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BIFFI OLGA-H Installation, Operation And Maintenance Manual

BIFFI OLGA-H Installation, Operation And Maintenance Manual

High pressure double acting hydraulic actuator

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BIFFI OLGA-H HIGH PRESSURE DOUBLE ACTING HYDRAULIC ACTUATOR
INSTALLATION, OPERATION AND MAINTENANCE MANUAL
Before installation these instructions must be read fully and understood

TABLE OF CONTENTS

1 General warnings ������������������������������������������ 1
2 Installation ����������������������������������������������������� 3
3 Operation and use ����������������������������������������� 9
4 Operational tests and inspections�������������� 23
5 Maintenance� ����������������������������������������������� 23
6 Troubleshooting ������������������������������������������ 30
7 Layouts ��������������������������������������������������������� 30
1 GENERAL WARNINGS
IMPORTANT
The manual is an integral part of the machine. It
should be read carefully before carrying out any
operation and should be kept for future reference.
1.1 Generalities
Biffi� actuators are conceived, manufactured
and controlled according to a Quality Control
System in compliance with EN ISO 9001
international regulation�
www.biffi.it
1.1.1 Applicable regulation
EN ISO 12100-1: 2005: Safety of machinery
- Basic notions, general design principles�
Part 1-Basic terminology, method�
EN ISO 12100-2: 2005: Safety of machinery
- Basic notions, general design principles�
Part 2-Technical principles and specification�
2006/42/EC: Machine directive�
97/23/EC: Directive for pressure PED
equipment�
2006/95/EC: Directive for low voltage
equipment�
2004/108/EC: Directive for the electromagnetic
compatibility�
94/9/EC: Directive and safety instructions for
use in hazardous area�
1.1.2 Terms and conditions
Biffi 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�
Copyright © Biffi� All rights reserved�
VCIOM-03744-EN 17/12

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Summary of Contents for BIFFI OLGA-H

  • Page 1: Table Of Contents

    BIFFI OLGA-H HIGH PRESSURE DOUBLE ACTING HYDRAULIC ACTUATOR INSTALLATION, OPERATION AND MAINTENANCE MANUAL Before installation these instructions must be read fully and understood 1.1.1 Applicable regulation EN ISO 12100-1: 2005: Safety of machinery – Basic notions, general design principles� Part 1-Basic terminology, method�...
  • Page 2 BIFFI OLGA-H HIGH PRESSURE DOUBLE ACTING HYDRAULIC ACTUATOR INSTALLATION, OPERATION AND MAINTENANCE MANUAL 1.4 Data sheet FIGURE 1 The actuator (see figure 2) is made up of Data plate a weatherproof Scotch yoke mechanism transforming the linear movement of the...
  • Page 3: Installation

    INSTALLATION, OPERATION AND MAINTENANCE MANUAL 2 INSTALLATION FIGURE 3A, 3B, 3C, 3D Lifting points for OLGA-H / OLGA-H-MHP / OLGA-H-MSJ actuators 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 (section 1�2)�...
  • Page 4 BIFFI OLGA-H HIGH PRESSURE DOUBLE ACTING HYDRAULIC ACTUATOR INSTALLATION, OPERATION AND MAINTENANCE MANUAL For the transport of OLGA-H actuators with hydraulic manual hand-pump, when it was 2.3 Storage necessary put in horizontal position the tank If the actuator needs storage, before...
  • Page 5 BIFFI OLGA-H HIGH PRESSURE DOUBLE ACTING HYDRAULIC ACTUATOR INSTALLATION, OPERATION AND MAINTENANCE MANUAL FIGURE 5A FIGURE 5B Actuator models 0�3 to 6 Actuator models 14 to 42 Drive sleeve Drive sleeve +0�1 d₂ d₄ Ø Ø d₂ +0�1 Ø d₄...
  • Page 6 264�8 264�8 If required, for the standard models size The Biffi insert bush with 2 external keys at 45° 0�3 to 6, Biffi can supply an insert bush with allows to position the keyway for the valve every un-machined bore in accordance with Biffi 90°�...
  • Page 7 BIFFI OLGA-H HIGH PRESSURE DOUBLE ACTING HYDRAULIC ACTUATOR INSTALLATION, OPERATION AND MAINTENANCE MANUAL 2.5 Pneumatic connections 2.4.2 Assembly procedure IMPORTANT IMPORTANT Failure to comply with the following procedures Check that the values of pneumatic supply may impair product warranty. available are compatible with those reported on the identification plate of the actuator.
  • Page 8 BIFFI OLGA-H HIGH PRESSURE DOUBLE ACTING HYDRAULIC ACTUATOR INSTALLATION, OPERATION AND MAINTENANCE MANUAL 2.6 Electrical connections (if any) Upon actuator commissioning please carry out FIGURE 6 the following checks: Junction box on control group (if foreseen) IMPORTANT • Check that paint is not be damaged during...
  • Page 9: Operation And Use

