Spring-Return Hydraulic Actuator

Installation, Operation and Maintenance Manual MAN610-1 Rev. 6September 2021

Biffi OLGAS-QA (Quick Acting) Spring-Return Hydraulic Actuator

Copyright © Biffi. The information in this document is subject to change without notice. Updated data sheets can be obtained from our website www.biffi.it or from your nearest Biffi Center: Biffi Italia s.r.l. - Strada Biffi 165, 29017 Fiorenzuola d'Arda (PC) – Italy PH: +39 0523 944 411 – [email protected]

Installation, Operation and Maintenance ManualMAN610-1 Rev. 6

Revision DetailsSeptember 2021

Revision Details

Revision Details

Rev. Date Description Prepared Checked Approved

6 September 2021 Added Section 1.1.3. and 1.1.4

5 May 2021 General update (Migration to new template)

4 May 2018 Revised data plate Ermanni Orefici Vigliano

3 November 2017 Section 1.3 revision and page 9 Ermanni Orefici Vigliano

2 April 2016 Updated applicable regulation (chapter 1.1.1) Ermanni Orefici Vigliano

1 February 2011 General update Ermanni Stoto Vigliano

0 Decmber 2010 Document release Ermanni Stoto Vigliano

i

Table of Contents

Table of Contents

Installation, Operation and Maintenance ManualMAN610-1 Rev. 6 September 2021

Table of Contents

Section 1: General Warnings1.1 Generalities ................................................................................................... 1

1.1.1 Applicable Regulation ........................................................................ 11.1.2 Terms and Conditions ......................................................................... 11.1.3 Electrostatic Charge ........................................................................... 21.1.4 Noise Emission ................................................................................... 2

1.2 Introducing the Actuator ............................................................................... 21.3 Data Sheet .................................................................................................... 3

Section 2: Installation2.1 Checks upon Actuator Receipt .......................................................................... 42.2 Actuator Handling ......................................................................................... 42.3 Storage ......................................................................................................... 62.4 Actuator Assembly on the Valve .................................................................... 6

2.4.1 Types of Assembly .............................................................................. 62.4.2 Assembly Procedure ......................................................................... 11

2.5 Hydraulic Connections ................................................................................ 122.6 Electrical Connections (If Any) ..................................................................... 132.7 Commissioning ........................................................................................... 13

Section 3: Operation and Use3.1 Operation Description ................................................................................. 143.2 Residual Risks .............................................................................................. 153.3 Operations .................................................................................................. 153.4 Calibration of the Quick Operation Time ..................................................... 15

3.4.1 Bypass Adjustment ........................................................................... 183.5 Calibration of the Angular Stroke ................................................................ 20

3.5.1 Calibration of Mechanical Stop on the Cylinder (If Applicable) .................. 213.5.2 Calibration of Mechanical Stop Placed on the Spring Container (If Applicable) ........................................................ 22

3.6 Calibration of Microswitches (Biffi Limit Switch Box) .................................... 23

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September 2021


Table of Contents

Table of Contents

Section 4: Maintenance4.1 Periodic Maintenance .................................................................................. 264.2 Extraordinary Maintenance ......................................................................... 26

4.2.1 Replacing the Gaskets of the Hydraulic Cylinder ................................ 264.2.2 Replacing the Gaskets of the Scotch Yoke Mechanism ...................... 284.2.3 Hydraulic Oil Features ....................................................................... 29

4.3 Lubrication of Mechanism ........................................................................... 304.4 Dismantling and Demolition ....................................................................... 31

Section 5: Troubleshooting5.1 Failure or Breakdown Research .................................................................... 32

Section 6: Spare Parts6.1 Spare Parts Order ........................................................................................ 33

Section 7: Cross Section Tables for Maintenance ActivitiesCross Section Tables for Maintenance Activities .................................................... 34

Section 8: Date Report for Maintenance OperationsDate Report for Maintenance Operations .............................................................. 39

1


Section 1: General Warnings

General Warnings


NOTICEThe manual is an integral part of the machine, it should be carefully read before carrying out any operation and it should be kept for future references.

1.1 Generalities

Biffi Italia s.r.l. actuators are conceived, manufactured and controlled according to the Quality Control System in compliance with EN-ISO 9001 international regulation.

1.1.1 Applicable Regulation

EN ISO 12100:2010: Safety of machinery – General principles for design – Risk assessment and risk reduction

2006/42/EC: Machine directive

2014/68/EU: Directive for pressure PED equipment

2014/35/EU: Directive for low voltage equipment

2014/30/EU: Directive for the electromagnetic compatibility

2014/34/EU: Directive and safety instructions for use in hazardous area

NOTICEBiffi Italia s.r.l. pays the highest attention to collecting and verifying the documentation contained in this Installation, Operation and Maintenance manual. The information contained is of exclusive reserved ownership of Biffi Italia s.r.l. and may be modified without prior notice. All rights reserved.

1.1.2 Terms and Conditions

Biffi Italia s.r.l. guarantees that all the items produced are free of defects in workmanship and manufacturing materials and meet relevant current specifications, provided they are installed, used and serviced according to the instructions contained in the present manual. The warranty can last either one year from the date of installation by the initial user of the product, or eighteen months from the date of shipment to the initial user, depending on which event occurs first. All detailed warranty conditions are specified in the documentation forwarded together with the product. This warranty does not cover special products or components not warranted by subcontractors, or materials that were used or installed improperly or were modified or repaired by unauthorized staff. In the event that a fault condition be caused by improper installation, maintenance or use, or by irregular working conditions, the repairs will be charged according to applicable fees.

