INSTALLATION AND OPERATION MANUAL FOR SBWG SERIES WORM GEAR ACTUATORS

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1 INSTALLATION AND OPERATION MANUAL FOR WORM GEAR ACTUATORS Thank you for purchasing our SBWG Worm Gear Actuator. Before installing or operating actuator, please carefully read this manual. The contents in this manual is subject to change due to quality improvement without individual notice. 1

2 Index This operating instruction can be applied for all worm gear models made by SAMBO Gears. - Standard type : Gear actuators for general type - Single reduction type (-1S type) : Horizontal input with single reduction gear attachment - Double reduction type(-1sd type) : Horizontal input with double reduction gear attachment - Triple reduction type(-2sd type) : Horizontal input with triple reduction gear attachment - Declutch type : Use for emergency such as fire and explosion 1. SAFETY INSTRUCTIONS 1.1 Range of Application Maintenance Warning 3 2. TECHNICAL DATA 4 3. TRANSPORT, STORAGE & PACKING 3.1 Transport Storage Packing 6 4. FITTING HAND WHEEL & STEM BUSH 4.1 Hand wheel Splined bushing 7 5. INPUT, OUTPUT SHAFT ROTATION OPTIONS 5.1 Right hand input Left hand input 8 6. ADJUSTMENT OF SET SCREWS 6.1 Adjustment of set screws for 90 Rotation (Manual) Adjustment of set screws for 90 Rotation (MOV) 9 7. ENCLOSURE PROTECTION IP-67, MAINTENANCE 8.1 General Maintenance Sealing Grease Removal & Replacement SPARE PARTS LIST: STANDARD TYPE SPARE PARTS LIST: SINGLE REDUCTION TYPE SPARE PARTS LIST: DOUBLE REDUCTION TYPE SERVICE 16 2

3 SAFETY INSTRUCTIONS 1.1 Range of Application Challenger Worm Gear Actuators are quarter-turn gearboxes intended to be used for the operation of valves (eg. Butterfly Valves, Ball Valves, Damper etc.). This gearbox is designed for not only manual operation but also motorised operation. If you need to use for other applications, please contact Challenger are note responsible for any damage caused by incorrect use of the gearbox. The qualified personnel must be fully aware of the instructions as described in this manual. 1.2 Maintenance For safe operation of Worm Gearbox, please observe maintenance instructions (pg 12). 1.3 Warning This manual contacts Warnings, marking activities or procedures which, if not carried out correctly, can affect the safety of persons or material. Every caution should be taken to ensure all instructions contained herein are fully understood and addressed during operation. 3

4 TECHNICAL DATA FEATURES AND FUNCTIONS Housing Housing Cover All external castings are Ductile Iron Class , Tensile Strength of 65,000PSI. This provides high strength and excellent impact. Indicators, "Close-Open-Close" are cast directly on the cover. This permits operation in either direction with position indication. Worm Gear Standard material is Ductile Iron, Grade , suitable for most Industrial applications. Normally required for motorised applications involving modulating service and is also a requirement to meet the AWWA standards. The internal is splined to accept the splined bushing. Worm Splined Bushings Thrust Washer Indicator Plate Tapered Roller Bearing Gasket 4140 Heat Treated Steel, with ground and polished worm threads. Precision cutting of the threads provides minimum backlash between the worm gear and worm. All units furnished with removable splined bushings to permit accurate position between the gear drive and the valve shaft. The drive sleeve is furnished with hardened steel thrust washers above and below worm gear. This minimises frictional losses between the gear and the ductile iron castings. Pointer provides positive position indication. The pointer can easily be repositioned if required. The worm is supported on tapered roller bearings which support both the axial and radial forces generated by the gearings. They have excellent load bearing capacity. Each end of the worm assembly is equipped with special design material (non-asbestos), which are completely water resistant. External Adjustable Stops The stop bolts allow for position accuracy of +/- 5. Output Torque Self-locking Units are available with single, double and triple reduction spur gears. This series of Worm Gears range from 310Nm Nm. The gearboxes are self-locking when at a stand-still under normal service conditions: strong vibrations may cancel the self-locking effect. While in motion, safe braking is not guaranteed. 4

