BIFFI WGR Series Parts list manual

WGR –Worm Gear Reducer
Instruction and operating manual
© Copyright by BIFFI Italia. All right reserved MAN 684/Rev 5 Page 1
MAN 684
WGR - Worm Gear Reducer
Instruction and Operating Manual
5
19/01/2017
Added sight glass with optional
relief version
Toscani
Orefici
Vigliano
4
18/04/2016
Updated applicable regulation
(chapter 1.7)
Ermanni
Orefici
Vigliano
3
11/06/2012
Revised chapter 11 (parts list)
Ermanni
Ghiadoni
Vigliano
2
08/03/2012
Revised Pictures
Guarnieri
Ghiadoni
Vigliano
1
23/05/2010
Revised Chapter 7
Schiavi
Ghiadoni
Vigliano
0
04/12/2007
Issue
Orefici
Alfieri
Alfieri
Rev.
Date
Description
Prepared
Verified
Approved

WGR –Worm Gear Reducer
Instruction and operating manual
© Copyright by BIFFI Italia. All right reserved MAN 684/Rev 5 Page 2
BIFFI ITALIA has taken every care in collecting and verifying the documentation contained in this Instruction and
Operating Manual. The information herein contained are reserved property of BIFFI ITALIA.
Contents may change without notice.

WGR –Worm Gear Reducer
Instruction and operating manual
© Copyright by BIFFI Italia. All right reserved MAN 684/Rev 5 Page 3
INDEX
1GENERAL SAFETY INSTRUCTIONS.................................................................................5
1.1 Manufacturer 5
1.2 Machine Intended Use 5
1.3 Terms and conditions 6
1.4 Manufacturer’s Liability 6
1.5 Applicable Standards and Regulations 6
1.6 Installation in hazardous area 6
1.7 Marking for application in hazardous area 7
1.7.1 Label for ICON2000/ICON2000EC ............................................................................................................................. 7
1.7.2 Extract from the Standard........................................................................................................................................... 7
2MACHINE DESCRIPTION .................................................................................................7
2.1 General 7
2.2 Main Parts Description 8
3TECHNICAL DATA..............................................................................................................9
3.1 Application range 9
4TRANSPORT AND STORAGE ..........................................................................................10
4.1 Transport 10
4.2 Checks to be carried out on receipt of the WGR reducer 11
4.3 Storage Procedure 11
5INSTALLATION ................................................................................................................12
5.1 Working condition 12
5.2 Safety Instructions for installation in Hazardous Area 12
5.2.1 Instructions for the explosion-proof enclosures ................................................................................................ 12
5.2.2 Installation in ambient with explosive dusts ...................................................................................................... 12
6ASSEMBLING THE WORM GEARBOX ONTO THE VALVE ...........................................13
7ADJUSTING THE MECHANICAL STOPPERS.................................................................15
7.1 Grease-lubrication-type gearbox (WGR standard type) 15
7.2 Oil-lubrication-type gearbox (WGR-DW series models) 15
8MAINTENANCE ................................................................................................................17
8.1 Standard Maintenance 17
8.2 Special Maintenance 17

WGR –Worm Gear Reducer
Instruction and operating manual
© Copyright by BIFFI Italia. All right reserved MAN 684/Rev 5 Page 4
9DISASSEMBLY INSTRUCTIONS ....................................................................................18
9.1 Access to the main reduction and to the epicyclical reduction 18
9.2 Epicyclical reduction removal 20
9.3 Main reduction removal 21
9.4 Greasing the main reduction and the epicyclical reduction 22
10 LUBRICATION ..............................................................................................................25
10.1 Grease lubrication type gearbox (WGR standard type) 25
10.2 Oil lubrication type gearbox (WGR-DW series models) 25
10.3 Refilling procedure (only for WGR-DW series models) 26
11 PARTS LIST...................................................................................................................27
11.1 How to Order Parts List 27
11.2 WGR100 Parts List 28
11.3 WGR200 Parts List 30
11.4 WGR400 Parts List 32
11.5 WGR800 Parts List 34
11.6 WGR1600 Parts List 36
11.7 WGR3200 Parts List 38
11.8 WGR6300 Parts List 40
11.9 Optional Relief on sight glass Parts List ( applicable to all WGR Models) 42
12 DISASSEMBLING AND DEMOLITION .......................................................................44