The warranty and Biffi Italia s.r.l. liability shall lapse in the event that any modification or tampering whatsoever be performed on the actuator.

2

September 2021



General Warnings

Figure 1 OLGAS-QA parts identification

1.2 Introducing the Actuator

The OLGAS-QA actuator is designed for use in power plants and process plants, of the chemical, petrochemical and of heavy industry in general. It is used for the operation of quarter-turn valves if quick acting is required (opening or closing stroke).

The OLGAS-QA actuator is equipped (Figure 1) with a fast operation hydraulic cylinder that, pressurized, determines the linear motion of the piston contained in it. The linear motion of the piston is transformed into rotation by a scotch yoke mechanism.

The fast return operation is made by one or more compression helicoidal springs.

The quick acting time can be set through a hydraulic valve with fast discharge.

The OLGAS-QA actuator is equipped with a damping system active in the last degrees of the angular stroke of fast return.

The expected lifetime of actuator is approximately 25 years as conformity IEC61508 (SIL std reference).

Limit switch box

Damper system

Hydraulic cylinder

Scotch yoke mechanism

Lifting eyelets

Spring container

1.1.3 Electrostatic Charge

An electrostatic charge risk is present on the actuator surface; in case of cleaning, use only antistatic cloth; in case of maintenance, avoid all rubbing/frictions that could electrostatically charge the equipment.

1.1.4 Noise Emission

The verification of the noise of the actuated valve is at valve maker care. Biffi points out that the actuator's noise can be considered negligible since it is an equipment for regular on-off or intermittent use.

If it presents the integral quick exhaust valve, we recommend using ear PPE (personal protective equipment) to avoid any possible acoustic discomfort.

3



General Warnings

1.3 Data Sheet

Figure 2 Actuator identification plate

!WARNINGSpecific data sheet of each actuator are reported on the identification plate and in the documentation supplied with the equipment.

!WARNINGIt is forbidden to modify the information and the markings without the previous written authorization of Biffi Italia s.r.l. (Figure 2).

Supply fluid and pressure from 5 to 250 Bar g maximum

Operating temperature Standard: from –30 °C to +100 °COptional: from –60 °C to +140 °C

Operating time

0.2 second to 1 second, depending on:- valve size, type and torques- supply pressure- inertia of the valve and actuator mobile parts

Torque range up to 80000 Nm Higher values available on request

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September 2021


Section 2: Installation

Installation


2.1 Checks upon Actuator Receipt

• Check that the model, the serial number of the actuator and the technical data reported on the identification plate correspond with those of order confirmation, refer to Section 1.3.

• Check that the actuator is equipped with the fittings as provided for by order confirmation.

• Check that the actuator was not damaged during transportation: if necessary, renovate the painting according to the specification reported on the order confirmation.

• If the actuator is received already assembled with the valve, its settings have already been made.

• If the actuator is delivered separately from the valve, it is necessary to check, and, if required, to adjust, the settings of the fast discharge valve, (Section 3.4), of mechanical stops (Section 3.5) and of microswitches (if present) (Section 3.6).

NOTICEThe adjustment of the fast discharge valve completion is shown by a yellow paint dash on the locking pin of the valve adjustment handle (Section 3.4).

2.2 Actuator Handling

NOTICEThe lifting and handling of the actuator must be done by qualified personnel and in accordance with the laws and regulations in force. Avoid the lifted actuator to be hung above the personnel.

!WARNINGThe actuator must be lifted by means of a suitable lifting apparatus. The weight of the actuators is indicated in the technical documentation attached to the equipment itself.

!WARNINGFor lifting and moving the actuator, use only hooks fitted with safety latch, like the one, for example, shown in Figure 3.

5



Installation

Figure 3 Example of hook with safety latch

Figure 4 Lifting points

1 = balancing

2 and 3 = obligatory

1 = point of support

2 = supports for lateral positioning

!WARNING3 = don’t lay the actuator on tie-rods of cylinder/s and don’t lay the actuator on accessories (manual override, pneumatic control group etc.).

Figure 5 Lifting points

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September 2021



Installation

2.3 Storage

If the actuator needs storage, before installation follow these steps:

• Place it on a wood surface in order not to deteriorate the area of valve coupling.

• Make sure that plastic plugs are present on the hydraulic and electrical connections (if present).

• Check that the cover of electrical housings (if present) is properly closed.

If the storage is long-term or outdoor (maximum allowable 36 months):

• Keep the actuator protected from direct weather conditions.

• Replace plastic plugs of hydraulic and electrical connections (if present) with metal plugs that guarantee perfect tightness.

• Coat with oil, grease or protection disc, the valve coupling area.

• Periodically operate the actuator (Section 3.3).

• For lifting unbalanced loads, use ropes of different lengths or chains with adjustable length.

• Check each time the conditions of all lifting equipment used and discard it if not in perfect working order.

• Do not knot or twist the ropes so as not to reduce the lifting capacity or produce torsional effects on the load being lifted.

• Use the utmost caution and remain at a safe distance from lifted actuator unless absolutely necessary; do not stand or pass under suspended loads.

• Pay attention in putting under tension the ropes to prevent the load shifting sideways in an uncontrolled manner.

• Use slings of such length that the angles of the leg from vertical are as narrow as possible (αMAX < 20°).

• During handling, do not transport the suspended actuator above staff members in charge of the operation.

!WARNINGDo not use the lifting eyelets on actuator to lift valve + actuator assembly.