5 TECHNICAL DATA (cont.) WORM GEAR ACTUATORS FOR REDUCTION TYPE Worm gear actuators for reduction type Attachment on standard type and the reduction types are enabled to have various gear ratios and direction to reduce the input torque. VALVE ATTACHMENT Mounting to valve STANDARD: Manufacturing based on ISO Spline bushing STANDARD: Supplied by Solid (blank) type or minimum pilot hole OPTION: Supplied by One, two or four keyway etc. SERVICE CONDITIONS Enclosure protection STANDARD: IP-67 (Perfect protection against dust and waterproof) OPTION: IP-68 (To operate continuously in waterproof application contact Challenger Valves and Actuators to confirm suitability). Corrosion protection STANDARD: Challenger gears are suitable for installation in industrial units in water or power plants with a low pollutant concentration. OPTION: Suitable for installation in extremely aggressive atmosphere with high humidity and high pollutant concentration (Contact Challenger Valves and Actuators to confirm suitability). Painting STANDARD: Jotun 412 Black (Contact Challenger Valves and Actuators for special painting options) STANDARD: -20 C to +120 C OPTION: (Low temperature) -40 C to +90 C Ambient temperature (Extreme low temperature) -60 C to +90 C (High temperature) -10 C to +200 C (Contact Challenger Valves and Actuators for additional temperature options). 5

6 TRANSPORT, STORAGE & PACKAGING 3.1 Transport Transport to installation site in sturdy packaging. If mounted together with actuator, attach slings or hooks for the purpose of lifting by hoist only to the gearbox and not to the actuator. 3.2 Storage Challenger gears should be stored in a clean, dry area in their shipping containers. If stored for long periods of time, the actuator mounting bases should be lightly greased to prevent corrosion. 3.3 Packaging The gears are transported within protective packaging which consists of environmentally friendly materials for easy separation and recycling. FITTING THE HAND WHEEL 4.1 Hand wheel For gearboxes designed for manual operation, the hand wheel is supplied separately. Fitting is done on site according to Figure 1. Figure 1: Hand wheel 6

7 FITTING THE HAND WHEEL (cont.) 4.2 Splined Bushing All units furnished with removable splined bushings to permit accurate position between the gear drive and the valve shaft. Removal and reassembly of the Splined Bushing is as follows: Assembly 1.) Turn gearbox face down POSITION INDICATOR OPEN CLOSE 2.) Insert bush correctly into the worm gear - Insert bush into groove of worm gear - There are 2 grooves at bottom of worm gear - One groove is for open and the other is for close 3.) Fix spring Remove 1.) Remove fixed spring using suitable tool (flat head screw driver) WORM GEAR 2.) Remove splined bush STEM BUSH FIX SPRING 7

8 INPUT, OUTPUT SHAFT ROTATION OPTIONS 5.1 Right Hand Input RR(CW IN - CW OUT) - Right hand input to clockwise (CW) rotation, output to clockwise (CW) rotation. (CLOSE position) - Standard type: Standard Flat Face. (Raised face available on request) RL(CW IN - CCW OUT) - Right hand input to clockwise (CW) rotation, output to counter clockwise (CCW) rotation. (OPEN position) 5.2 Left Hand Input LL (CW IN - CW OUT) - Left hand input to clockwise (CW) rotation, output to clockwise (CW) rotation. (CLOSE position) LL (CW IN - CCW OUT) - Left hand input to clockwise (CW) Rotation, output to counter clockwise rotation. (OPEN Position) 8

9 ADJUSTMENT OF SET SCREWS 6.1 Adjustment of set screws for 90 Rotation (manual hand wheel type) - Manoeuvre valve and actuator to closed position. - Adjust the closed set screw on the gearbox, repeat for the open position 6.2 Adjustment of set screws for 90 Rotation (MOV type) - Manoeuvre valve and actuator to closed position. - Adjust the closed set screw on the gearbox, repeat for the open position WARNING: Set screws are set in the warehouse prior to delivery, if settings are altered the user is responsible for any damage that may occur. 9