WGR –Worm Gear Reducer
Instruction and operating manual
© Copyright by BIFFI Italia. All right reserved MAN 684/Rev 5 Page 5
1GENERAL 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 WGR series (on-off type, up to
60 starts/hour) and WGR-DW series (intermittent type up to 1200 starts/hour), designed to operate
any kind of quarter-turn industrial valve for applications in heavy industrial, chemical, petrochemical, food, water
and power generating plants. They are designed for motor operation in conjunction with 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.
WGR reducers are produced by BIFFI ITALIA and identified on the proper label by product designation WGR-
XXXX.
Important
This Manual provides basic information for the setting of WGR series reducers;
more detailed information on the setting and control of Electric Actuators
ICON2000 can be found in MAN 618, which forms part of the mandatory
instructions documentation.
Warning
It is assumed that the installation, setting, commissioning and 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
storage or installation of the device. If an electric actuator is attached to the WGR
reducer, please be aware of the electrical hazards and consult the relevant
electric actuator installation and maintenance manual for guidance.
The WGR series is designed in accordance with the applicable International Rules and Specifications, but in all
cases the following Regulation must be observed:
the general installation and safety regulations
the plant specific regulations and requirements
the proper use of personal protective equipment (goggles, clothing, gloves)
the proper use of tools, lifting and transport equipment.

WGR –Worm Gear Reducer
Instruction and operating manual
© Copyright by BIFFI Italia. All right reserved MAN 684/Rev 5 Page 6
1.3 Terms and conditions
BIFFI ITALIA guarantees each single product to be free from defects and in accordance to current goods
specifications and applicable regulations. 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 damage or corrosion due to 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.
2014/34/EU ATEX Directive.
1.6 Installation in hazardous area
Warning
In case the WGRs are to be installed in a HAZARDOUS AREA, as defined by
the applicable Rules, it is mandatory to check whether 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 be carried out by qualified personnel and
checked by responsible Specialists.
Standard WGRs have IP66/67/68 degree of protection according to EN 60529.
IP 68 achieved with a submersion under 15 meter for 100 hours.

WGR –Worm Gear Reducer
Instruction and operating manual
© Copyright by BIFFI Italia. All right reserved MAN 684/Rev 5 Page 7
1.7 Marking for application in hazardous area
1.7.1 Label for ICON2000/ICON2000EC
The ICON 2000/ICON 2000 EC associated to the WGR, for the application in hazardous areas, must bear 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 2014/34/EU 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
2MACHINE DESCRIPTION
2.1 General
The WGR is a worm gear reducer designed to operate, in conjunction with ICON2000 electric actuator, any kind of
quarter-turn industrial valve.
The gear box is suitable to guarantee the output bush rotation of 90° with the possibility to obtain an extra stroke
of 5° for each direction of rotation. The rotation bush is stopped, in both the rotation direction, against mechanical
stoppers integrated in the gear box frame with the possibility to regulate the travel of 5° for each rotation
direction. The housing is provided with an optional vent valve in order to avoid any eventual overpressure.

WGR –Worm Gear Reducer
Instruction and operating manual
© Copyright by BIFFI Italia. All right reserved MAN 684/Rev 5 Page 8
2.2 Main Parts Description
Picture 1
Picture 2
Main Reduction Case
Epicyclical Reduction Case
Mechanical Stoppers
Close Position Label
Open Position Label
Position Indicator
WGR Identification and
Characteristics Label
Closing Direction Label