2.4 Actuator Assembly on the Valve

2.4.1 Types of AssemblyFor coupling to the valve, the housing is provided with a flange with threaded holes according to Biffi standard tables (SCN6200 and SCN6201). The number, dimensions and diameter of the holes are made in accordance with ISO 5211, but for actuator models 0.3 to 6 the holes are drilled on the centreline in order to allow an easier assembly of an intermediate flange, when required. This intermediate flange (or spool-piece) can be supplied when the valve flange can not directly match the actuator flange in its “standard” configuration. For the biggest actuator models, the actuator flange can be machined in accordance with the valve flange dimensions.

The yoke has bored with keyways for coupling to the valve stem, the dimensions of which are according to Biffi standard tables SCN6200 and SCN6201.

7

0.3 240 93 165 M20 4 5 17 127 70 12 75,6

0.9 310 112 254 M16 8 5 19 150 86 14 93,6

1.5 360 144 298 M20 8 6 19 190 112 18 119,0

3 430 195 356 M30 8 9 23 200 157 25 167,8

6 520 250 406 M36 8 14 29 260 200 28 212,8



Installation

Figure 6 Coupling dimensions for scotch yoke standard actuators

Drive sleeveH

max

N.4

hol

es fl

ange

N.8

hol

es fl

ange

N. THREADED HOLESP.C.D., number and size according to ISO 5211 (but the holes are on centerline instead of straddle the centerline)

ø d1 max

Flow line

Top view of the scotch yoke mechanism (actuator shown in closed position)

Models from 0.3 to 6

Dimensions in millimeters

Actuator model Ø d1 Ø d2 Ø d3 Ø d4 N h1 h2 H max Ø d5 W K

Table 1. SCN6200

8

14 580 250 483 M36 12 10 29 340 175 45 195,8

18 680 290 603 M36 16 12 32 350 200 45 220,8

32 780 290 603 M36 16 12 32 400 220 50 242,8

35 780 315 603 M36 16 11 32 400 240 50 242,8

42 840 310 603 M36 16 12 32 400 220 50 242,8

September 2021



Installation

Drive sleeve

H m

ax

N.1

6 ho

les

flang

eN

.12

hole

s fla

nge

N. THREADED HOLESP.C.D., number and size according to ISO 5211

ø d1 max

Flow line


Models 14, 18, 32, 35, 42




Table 2. SCN6201

9

50 800 315 698 M36 24 10 32 430 240 56 264,8

60 840 315 698 M36 24 10 32 430 240 56 264,8



Installation

Drive sleeve

H m

ax

N.1

6 ho

les

flang

eN

.12

hole

s fla

nge

N. THREADED HOLESFlange sizing according to ISO

ø d1 max

Flow line


Models 50, 60




Table 3. SCN6201-1

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September 2021



Installation

Table 4.

If required, for the standard models size 0.3 to 6, Biffi can supply an insert bush with unmachined bore in accordance with Biffi standard table SCN6202. On request, the insert bush bore can be machined by Biffi to couple the valve stem, provided its dimensions match the maximum stem acceptance of the bush according to Biffi table TN1005, enclosed. The particular execution of the flange and bushing allow the actuator to be rotated by 90° in 4 different positions according to the following figure:

Figure 9 Insert Bush + Intermediate Coupling Flange

Position 2 Position 3 Position 4

Rotate insert-bush 180° around vertical-standard position (1)

Rotate insert-bush 180° around axis A-A, from position 2

Rotate insert-bush 180° around axis A-A from position 1

Insert bush turned upside down

The Biffi insert bush with 2 external keys at 45° allows to position the keyway for the valve every 90°. Consequently, actuator can be mounted in 4 positions at 90° on top of the valve. For biggest actuator models, the bore of the yoke can be machined according to the dimensions of valve stem.

Housing Drive sleeve

Snap ring

Adaptor flange

Standard position 1

Position 2 Position 3 Position 4

Flow line

Drive sleeve

Insert bush

Insert bush

N.4

hol

es fl

ange

N.8

hol

es fl

ange

11



Installation

2.4.2 Assembly Procedure

!WARNINGFailure to comply with the following procedures may impair product warranty.

NOTICEInstallation, commissioning and maintenance and repair works should be carried out by qualified staff. A non-conforming assembly could be the source of serious accidents.

For actuator assembly on the valve:

NOTICECheck that the assembly position, as shown on the documentation, complies with system’s geometry. Check the consistency of the parts of actuator-valve coupling.

!WARNINGThe actuator should be in the spring idle position (spring totally extended). The hydraulic cylinder should not be pressurized.

• Check that the actuator position is matched with valve position.

• Lubricate valve stem with oil or grease.

• Properly clean and remove grease from coupling flange surfaces.

• Connect, if supplied separately, the adjustment insert to valve stem and fasten it with the special fastening pins.

• Lift the actuator using the special lifting points (Section 2.2).

• Install the actuator so that valve stem inserts in the coupling area. This coupling should be made without holes.

• Fasten the two parts with the threaded connections (screws, tie rods, nuts).

• If holes of coupling flanges are not aligned, adequately operate the actuator progressively pressurizing the cylinder until the assembly is possible. If necessary move the mechanical stops backwards (Section 3.4).

• Fasten threaded connections. Please refer to Table 5.

12

Threading Tightening Torque (Nm)

M8 20M10 40M12 70M14 110M16 160M20 320M22 420M24 550M27 800M30 1100M33 1400M36 1700

September 2021



Installation

The screwing values in Table 1 were calculated considering the materials ASTM A320 L7 for screws or tie rods and ASTM A194 gr.2H for the nuts.