10 ENCLOSURE PROTECTION IP-67, 68 Definition: IP67: According to IEC 529, the conditions for meeting the requirements of enclosure protection IP67. Under the conditions for regular pressure and time, test regulation can meet to prevent ingress of water. (15cm-1m) Contents: - Challenger worm gearboxes in enclosure protection IP 67 fulfil the following requirements in compliance with Challenger definitions. - IP67: Complete enclosure protection for dust and no ingress of water during submersion. (Standard) - IP68: Complete enclosure protection for dust and suitable to use continuously during submersion. - Test regulation is to be agreed between manufacturer and user. (OPTION) - If submersed in other media, additional measures for corrosion protection may be necessary. (Please contact Challenger Valves and Actuators) Note: The enclosure protection IP 67 is available to the interior of the gearbox, but does not protect mounting flange. If gearboxes are likely to be repeatedly submersed, a higher corrosion protection may be necessary (Please contact Challenger Valves and Actuators). - Use suitable sealing material between valve flange and gearbox. - If unsuitable sealing material is used, water can not be prevented from entering the coupling via the mounting flange part, this leads to corrosion within the interior of the gearbox. - To protect from this type of corrosion, we would suggest you select higher corrosion protection before mounting valve. 10

11 MAINTENANCE 8.1 General Maintenance - Check the external appearance for foreign matter and clean if required. - If coating is damaged this may lead to corrosion or rust, re-coat if necessary. - The gearbox is required to operate at least 10 times per year - Check the following points: 8.2 Sealing - Every 6-12 months check worm gear actuators for cleanliness and general condition. - Valve must operate 5 times per 6 months. - Check for grease leakage every 12 months. (Fill up grease if required) - Life cycle of NBR seals is about 12 years from manufacturing date. (The life cycle is based on average 40 C) 8.3 Grease - Change grease as per below: - In case of operating rarely: 10 to 12 years - In case of operating normally: 6 to 8 years - In case of operating frequently: 4 to 6 years - Contact Challenger Valves and Actuators for grease specification. - Do not mix lubricant with any other fluids. - When removing lubricant and cleaning inside gear actuators, observe the correct instruction of replacement & remove (see 8.4) - Challenger is not responsible for any damage caused by incorrect removal and replacement. 8.4 Removal & Replacement - Challenger worm gears have a long life cycle, but proper replacement should be required to maintain this long life cycle. - Challenger is not responsible for any damage caused by incorrect removal, assembly or replacement. 11

12 SPARE PARTS LIST: STANDARD TYPE 12

13 SPARE PARTS LIST: STANDARD TYPE (cont.) No. Description Name Material ASTM Remark 01 Housing Ductile Iron A Note 1 02 Cover Ductile Iron A Worm Alloy Steel A Note 2 04 Stem Nut Ductile Iron Worm Wheel Ductile Iron B1486-C (ALBC3) 06 Front Cap Carbon Steel A End Cap Carbon Steel A Indicator Plate Carbon Steel A Thrust Washer Carbon Steel A283 GR.D 10 Fixed Spring Special Steel AISI Taper Roll Bearing Special Steel A Hex Bolt (S/W) Alloy Steel A Hex Bolt (S/W) Alloy Steel A Hex Bolt (P/W) Alloy Steel A Hex Bolt Alloy Steel A Hex Nut Alloy Steel A O-Ring Buna N NBR 18 O-Ring Buna N NBR 19 O-Ring Buna N NBR Note 3 20 O-Ring Buna N NBR 21 Cover Gasket NON-Asbestos 22 Cap Gasket NON-Asbestos VALQUA Packing Seal Buna N NBR 24 Grease Fitting Carbon Steel A Eye Bolt Carbon Steel A OP-1 Hand Wheel Steel Pipe A53 OP-2 Key (1R) Carbon Steel A OP-3 Name Plate Aluminium OP-4 Washer Carbon Steel A283 GR.D Handle Part Note 4 OP-5 Hex. Bolt (S/W) Alloy Steel A Material details: Options and Material changes 1. All castings are Ductile Iron, FCD-450 (ASTM Class ) 2. Option for Nickel coating, high tensile stainless. 3. O-Ring Seals and Lubricant: - Standards is Buna N, temperature range 30 C to +120 C - Standard lubricant is Shell Alvania EP2, Temperature range 20 C to 120 C Other Options: High Temperature Viton O-Ring Grade V75, Temperature range 25 C to +200 C Lubricant Shell Darina R2, Temperature range 10 C to +200 C Low Temperature Viton O-Ring Grade V115, Temperature range 35 C to +160 C Lubricant Shell S-6751, Temperature range 40 C to +90 C 4. We offer a wide variety of Hand Wheels, Chain Wheels, Input Shaft Locking Devices, etc. 13

