biffi italia sgr man 685 - ellingsen-gruppen they are designed for motor operation in conjunction...

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


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.


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


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


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.



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.



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



Dust Zone 20 1D

Dust Zone 21 2D

Dust Zone 22 3D



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



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



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.



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.



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).



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.



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.



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.



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.



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



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


Batteries YES YES Will require special treatment before disposal, use


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.



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.



9.2 SGR160 Parts List



9.6 SGR1000 e SGR 1600 Parts List



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]

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