2.5 Hydraulic Connections

!WARNINGCheck that the values of hydrualic supply available in the system are compatible with those reported on the identification plate of the actuator. The connections should be made by qualified staff.

NOTICEUse pipes and connections appropriate as for type, material and dimensions. Use motor fluid with purity degree ISO 4406 17/14 or NAS 1638 Class 8 (AS4059 Class 4B-F). For special applications the lower contamination degree is required. Please refer to technical data sheet for actuators supplied.

• Properly burr the ends of rigid pipes if present.

• Properly clean the interior of pipes sending through them plenty of the supply fluid used in the system.

• Mould and fasten the connection pipes so that no irregular strains at entries or loosening of threaded connections occur.

• Make the connections according to the functional diagram.

• Check the absence of leakages from hydraulic connections.

!WARNINGFor the characteristics of the motor fluid please refer to the documentation supplied.

Table 5. Nuts Tightening Torque

13



Installation

2.6 Electrical Connections (If Any)

NOTICEUse components appropriate as for type, material and dimensions.

!WARNINGThe connections should be made by qualified staff. Before carrying out any operation, cut line power off. Safety provisions: 2006/95/EC: Directive for low voltage equipment (until 19 April 2016) 2014/35/EU from 20 April 2016 2004/108/EC: Directive for the electromagnetic compatibility (until19 April 2016) 2014/30/EU from 20 April 2016 94/9/CE: Directive and safety instructions for use in hazardous Area (until 19 April 2016) 2014/34/EU from 20 April 2016

Remove plastic plugs from cable entries:

• Screw firmly the cable glands.

• Introduce connection cables.

• Make the connections in compliance with applicable wiring diagrams on the documentation supplied.

• Screw the cable gland.

• Replace the plugs of unused entries with metal plugs.

2.7 Commissioning!WARNING

Installation, commissioning and maintenance and repair works should be made by qualified staff. Any calibration relative to functional aspects of the actuator are preset at the factory. Before any modifications please read Biffi Italia s.r.l.

Upon actuator commissioning please carry out the following checks:

• Check the fast discharge valve adjustment (Section 3.4).

• Check that the values of hydraulic supply available in the system are compatible with those reported on the identification plate of the actuator (Figure 2) and on the documentation supplied.

• Check the power voltage of electrical components complies with the one reported on the documentation supplied.

• Check the absence of leakages in the cylinder and in hydraulic connections.

• Check that paint is intact and in case renovate it according to the specification on order confirmation.

• Carry out all kinds of operations and check their proper execution (Section 3.3).

• Check the proper operation of all the warnings.

NOTICEThe fast discharge valve adjustment is completed when a yellow paint dash is present on the locking pin of the adjustment handle of the valve (Section 3.4).

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September 2021


Section 3: Operation and Use

Operation and Use


3.1 Operation Description

The actuator is operated by:

1. Pressurized motor fluid.

2. Elastic return of compression helicoidally spring.

In the first case the alimentation fluid pressurizes a chamber of the cylinder and compresses the spring (Figure 11); this determines the linear motion of the piston and the consequent rotation motion of the scotch yoke mechanism to which valve stem is coupled.

The fluid contained in the other chamber is discharged through the return line.

In the second case, cutting off or in case of lack of pressure to the cylinder and to the pilot of the fast discharge valve, the opening of the latter is determined, the fast discharge of motor fluid, the quick extension of the spring and the consequent fast operation of the actuator. The motor fluid going out from one chamber of the cylinder partially returns in the other chamber and partially flows through the discharge line.

Ang

ular

str

oke

%

Time (ms)

Quick operation signal

Quick operation time

Damper action

Figure 10 Angular Stroke/Quick Operation Time Diagram

The last part of the cylinder stroke is strongly slowed down by a damper with bypass system that throttles the outlet of the motor fluid. Figure 10 shows the diagram angular stroke/time. Bypass action must be regulate to make more slowly the last part of cylinder stroke (see Section 3.4.1).

The power and control systems are supplied on specific customer demand.

For the relevant information please refer to the specific documentation supplied.

15



Operation and Use

Figure 11 Generic Operating Diagram

Pilot and control system on demand

Discharge lineSupply lineElectric connection from remote control room

3.2 Residual Risks

!WARNINGThe actuator has parts under pressure. Use the due caution. Use individual protections provided for by the laws and provisions in force.

3.3 Operations

The operations are carried out sending the proper signal through the control system in compliance with Customer specifications. Please refer to the functional diagram and specific documentation supplied.

3.4 Calibration of the Quick Operation Time

The calibration of the quick operation time of the actuator is carried out through the adjustment of the fast discharge valve positioned in the tail flange of the hydraulic cylinder, see Figure 12.

The following calibration procedure allows modifying the quick operation time, as shown in Figure 15.

NOTICEThe calibration should be carried out by qualified staff.

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September 2021



Operation and Use

Knob for dump-valve adjustment

Figure 12 Dump-valve manual regulation

Figure 13 Dump-valve manual regulation label placed on knob

Figure 14 Dump-valve manual regulation

17



Operation and Use

Loosen the protection-screw that stops the knob in position:

• Turn the knob in anticlockwise direction to increase the exhaust flow and consequently to decrease the operating time

• Turn the knob in clockwise direction to decrease the exhaust flow and consequently to increase the operating time

• Tighten the protection-screw to make sure that the knob is stopped in correct position.