    BIFFI OLGA-H HIGH PRESSURE DOUBLE ACTING HYDRAULIC ACTUATOR INSTALLATION, OPERATION AND MAINTENANCE MANUAL 3 OPERATION AND USE For local or remote operations, please refer to section 3�3�1, 3�3�2, 3�3�3 and 3�3�4 and prior 3.1 Operation description to technical documentation furnished with In the normal operating situation, the double actuators�...
  • Page 10 BIFFI OLGA-H HIGH PRESSURE DOUBLE ACTING HYDRAULIC ACTUATOR INSTALLATION, OPERATION AND MAINTENANCE MANUAL FIGURE 8 OLGA-H with hydraulic manual hand pump 3.3 Operations (refer to specific document: operating diagram furnished) 3.3.1 Local manual operation The OLGA-H actuators can only have the hydraulic manual override for local operation�...
  • Page 11 BIFFI OLGA-H HIGH PRESSURE DOUBLE ACTING HYDRAULIC ACTUATOR INSTALLATION, OPERATION AND MAINTENANCE MANUAL FIGURE 9A, 9B Mechanical stops 3.4 Calibration of the angular stroke FIGURE 10 Mechanical stop of the cylinder The angular stroke of the yoke can be adjusted between 82°÷98°...
  • Page 12 BIFFI OLGA-H HIGH PRESSURE DOUBLE ACTING HYDRAULIC ACTUATOR INSTALLATION, OPERATION AND MAINTENANCE MANUAL For the adjustment of the mechanical stop FIGURE 11A, 11B srewed into the left side of housing, follow Mechanical stop on the housing these steps (figures 11A and 11B): •...
  • Page 13 BIFFI OLGA-H HIGH PRESSURE DOUBLE ACTING HYDRAULIC ACTUATOR INSTALLATION, OPERATION AND MAINTENANCE MANUAL 3.5 Calibration of microswitches (with safety instructions for limit switch box) WARNING If the actuator is delivered separately from the valve, it is necessary to check, and, if required,...
  • Page 14 BIFFI OLGA-H HIGH PRESSURE DOUBLE ACTING HYDRAULIC ACTUATOR INSTALLATION, OPERATION AND MAINTENANCE MANUAL FIGURE 22 Example of operating time adjustment (if foreseen), by flow-regulator valve (please refer to specific operating diagram, item 526/530 and to specific flow-regulator valve) TECHNICAL FEATURES Max� adjusted flow (l/min�) Max�...
  • Page 15: Operational Tests And Inspections