WGR –Worm Gear Reducer
Instruction and operating manual
© Copyright by BIFFI Italia. All right reserved MAN 684/Rev 5 Page 9
3TECHNICAL DATA
WGR Model
ICON2000
Model
Nominal Torque (100%)
[Nm]
Maximum Torque
[Nm]
WGR Ratio
(10%)
Valve Attachment
ISO 5211
WGR 100
010
1.000
1.500
50:1
F14
WGR 200
010
2.000
3.000
98:1
F16
WGR400
010
4.000
6.000
124:1
F16
WGR 800
020
8.000
12.000
183:1
F25/F30
WGR 1600
020
16.000
24.000
373:1
F25/F30
WGR 3200
020
32.000
48.000
747:1
F30/F35
030
32.000
48.000
400:1
F30/F35
WGR6300
020
63.000
94.500
1680:1
F40
030
63.000
94.500
920:1
F40
040
63.000
94.500
377:1
F40
3.1 Application range
WGR gear boxes are suitable to operate in on-off or intermittent service up to 60 starts/hour max.
WGR-DW gear boxes are suitable to operate in modulating service (up to 1200 starts/hour max).
Quarter-turn worm screw gear boxes are suitable to be motorized for applications in standard temperature range
from –30°C to +85°C (low temperature version are suitable to operate in temperature range from -40°C up to
+85°C).
WGR gear boxes are suitable to guarantee the output bush rotation of 90° with the possibility to obtain a 5° extra
stroke for each direction of rotation.
WGR gear boxes have protection degree IP66M and IP67M according to EN 60529, complete with third-party
certificate (the enclosure protection IP66/IP67/IP68 refers to the interior of the gearboxes, but not to the coupling
compartment).
IP 68 achieved with a submersion under 15 meter for 100 hours.
WGR gear boxes are also available with protection degree IP68 according to EN60529 (the enclosure protection
IP68 refers to the interior of the gearboxes, but not to the coupling compartment).
Please check with Biffi the acceptance of the submersion request (depth, medium, etc.) in order to verify the
compatibility requirements.

WGR –Worm Gear Reducer
Instruction and operating manual
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4TRANSPORT and STORAGE
Important
Not performing the following procedures will invalidate the product guarantee.
Important
Gear box (and actuator) lifting and transportation must be done by qualified
personnel only and in accordance with the local regulation and area classification.
Warning
The lifting studs are suitable for the transportation of the actuator and gear box
only, NOT for the valve-actuator assembly.
The actuator and gear box weights are indicated on delivery documents.
4.1 Transport
Make sure the worm gearbox has a strong protecting packing during transport to destination.
If the worm gearbox is assembled onto the electric actuator, hoist it with ropes or hooks making sure they are
attached to the gearbox and not to the actuator.

WGR –Worm Gear Reducer
Instruction and operating manual
© Copyright by BIFFI Italia. All right reserved MAN 684/Rev 5 Page 11
4.2 Checks to be carried out on receipt of the WGR reducer
Carefully remove the reducer from its shipping carton or skid. Check that the worm gearbox has not been
damaged during transport. If damaged, immediately report the damage to the transport company.
First of all check whether the information on the nameplate (Model, Nominal torque, Degree of protection,…)
correspond to the order acknowledgement data.
If the actuator and WGR are already assembled onto the valve, the setting of the mechanical stops and of the
electric end of travel has already been done in-house.
If the actuator and WGR are shipped separately from the valve, the setting of the mechanical stops and of the
electric end of travel must be checked and, if necessary, carried out while assembling the actuator and the
gearbox onto the valve.
Check that the fitted accessories comply with those listed in the order acknowledgement and the delivery note.
4.3 Storage Procedure
Important
Please make sure you stick to the following storage procedure to maintain top
WGR integrity during storage; failure to comply with the recommended procedure
will invalidate the warranty.
The worm gearboxes 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 installation
on the plant, it is necessary to observe a few rules and take appropriate measures during the storage period.
Store in a well-ventilated, protected, dry room.
Store the gearboxes on wooden skids or shelves to protect the machined mounting flange.
If the WGRs are supplied separately from the valves, they must be placed onto a wooden pallet. In case of
long-term storage (over six months), the worm gearboxes must be covered and protected from dust and dirt,
and it is necessary to apply a suitable corrosion protection agent to bare surfaces, particularly the output drive
parts and mounting surfaces.
In case of long-term storage, it is advisable to keep the worm gearboxes in a clean, dry place in order to
provide at least some means of weather protection.
If the gearboxes must be stored outside, they must be adequately protected (for example covered in
polyethylene protection with silica gel crystals to absorb moisture).
For the storage of the Electric Actuator supplied together with the worm gearbox, please refer to the storage
instructions included in the actuator’s IOM (MAN 618).