Angular stroke/quick operation time diagram

Ang

ular

str

oke

%

Time (ms)

Dump-valve opening

Figure 15 Dump-valve action in angular stroke / quick operation time diagram

100

80

60

40

20

00 50 100 150 200 250 250

!WARNINGIt is absolutely forbidden to go below minimum time of quick operation set under the terms of the contract. Please refer to the documentation supplied.

NOTICEFactory calibration is made by Biffi Italia s.r.l. with the actuator NOT assembled to the valve.

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September 2021



Operation and Use

3.4.1 Bypass Adjustment

Figure 16

Figure 17 Bypass action to angular stroke / quick operation time diagram

Adjustable needle for bypass action

Angular stroke/quick operation time diagram

Ang

ular

str

oke

%

Time (ms)

100

80

60

40

20

00 100 200 300 400

Protection cap

Bypass valve opening

19



Operation and Use

Remove the protection cap from adjusting needle-valve and turn it clockwise to increase throttling-action and consequently to slow the last part of cylinder stroke. To decrease throttling-action, turn the needle for by-pass in anti-clockwise direction.

NOTICETo correctly calibrate the quick operation time it is necessary to arrange the data acquisition using a position transmitter and an ascillographic recorder compatible with required time. If specific signals are built on by specific instrumentation please refet to dedicated documentation.

Figure 18 Hydraulic cylinder sectional drawing

bypass detail

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September 2021



Operation and Use

3.5 Calibration of the Angular Stroke

The angular stroke of the yoke can be adjusted between 82°÷98° (±4° with respect to the nominal positions of complete opening and closing) using the mechanical stops screwed in the tail flange of the spring container and in the tail flange of the cylinder (if present) (Figure 19). For the lower values of angular stroke, please refer to the documentation supplied.

Figure 19 Mechanical stops

21



Operation and Use

3.5.1 Calibration of Mechanical Stop on the Cylinder (If Applicable)

!WARNINGBefore calibration of mechanical stop completely relieve pressure from the cylinder.

!WARNINGDo not alter the adjustment made unless the actuator is disassembled from the valve.

For the adjustment of the mechanical stop on the end flange of the cylinder, follow these steps (Figure 20):

1. Remove with the specific wrench (c1) the plug (t).

2. Insert a wrench for Allen keys (c2) in the through hole until reaching the adjustment pin (g).

3. Keep the protection cover blocked with the special wrench (c3).

4. Bring back the adjustment pin

5. Check that the proper position is reached (open or closed) of the valve. If necessary progressively pressurize the cylinder.

6. Approach the pin to the stop against the piston and then make the adjustment: turn counter-clockwise to increase the angular stroke, turn clockwise to decrease it.

7. Once the adjustment is made, close the plug (t).

Figure 20 Mechanical stop of the cylinder

c3

g

t

c2

c1

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September 2021



Operation and Use

Figure 21 Mechanical stop of spring container

c1

v

d

c2

g

c2

c1

d

3.5.2 Calibration of Mechanical Stop Placed on the Spring Container (If Applicable)

!WARNINGBefore calibration of mechanical stop completely relieve pressure from the cylinder.

!WARNINGDo not alter the adjustment made unless the actuator is disassembled from the valve.

For the adjustment of the mechanical stop placed on the end flange of the spring container, follow these steps (Figure 6):

1. Loosen the locknut (d) with the specific wrench (c2).

2. Adjust the pin (g)/screw (v) with the adequate wrench (c1).

3. Turn counterclockwise to increase the angular stroke, turn clockwise to decrease it.

4. When the adjustment is over tighten the locknut (d).

23



Operation and Use

3.6 Calibration of Microswitches (Biffi Limit Switch Box)

NOTICEThe operation of end of stroke microswitches should occur before the stop of the stroke of the actuator due to mechanical stops. Set the relative cams adequately.

!WARNINGIf different microswitches assembly or limit switch box is supplied, please refer to the specific documentation.

Microswitches are placed inside a special box (Figure 22).

For microswitches calibration please refer to the relative wiring diagram and follow these steps:

1. Unscrew the fastening screws of the cover (Figure 22).

2. Remove the cover paying attention not to deteriorate the gasket and the cylindrical and flat coupling surfaces.

3. Operate the actuator (in opening or closing).

4. Unscrew the screw of the operating cam relative to the microswitch to calibrate and adjust it according to the settings (Figure 23 - 24).

5. Tighten the screw.

6. Operate the actuator and adjust any other microswitch with the procedure already described.

7. Position the cover making sure the cam-carrier shaft grips with the index dragging shaft.

8. Check that the cover and the index show the proper position of the valve (Figure 25).

9. Tighten the screws.

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September 2021



Operation and Use

Figure 22 Biffi microswitches box

Figure 23 Cam adjustment

Figure 24 Adjustment of the magnetic proximity micro

25



Operation and Use

• Operate only the microswitch corresponding with the direction of the operation being carried out, as clearly shown on the microswitch.

• If the indicator of the box (Picture 8), does not signal the proper position of the valve but is turned by 90°:

• Remove the roll pin placed on the indicator.

• Turn the indicator until reaching its proper positioning.

• Put the roll pin back in its position.

pin

indicator

Figure 25 Pin and indicator of microswitches box

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September 2021


Section 4: Maintenance

Maintenance


NOTICEBefore executing any maintenance operation, it is necessary to intercept the hydraulic supply line and discharge pressure from the cylinder of the actuator, from the control unit and from the accumulation tank if present.

!WARNINGInstallation, commissioning and maintenance and repair works should be carried out by qualified staff. Before carrying out any operation, cut power off from the electrical line. Please refer to warning on Section 1.