14 SPARE PARTS LIST: SINGLE REDUCTION TYPE No. Description Name Material ASTM Remark 01 Housing Ductile Iron A Cover Ductile Iron A Worm Alloy Steel A Stem Nut Ductile Iron A Worm Wheel Ductile Iron A ALBC3 06 Front Cap Carbon Steel A End Cap Carbon Steel A Indicator Plate Carbon Steel A Thrust Washer Carbon Steel A283 GR.D 10 Fixed Spring Special Steel AISI Taper Roll Bearing Special Steel A Hex Bolt (S/P) Alloy Steel A Hex Bolt (S/P) Alloy Steel A Hex Bolt (S/P) Alloy Steel A Hex Bolt Alloy Steel A Hex Nut Alloy Steel A O-Ring Buna N NBR 18 O-Ring Buna N NBR 19 O-Ring Buna N NBR 20 Retainer Buna N NBR Material No. Description Remark Name ASTM SU-1 Support Housing Ductile Iron A SU-2 Helical Pinion Alloy Steel A SU-3 Radial Ball B/R Special Steel A SU-4 Radial Ball B/R Special Steel A SU-5 Idle Gear Alloy Steel A SU-6 Radial Ball B/R Special Steel A SU-7 Helical Gear Alloy Steel A SU-8 Key (1R) Carbon Steel W1-8 SU-9 Snap Ring Carbon Steel A SU-10 Radial Ball B/R Special Steel A SU-11 Support Cover Ductile Iron A SU-12 S-Cover Gasket NON-Asbestos VALQUA 6500 SU-13 Hex Bolt (S/W) Alloy Steel A SU-14 Retainer Buna-N NBR 21 Cover Gasket NON-Asbestos 22 End Cap Gasket NON-Asbestos 23 Packing Seal Buna N NBR 24 Grease Fitting Carbon Steel A VALQUA 6500 OP-1 Hand Wheel Steel Pipe A53 OP-2 Key (1R) Carbon Steel A OP-3 Name Plate Aluminium OP-4 Washer Carbon Steel A283 GR.D Option Handle Part 25 Eye Bolt Carbon Steel A OP-5 Hex Bolt (S/W) Alloy Steel A

15 SPARE PARTS LIST: DOUBLE REDUCTION TYPE No. Description Name Material ASTM Remark 01 Housing Ductile Iron A Cover Ductile Iron A Worm Alloy Steel A Stem Nut Ductile Iron A Worm Wheel Ductile Iron A ALBC3 06 Front Cap Carbon Steel A End Cap Carbon Steel A Indicator Plate Carbon Steel A Thrust Washer Carbon Steel A283 GR.D 10 Fixed Spring Special Steel AISI Taper Roll Bearing Special Steel A Hex Bolt (S/P) Alloy Steel A Hex Bolt (S/P) Alloy Steel A Hex Bolt (S/P) Alloy Steel A Hex Bolt Alloy Steel A Hex Nut Alloy Steel A O-Ring Buna N NBR 18 O-Ring Buna N NBR 19 O-Ring Buna N NBR 20 Retainer Buna N NBR No. Description Name Material ASTM SU-1 Support Housing Ductile Iron A SU-2 Helical Pinion Alloy Steel A SU-3 Radial Ball B/R Special Steel A SU-4 Radial Ball B/R Special Steel A SU-5 Idle Gear Alloy Steel A SU-6 Radial Ball B/R Special Steel A SU-7 Helical Gear Alloy Steel A SU-8 Key (1R) Carbon Steel A SU-9 Snap Ring Carbon Steel A SU-10 Radial Ball B/R Special Steel A SU-11 Support Cover Ductile Iron A Remark SU-12 S-Cover Gasket NON-Asbestos VALQUA 6500 SU-13 Hex Bolt (S/W) Alloy Steel A SU-14 Retainer Buna-N NBR 21 Cover Gasket NON-Asbestos 22 End Cap Gasket NON-Asbestos 23 Packing Seal Buna N NBR 24 Grease Fitting Carbon Steel A VALQUA 6500 OP-1 Hand Wheel Steel Pipe A53 OP-2 Key (1R) Carbon Steel A OP-3 Name Plate Aluminium OP-4 Washer Carbon Steel A283 GR.D Option Handle Part 25 Eye Bolt Carbon Steel A OP-5 Hex Bolt (S/W) Alloy Steel A

16 SERVICE Horizontal Type Flange (for electric actuator) Locking Device Vertical Type Flange (for electric actuator) Square Adaptor Underground Special Type Travelling Nut Stop Declutch Gear Planet Reduction Air Cylinder 16

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