WGR –Worm Gear Reducer
Instruction and operating manual
© Copyright by BIFFI Italia. All right reserved MAN 684/Rev 5 Page 12
5INSTALLATION
5.1 Working condition
Standard WGR gearboxes 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 -40°C up to +85°C
Important
Check the "temperature ambient range" on the nameplate for correct use.
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 WGR - Electric Actuator in hazardous
areas, please refer to the Electric Actuator IOM (MAN 618).
5.2.2 Installation in ambient with explosive dusts
Important
For the installation of the assembly WGR - Electric Actuator in ambient with
explosive dusts, please refer to the Electric Actuator IOM (MAN 618).

WGR –Worm Gear Reducer
Instruction and operating manual
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6ASSEMBLING the WORM GEARBOX ONTO the VALVE
The worm gearbox is provided with an output flange and an insert (machined or not machined, based on Customer
requirements) for the coupling to the valve. 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 worm
gearbox coupling dimensions.
Arrange the valve in the position related to the worm gearbox operation (for both butterfly valves and ball
valves the recommended position is OPEN).
Lubricate the valve stem with oil or grease in order to make the assembly easier: be careful not to contaminate
with lubricant the flange surfaces which have to be connected to transmit the actuator torque.
Clean the valve flange and remove anything that might prevent a perfect adherence to the worm gearbox
flange and especially all traces of grease.
If the insert supplied is not machined, remove it from the WGR output drive, machine it and reassemble it in
the WGR output drive.
Bring the worm gearbox to the recommended position (for both butterfly valves and ball valves the
recommended position is OPEN).
Clean the worm gearbox flange and remove anything that might prevent a perfect adherence to the valve
flange and especially all traces of grease.
Lower the actuator/WGR package onto the valve so that the WGR output drive couples with the valve stem
(for example, if the connection is made by key, the valve stem key groove must match with the WGR output
drive key groove). This coupling must take place without forcing and only with the weight of the actuator and
worm gearbox. When the worm gearbox output drive and the valve stem are connected, check the holes of the
valve flange. If they do not meet with the holes of the spool piece flange or the stud bolts screwed into them,
the worm gearbox output drive must be rotated until coupling is possible.
Tighten the nuts of the connecting stud bolts evenly with the torque prescribed in the table. If no different
materials are specified, the stud bolts must be made of ASTM A 320 Grade L 7 steel, the nuts must be made of
ASTM A 194 Grade 2 or better.

WGR –Worm Gear Reducer
Instruction and operating manual
© Copyright by BIFFI Italia. All right reserved MAN 684/Rev 5 Page 14
Thread size
Recommended tightening
torque (Nm)
M16
160
M20
320
M22
420
M24
550
M27
800
M30
1100
M36
1700
If possible, operate the actuator to check that it moves the valve smoothly.

WGR –Worm Gear Reducer
Instruction and operating manual
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7ADJUSTING THE MECHANICAL STOPPERS
7.1 Grease-lubrication-type gearbox (WGR standard type)
Please refer to the following Picture 3
Important
Closed position:
1. Loose the nut (1).
2. Loose the stopper (2) with a hex-head wrench. Stopper shall be taken out
as much as possible from the body of the gear.
3. Set-up actuator stroke limits according to the procedure described in
MAN618, chapter 1, paragraphs 1.1 and 1.2.
4. Tighten the stopper (2) until it stops, then step back a quarter of turn.
5. Tighten the nut (1).
Open position:
the same procedure of closed position, on the opposite stopper.
Picture 3
7.2 Oil-lubrication-type gearbox (WGR-DW series models)
Please refer to the following Picture 4
Important
Closed position:
1. Remove the plug (1) with a hex-head wrench.
2. Release the cap (2).
3. Loose the nut (1).
4. Loose the stopper (2) with a hex-head wrench. Stopper shall be taken out
as much as possible from the body of the gear.
5. Set-up actuator stroke limits according to the procedure described in
MAN618, chapter 1, paragraphs 1.1 and 1.2.
6. Tighten the stopper (2) until it stops, then step back a quarter of turn.
7. Tighten the nut (1).
Open position:
the same procedure of closed position, on the opposite stopper.
(1)
(2)