4.1 Periodic Maintenance

OLGAS-QA actuators are designed to operate long-term in heavy-duty operating conditions, without maintenance needs.

NOTICEPeriodicity and regularity of inspections is particularly influenced by specific environmental and working conditions. They can be initially determined experimentally and then be improved according to actual maintenance conditions and needs.

Anyway every 2 years of operation the following is recommended:

• Check that the actuator properly operates the valve with all the control modes.

• Check the appropriateness of warnings to the control panel.

• Check there are no hydraulic leakages.

• Check the actuator did not undergo accidental damage with oil leakages found on site.

• Check the integrity of worn out parts (gaskets, bushes, pads etc.).

• Replace, if any, the filter cartridge of the supply fluid.

4.2 Extraordinary MaintenanceIn case of need extraordinary maintenance can be performed on the parts of the actuator.

4.2.1 Replacing the Gaskets of the Hydraulic Cylinder

!WARNINGBefore executing any maintenance operation, it is necessary to intercept the hydraulic line and discharge pressure and from the cylinder of the actuator. If the actuator can be operated, it is essential to take it to idle position, with the spring totally extended, otherwise the actuator should be disassembled from the valve and follow the steps below.

27



Maintenance

• Remove the plug (8) from the cover of the adjustment screw (21).

• Bring the adjustment screw back to the maximum (20) to let the spring loosen.

!WARNINGBefore disassembling the cylinder, make sure the above operation of spring release is done.

• Unscrew the nuts (36) of the flange tail (15) of the hydraulic cylinder.

• Remove the flange tail (15) from tie rods (37).

• Remove the damper flange (53) from the internal tube (10).

• Remove the tube (9-10) from the head flange (7).

• Remove the guard cover of the cinematic motion (table 1, pos.13).

• Operate with the special wrench on the hexagon of the rod (25) and unscrew it completely from the guide block (Table 9, pos.8).

• Remove the rod (25) and the piston (27) together

• Unscrew the 4 screws (Table 12, pos.5), that fasten the head flange (7) to the guard.

• Remove the head flange (7) leaving the tie rod (37) screwed on it.

• Replace the gaskets (2) after cleaning and greasing their seats.

• Remove the piston (27) from the rod (25) replace the gasket and the guide-sliding (40-41) of the piston and put it back on the rod.

• Introduce rod and piston on the head flange, paying attention not to deteriorate the gaskets previously assembled. Protect them wrapping the processed part of the rod with a layer of adhesive paper.

• Screw again, with the special wrench on the hexagon, the rod on the guide block inside the guard of the kinematic motion (Table 9, pos.8).

• Put the cover back (Table 9, pos.13) on the guard of the kinematic motion (Table 9, pos.4).

• Insert the internal tube (10) paying attention not to damage the gaskets previously assembled.

• Replace the O-Ring (26) and assemble the external tube (9).

• Replace the seals (26-29-33).

• Assemble the damper flange (51).

• Assemble the flange tail (15) on the tubes (9-10) and screw the nuts (36) with the recommended screwing values (Section 2.4 - Table 1).

• Replace the O-Ring (14) of the protection cover (21).

• Assemble again the protection cover on the adjustment screw (20).

• Calibrate again the adjustment screw of the cylinder (Section 3.5).

• Tighten the plug (8) in the protection cover (21).

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September 2021



Maintenance

4.2.2 Replacing the Gaskets of the Scotch Yoke Mechanism

!WARNINGBefore executing any maintenance operation, it is necessary to intercept the hydraulic supply line and discharge pressure from the cylinder of the actuator. If it is possible to operate the actuator, it is essential to take it to the idle position, with the spring completely extended, otherwise it is necessary to disassemble the valve actuator and follow the steps below.

• Remove the plug (Table 10, pos.8) from the cover of the adjustment screw (Table 10, pos.21).

• Bring the adjustment screw back to the maximum (Table 10, pos.20) for spring relief.

!WARNINGBefore disassembling the cylinder, make sure the above operation of spring relief was completed.

• Unscrew the nuts (Table 10, pos.36) of the tail flange (Table 10, pos.15) of the hydraulic cylinder.

• Remove the tail flange (Table 10, pos.15) from the tie rods (Table 10, pos.37).

• Remove the damper flange (Table 10, pos.53) from the internal tube (Table 10, pos.10).

• Remove the tubes (Table 10, pos.9-10) from the head flange (Table 10, pos.7).

• Remove the fastening screws of the guard cover (13).

• Remove the cover (13) of the guard (4).

• Remove the rod of the cylinder (Table 10, pos.25) from the guide block (8).

• Remove the rod (Table 10, pos.25) and the piston (Table 10, pos.27) together.

• Unscrew the 4 screws (Table 12, pos.5), that fasten the head flange (Table 10, pos.7) to the guard of the kinematic motion.

• Remove the head flange (Table 10, pos.7) from the guard, leaving the tie rods (Table 10, pos.37) screwed on it.

• Remove the fastening screws of the spring container (Table 12, pos.1).

• Remove the spring container (Table 11, pos.5) from the guard (4).

• Pull out the guide bar (5) from the guide block (8) through the guard (13).

• Pull out the yoke (6) and the guide block (8).

• Remove the bush (2) on which the yoke leans (6) and replace the O-Ring (1).

• Put the yoke back in position (6) as well as the guide block (8).

• Insert the guide bar (5).

• Replace the gasket (Table 12, pos.2) between guard and spring container.

