
Check that the valve coupling dimensions of the flange and stem, or of the relevant extension, meet the
SGR coupling dimensions.
Lubricate the valve stem with grease in order to make the assembly easier.
Arrange the valve in the closed position.
SGR WITH COUPLING TYPE “A”
Place the SGR vertical on the stem and engage the manual operation;
Screw the threaded bushing of the coupling block on the valve stem, rotating (normally counter-
clockwise) until the coupling block and flange surfaces of the valve are securely in contact.
For safety purposes, rotate the handwheel in the opening direction for about two turns in order to lift the
valve gate from its seat to avoid (during bolt fixing) excessive axial thrusts on the internal parts of the
valve and of the actuator.
SGR WITH COUPLING TYPE “B1” AND “B2”
Check the dimensions of the valve mounting details, paying particular attention to the protrusions of the
valve stem in order to avoid any axial thrusts to the internal parts of the SGR or the valve when the
screws are tightened.
Engage the manual operation. Place the SGR vertically on the valve stem. Carry out the coupling
operations (if necessary with the assistance of the manual operation);
Make sure that the parts in contact are not forced.
BIFFI ITALIA SGR – Spur Gear Reducer Instruction and operating manual
A© Copyright by BIFFI Italia. All right reserved MAN 685/Rev.0 Page 13 Page 13
6 MAINTENANCE
Warning
All installation, start-up, maintenance and repair works must be made by
specialised personnel..
6.1 Standard Maintenance
BIFFI SGR reduction units require no special maintenance.
After commissioning and once per year, check all the paint-coat of the SGR. If some areas
are damaged, repair the paint-coat according to the applicable specification.
In chemically aggressive or saline environments, remove rust from surfaces and protect
with a rust preventative.
Approx. six months after commissioning and once per year, check that the nuts and bolts
securing the SGR to the electric actuator and to the valve are tight, and, if necessary, re-
tighten.
Approx. every 2 years perform a visual inspection on the SGR unit for grease leakage.
For severe applications or if SGR operation is infrequent, perform maintenance checks at
shorter intervals.
Important
Regular checks may be determined by the specific environmental and
working conditions.
6.2 Special Maintenance
Restore periodically the grease inside the thrust coupling block by means of its grease nipple.
Also periodical lubrication of the reduction gears can be accomplished by removing the top
cover of the housing.
In case of malfunction or in case of grease leaks or in case of scheduled preventive
maintenance, the SGR unit must be disassembled: any damaged part can be requested to BIFFI
with reference to the attached exploded view drawing and parts list.
Every spare parts request has to clearly indicate the relevant SGR Serial Number and the spare
part item number.
Special maintenance is also recommended when, during operations, the actuator generates an
excessive noise.
BIFFI ITALIA SGR – Spur Gear Reducer Instruction and operating manual
A© Copyright by BIFFI Italia. All right reserved MAN 685/Rev.0 Page 14 Page 14
Important
After maintenance works, a few operations of the assembly actuator/SGR
must be done to check that movement is regular.
Important
For the maintenance instructions of the Electric Actuator ICON2000 supplied
together with the SGR reduction unit, please refer to the ICON2000 IOM
(MAN 618).
Important
Before reassembling the gearbox, the flexoid gasket must be replaced.
BIFFI ITALIA SGR – Spur Gear Reducer Instruction and operating manual
A© Copyright by BIFFI Italia. All right reserved MAN 685/Rev.0 Page 15 Page 15
7 LUBRICATION
In case of maintenance the following grease type are recommended:
AGIP MU/EP/2 or equivalent AEROSHELL GREASE 7 or equivalent
To be used in standard temperature
conditions (-30°C/+85°C)
NLGI consistency: 2
Worked penetration: 280 dmm
ASTM Dropping Point: 185°C
Base oil viscosity at 40°C: 160 mm²/s
ISO Classification: L-X-BCHB 2
DIN 51 825: KP2K - 20
To be used in low temperature conditions
(-60°C/+65°C)
Colour: Buff
Physical state: Semi-solid at ambient temperature
Odour : Slight
Density : 966 Kg/m³ at 15°C
Flash Point : ›215°C (COC)(Based on synthetic oil)
Dropping point : 260°C (ASTM D-566)
Product code : 001A0065
Infosafe No.: ACISO GB/eng/C
BIFFI ITALIA SGR – Spur Gear Reducer Instruction and operating manual
A© Copyright by BIFFI Italia. All right reserved MAN 685/Rev.0 Page 16 Page 16
8 DISMANTLING AND DEMOLITION
Warning
The actuator demolition must be done by specialised personnel.
Before starting dismounting, it is advisable to create sufficient space around the SGR so as to allow
movement and not cause any environment-induced risks.
Separate the SGR components according to their nature (i.e. metal parts, plastic, fluids, etc.) and dispose
them properly, as indicated by the laws in force and in the following table:
Subject Hazardous Recyclable Disposal
Electrical and electronic
equipment
YES YES Use specialist recyclers
Glass NO YES Use specialist recyclers
Metals NO YES Use licensed recyclers
Plastics NO YES Use specialist recyclers
Rubber (seals and O-
rings)
YES NO Will require special treatment before disposal, use
specialist waste disposal companies
Oil and grease YES YES Will require special treatment before disposal, use
specialist waste disposal companies
Batteries YES YES Will require special treatment before disposal, use
specialist waste disposal companies
Warning
Do not re-use parts or components which appear to be good condition after
they have been checked or replaced by qualified personnel and declared
unsuitable for use.
Important
In all cases check local authority regulation before disposal.
BIFFI ITALIA SGR – Spur Gear Reducer Instruction and operating manual
A© Copyright by BIFFI Italia. All right reserved MAN 685/Rev.0 Page 17 Page 17
9 PARTS LIST
9.1 How to Order Parts List
To order parts or obtain further information about Biffi valve operator, contact your local distributor sales
office or:
Biffi Italia S.r.l.
Località Caselle San Pietro
29017 FIORENZUOLA D’ARDA
PIACENZA (ITALY)
Telephone: 0039 0523 944 411
Fax: 0039 0523 944 546
All inquiries and orders must be accompanied by the following information, which are located in the
nameplate:
1. Operators model, size and ratio;
2. Order number;
3. Serial number.
BIFFI ITALIA SGR – Spur Gear Reducer Instruction and operating manual
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9.2 SGR160 Parts List
BIFFI ITALIA SGR – Spur Gear Reducer Instruction and operating manual
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BIFFI ITALIA SGR – Spur Gear Reducer Instruction and operating manual
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9.3 SGR250 Parts List
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9.4 SGR400 Parts List
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BIFFI ITALIA SGR – Spur Gear Reducer Instruction and operating manual
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9.5 SGR640 Parts List
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BIFFI ITALIA SGR – Spur Gear Reducer Instruction and operating manual
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9.6 SGR1000 e SGR 1600 Parts List
BIFFI ITALIA SGR – Spur Gear Reducer Instruction and operating manual
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BIFFI ITALIA SGR – Spur Gear Reducer Instruction and operating manual
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BIFFI ITALIA s.r.l.
Loc. Caselle S. Pietro
29017 Fiorenzuola d’Arda -Piacenza - ITALY -
Tel. (0523) 944411 - Fax (0523) 941885
E_mail: [email protected]