WGR –Worm Gear Reducer
Instruction and operating manual
© Copyright by BIFFI Italia. All right reserved MAN 684/Rev 5 Page 16
Picture 4
(1)
(2)
(3)

WGR –Worm Gear Reducer
Instruction and operating manual
© Copyright by BIFFI Italia. All right reserved MAN 684/Rev 5 Page 17
8MAINTENANCE
8.1 Standard Maintenance
BIFFI worm gearboxes require no maintenance.
After commissioning and once a year, check the paint-coat of the worm gearbox. 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 a year, check that the nuts and bolts securing
the worm gearbox to the electric actuator and to the valve are tight, and, if necessary, re-tighten.
Approx. every 2 years visually inspect the gearbox for grease leakage. For oil lubrication type
gearboxes (WGR-DW series models) visually inspect for oil leakage approximately every year.
For severe applications or if worm gearbox operation is infrequent, perform maintenance checks
at shorter intervals.
8.2 Special Maintenance
In case of malfunction, in case of grease leaks, or in case of scheduled preventive maintenance, the
worm gearbox must be disassembled: any damaged part can be requested from BIFFI with reference
to the attached exploded view drawing and parts list.
Every spare parts request must clearly indicate the relevant gearbox 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/WGR
must be done to check that movement is regular.
Important
For maintenance instructions of the Electric Actuator ICON2000 supplied
together with the worm gearbox WGR, please refer to the ICON2000 IOM
(MAN 618).

WGR –Worm Gear Reducer
Instruction and operating manual
© Copyright by BIFFI Italia. All right reserved MAN 684/Rev 5 Page 18
9DISASSEMBLY INSTRUCTIONS
9.1 Access to the main reduction and to the epicyclical reduction
Please refer to the following Pictures 5, 6 and 7.
Unscrew the screws (1) and remove the position indicator cover
Unscrew the screws (2) and remove the position indicator (3)
Release the cylindrical pin (4)
Unscrew the screws (5) and remove the upper cover (6)
Unscrew the screws (7) and remove the trunk (8)
After completing these operations, the main reduction and the epicyclical reduction will appear as
shown in Picture 7.
The flexoid gasket (9) and the o-ring (10) (please refer to Picture 7) must be replaced every time the
upper cover is opened.
Picture 5
(4) cylindrical pin: release it
to remove the upper cover
(5) screws: unscrew to remove
the upper cover
(1) screws: unscrew to remove
position indicator cover
(3) position indicator
(2) screws: unscrew to remove
position indicator

WGR –Worm Gear Reducer
Instruction and operating manual
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Picture 6
Picture 7
(3) position indicator
(6) upper cover
(8) trunk
(7) screws: unscrew to
remove the trunk
Main Reduction
Epicyclical Reduction
(9) Flexoid gasket
(10) o-ring
(5) screws: unscrew to remove
the upper cover
(4) cylindrical pin: release it
to remove the upper cover
(2) screws: unscrew to remove
position indicator

WGR –Worm Gear Reducer
Instruction and operating manual
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9.2 Epicyclical reduction removal
Please refer to the following Picture 8
Remove the trunk (8 in Picture 6) following the instructions of Par. 9.1
Remove the pin (1)
Remove the operating gear (planet wheel) (2)
Remove the seeger (3)
Remove the satellite holder (4)
Picture 8
(1) Pin
(2) Planet Wheel
(3) Seeger
(4) Satellite Holder