• Put back in position the spring container (Table 11, pos.5).

• Tighten the screws (Table 12, pos.1) at the recommended tightening values (Section 2.4 - Table 1).

NOTICEUse Loctite 510 to seal all the threads of the fastening guides.

29



Maintenance

• Replace the gasket (Table 12, pos.2) between guard and hydraulic cylinder.

• Screw the threaded part of the rod (Table 10, pos.25) in the guide block (8), install the hydraulic cylinder (Table 10), calibrating again the adjustment screw of the cylinder.

• Tighten the fastening screws (Table 12, pos.5) of the cylinder to the guard at the recommended tightening values (Section 2.4 - Table 1).

• Replace the gasket of the guard cover (7).

• Replace the upper O-Rings (1) of the bush of the yoke (9).

• Install the guard cover (13) paying attention to spread a layer of Loctite 510 to fasten the upper bush of the yoke to the cover (13).

• Tighten the screws (12) at the recommended tightening values (Section 2.4 - Table 1).

NOTICECarry out a few operations with proper clean oil (Section 4.2.3) to check there are no leakages from the gaskets.

4.2.3 Hydraulic Oil FeaturesThe following oils is used by Biffi and suggested for lubrication:

Table 6. Standard temperature conditions (-30 °C/+85 °C):Producer AGIPName ARNICA 22Viscosity at 40 °C 20.9 mm²/sViscosity at 100 °C 4.73 mm²/sViscosity index ASTM 153Flash point 192 °CPour point -42 °CSpecific weight (at 15 °C) 0,857 kg/lEquivalent oils SHELL TELLUS PLUS 22

CHEVRON HYDRAULIC OIL AW ISO 22MOBIL DTE22EXXON UNIVIS N22EQUIVIS ZS22BP ENERGOL HLP-HM22CASTROL DYSPIN AWS22

Low temperature conditions (until -46 °C):Manufactured SHELLName AEROSHELL FLUID 41Viscosity at -54 °C 2300 cST Viscosity at -40 °C 491 cSTViscosity at 40 °C 14,1 cSTViscosity at 100 °C 5,30 cSTViscosity index (ISO 2909) >200Flash point 105 °CPour point <-60 °C Specific weight 0,87 kg/dm3

(or equivalent)Low temperature conditions (until -60 °C):Manufactured SYNTESISName SYNTRASS-CS 500Viscosity at -60 °C 580 cSTViscosity at -30 °C 39cSTViscosity at 20 °C 5,8 cSTViscosity at 50 °C 2,1 cSTFlash point 152 °CPour point -68 °CSpecific weight 0,897 kg/dm3

(or equivalent)

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September 2021



Maintenance

4.3 Lubrication of MechanismFor normal duty the scotch yoke mechanism of the actuator is lubricated "for life". In case of high load and high frequency of operation it may be necessary to periodically restore lubrication: it is advisable to apply a generous coating of grease on the contact surfaces of the yoke and bushings, on the yoke link grooves, on the sliding blocks, on the guide bar.

For this operation it is necessary to disassemble the mechanism cover. In larger actuators the lubrication can be performed through the inspection holes of the cover after removing the plugs.

The following grease is used by Biffi for standard working temperature and suggested for re-lubrication:

AGIP MU/EP/2

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

Equivalent to: ESSO BEACON EP2BP GREASE LTX2SHELL ALVANIA GREASE R2ARAL ARALUB HL2CHEVRON DURALITH GREASE EP2CHEVRON SPHEEROL AP2TEXACO MULTIFAK EP2MOBILPLEX 47PETROMIN GREASE EP2

Table 7 . Lubrication

AEROSHELL GREASE 7 or equivalent

To be used in low temperature conditions:

(-60 °C/+65 °C)

Color: 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

31



Maintenance

4.4 Dismantling and Demolition

Before starting the disassembly, a large area should be created around the actuator so to allow any kind of movement without problems of further risks created by worksite.

!WARNINGBefore disassembling the actuator, it is necessary to close the hydraulic supply line and discharge pressure from the cylinder of the actuator, from the control unit and from the accumulator tank, if present. If the actuator can be operated, it is essential to take it to fail-safe position, with the spring totally extended.

If actuator is still mounted onto the valve, loosen the threaded connections between valve and actuator (screws, tie rods, nuts)

Lift the actuator using the proper lifting points (see Section 2.2).

If the actuator needs storage, before demolition, see Section 2 to 2.3.

NOTICEThe demolition of the actuator both concerning any electrical and mechanical part should be made by specialized staff.

Separate the parts composing the actuator according to their nature (e.g. metallic and plastic materials, fluids etc.) and send them to differentiate waste collection sites, as provided by the laws and provisions in force.

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September 2021


Section 5: Troubleshooting

Troubleshooting

Section 5: Troubleshooting

5.1 Failure or Breakdown Research

Table 8. Troubleshooting

Event Possible cause Remedy

Actuator does not work

Lack of power supply Open line stop valve

Blocked valve Repair or replace

Low supply pressure Reset (Section 1.4)

Clogged filter Clean or replace the cartridge.

Control group does not work properlyCheck the contacts of solenoid valve coils. If any component is damaged, replace it.

Actuator too slow

Low supply pressure Reset (Section 1.4)

Wrong calibration of flow regulator valves Reset (Section 3.6)

Wear of the valve Repair or replace

Actuator too fastHigh supply pressure Reset (Section 1.4)

Wrong calibration of flow regulator valves Reset (Section 3.6)

Leakages on hydraulic circuits

Deterioration and/or damage to gaskets, loosening of connections

Replace the gaskets, screw the connections

Incorrect position of the valve

Wrong adjustment of mechanical stops Reset (Section 3.4)

Wrong warning of microswitches Reset (Section 3.5)

33


Section 6: Spare Parts

Spare parts

Section 6: Spare Parts

6.1 Spare Parts Order

For spare parts order to the relevant Biffi office please make reference to Biffi order confirmation concerning all the supply.

For any specific spare part for some actuator model please refer to the serial number of the actuator (Section 1.2) and to the specific cross section tables, supplied in the documentation delivered with the supply.

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September 2021


Cross Section Tables

Section 7: Cross Section Tables

Section 7: Cross Section Tables for Maintenance ActivitiesFor the specific cross section tables please refer to the documentation delivered with the supply.

Item Qty Description Material

1 4 O - ring NBR

2 2 Yoke bushing Bronze

3 2 Retainer ring Stainless steel

4 1 Housing Carbon steel

5 1 Guide bar Alloy steel

6 1 Yoke Carbon steel

7 1 Cover gasket Fiber

8 1 Guide block Carbon steel

9 1 Bushing Steel + Bz + Teflon

10 2 Sliding block Bronze

11 1 Vent valve Stainless steel

12 12 Screw Carbon steel

13 1 Cover Carbon steel

14 1 Guide block pin Alloy steel

Table 9. Parts List

Figure 26 Scotch Yoke Mechanism

35




Figure 27 Quick Acting Hydraulic Cyclinder

36

September 2021




NOTE:* recommended spare parts


1 1 Bushing Fe+Bz+Teflon

2 2 Piston rod seal ring * Teflon + graphite

3 3 O-ring * Viton rubber

4 1 Scraper ring * Teflon + Viton rubber

5 1 Scraper ring flange Aluminium

6 3 Screw Stainless steel

7 1 Head flange Nikel plated carbon steel

8 2 Plug Stainless steel

9 1 External tube Nikel plated carbon steel

10 1 Internal tube Nikel plated carbon steel


12 2 Flow control valve -

13 2 Check valve -


15 1 End flange Nikel plated carbon steel

17 1 Dump valve -

18 1 Dump valve cover Nikel plated carbon steel

19 2 Solenoid valve -

20 1 Stop setting screw Alloy steel

21 1 Stop setting screw cover Carbon steel


23 3 Qiuck connector -

24 2 Dowel Stainless steel

25 1 Piston rod Chromium-plated alloy steel


27 1 Piston Nichel plated carbon steel

28 1 Dumping profile Nichel plated carbon steel


30* 1 Pipe fitting (optional) Stainless steel

31* mt. 0,5 Pipe (optional) Stainless steel




35 1 Back up-ring * Teflon

36 4 Nut Carbon steel

37 4 Tie rod Alloy steel

38 1 Washer Alloy steel

39 5 Plug Carbon steel

40 2 Guide sliding piston ring * Teflon + graphite

41 1 Piston seal-ring * Teflon + graphite






47 1 Stop setting screw cover Stainless steel

48 1 Stop setting screw Alloy steel

49 1 Knob Stainless steel


51 1 Dumping flange Aluminium

52 1 Needle Stainless steel

53 1 Ring nut Stainless steel

54 1 Nut Stainless steel


56 1 Nut Stainless steel





61 1 Indicating plate Stainless steel

62 1 Stop-screw for knob Stainless steel

Table 10. Parts List

37







2 1 Washer Carbon steel

3 1 Sealing washer * PVC

4 1 Stop setting screw Carbon steel

5 1 Spring container Carbon steel

6 2 Spring Carbon steel


8 1 Shoulder washer Carbon steel

9 1 Intermediate flange Carbon steel

10 1 Rod bushing Steel + Bz + Teflon

11 1 Guide rod Alloy steel (Chromium plated)

12 1 Spring thrust flange Carbon steel

13 1 Rod bushing Steel + Bz + Teflon

14 1 Container rod Alloy steel (Chromium plated)


Figure 28 Spring Cartridge

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September 2021






1 6 Screw Teflon coated alloy steel

2 1 Gasket * Fiber

3 1 Side plate Carbon steel

4 2 Gasket * Fiber

5 1 Washer Carbon steel

6 1 Adaptor bush Alloy steel

7 1 Plug Carbon steel

8 4 Screw Alloy steel


Figure 29 Assembly Kit

39


Section 8: Date Report for Maintenance Operations

Date Report for Maintenance Operations

Section 8: Date Report for Maintenance Operations

Last maintenance operation date: (in factory, on delivery):

……… exec. by : ………… ……… exec. by : ………… ……… exec. by : …………

Next maintenance operation date: ……… exec. by : ………… ……… exec. by : ………… ……… exec. by : …………

Start-up date: (in factory, on delivery) ……… (on plant)…………

For complete list of sales and manufacturing sites, please visit www.biffi.it or contact us at [email protected]

Biffi Italia s.r.l. Strada Biffi 16529017 Fiorenzuola d’Arda (PC)ItalyT +39 0523 944 411

VCIOM-08598-EN ©2021 Biffi. All rights reserved.

The contents of this publication are presented for information purposes only, and while every effort has been made to ensure their accuracy, they are not to be construed as warranties or guarantees, express or implied, regarding the products or services described herein or their use or applicability. All sales are governed by our terms and conditions, which are available on request. We reserve the right to modify or improve the designs or specifications of our products at any time without notice.

Spring-Return Hydraulic Actuator

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