    BIFFI OLGA-H HIGH PRESSURE DOUBLE ACTING HYDRAULIC ACTUATOR INSTALLATION, OPERATION AND MAINTENANCE MANUAL 4 OPERATIONAL TESTS AND INSPECTIONS FIGURE 24 Level measuring stick IMPORTANT MAXIMUM LEVEL To ensure the guaranteed SIL Level, according to IEC 61508, the functionality of actuator must be checked with regular intervals of time, as described following.
  • Page 16 BIFFI OLGA-H HIGH PRESSURE DOUBLE ACTING HYDRAULIC ACTUATOR INSTALLATION, OPERATION AND MAINTENANCE MANUAL 5.2 Extraordinary maintenance TABLE 2 Features of hydraulic oil suggested for refilling in different working conditions If there are leaks in the hydraulic cylinder, pneumatic cylinder or a malfunction in Standard temperature conditions (-30°C/+85°C)
  • Page 17 BIFFI OLGA-H HIGH PRESSURE DOUBLE ACTING HYDRAULIC ACTUATOR INSTALLATION, OPERATION AND MAINTENANCE MANUAL Seals replacement the threaded end of the piston rod (18) and the threaded hole of the adaptor bush (32) Prior to reassemble check that the actuator components are in good conditions and clean�...
  • Page 18 BIFFI OLGA-H HIGH PRESSURE DOUBLE ACTING HYDRAULIC ACTUATOR INSTALLATION, OPERATION AND MAINTENANCE MANUAL FIGURE 26 OLGA-H double acting hydraulic actuator with manual override PARTS LIST Item Description Item Description Item Description Screw Cover Head flange Piston rod Screw O-ring Guide block pin...
  • Page 19 BIFFI OLGA-H HIGH PRESSURE DOUBLE ACTING HYDRAULIC ACTUATOR INSTALLATION, OPERATION AND MAINTENANCE MANUAL Replacement of seals for actuators with Biffi tube, taking cares not to damage the O-ring 3� Assemble the new dual-seal ring (9) by manual hand-pump (see figure 27) introducing one side of it into the groove (item 3)�...
  • Page 20 BIFFI OLGA-H HIGH PRESSURE DOUBLE ACTING HYDRAULIC ACTUATOR INSTALLATION, OPERATION AND MAINTENANCE MANUAL FIGURE 27 Hydraulic cylinder for Biffi manual hand pump PARTS LIST Item Q.ty Description Material Piston rod bushing Steel + bronze + PTFE Head flange Carbon steel...
  • Page 21 BIFFI OLGA-H HIGH PRESSURE DOUBLE ACTING HYDRAULIC ACTUATOR INSTALLATION, OPERATION AND MAINTENANCE MANUAL 5.3 Lubrication of mechanism AGIP MU/EP/2 AEROSHELL GREASE 7 or equivalent For normal duty the scotch yoke mechanism To be used in standard temperature conditions To be used in low temperature conditions of the actuator is lubricated “for life”�...
  • Page 22: Troubleshooting

    BIFFI OLGA-H HIGH PRESSURE DOUBLE ACTING HYDRAULIC ACTUATOR INSTALLATION, OPERATION AND MAINTENANCE MANUAL 6 TROUBLESHOOTING 6.1 Failure or breakdown research Event Possible cause Remedy Actuator does not work 1� Lack of power supply 1� Restore it 2� Lack of pneumatic supply 2�...
  • Page 23 BIFFI OLGA-H HIGH PRESSURE DOUBLE ACTING HYDRAULIC ACTUATOR INSTALLATION, OPERATION AND MAINTENANCE MANUAL 7.2 Parts list for maintenance and replacing procedure FIGURE 28 Scotch yoke mechanism PARTS LIST Item Q.ty Description Material O-ring Yoke bushing Bronze Retainer ring Stainless steel...
  • Page 24 BIFFI OLGA-H HIGH PRESSURE DOUBLE ACTING HYDRAULIC ACTUATOR INSTALLATION, OPERATION AND MAINTENANCE MANUAL FIGURE 29 Hydraulic cylinder PARTS LIST Item Q.ty Description Material Piston rod bushing Steel + bronze + PTFE Head flange Nickel plated carbon steel O-ring Piston rod seal ring...
  • Page 25 BIFFI OLGA-H HIGH PRESSURE DOUBLE ACTING HYDRAULIC ACTUATOR INSTALLATION, OPERATION AND MAINTENANCE MANUAL FIGURE 30 Hydraulic cylinder for manual hand pump (optional) PARTS LIST Item Q.ty Description Material Piston rod bushing Steel + bronze + PTFE Head flange Carbon steel...
  • Page 26 BIFFI OLGA-H HIGH PRESSURE DOUBLE ACTING HYDRAULIC ACTUATOR INSTALLATION, OPERATION AND MAINTENANCE MANUAL FIGURE 31 Assembly kit PARTS LIST Item Q.ty Description Material Screw Alloy steel Carbon steel Carbon steel Screw Alloy steel Flange Carbon steel Gasket Fiber Stopper bush...
  • Page 27 BIFFI OLGA-H HIGH PRESSURE DOUBLE ACTING HYDRAULIC ACTUATOR INSTALLATION, OPERATION AND MAINTENANCE MANUAL FIGURE 32 Hydraulic control unit MHP...
  • Page 28 BIFFI OLGA-H HIGH PRESSURE DOUBLE ACTING HYDRAULIC ACTUATOR INSTALLATION, OPERATION AND MAINTENANCE MANUAL PARTS LIST - HYDRAULIC CONTROL UNIT MHP Item Q.ty Description Material Dipstick Cap nut Carbon steel Washer Carbon steel + rubber Hydraulic tank Carbon steel Hand pump...
  • Page 29 BIFFI OLGA-H HIGH PRESSURE DOUBLE ACTING HYDRAULIC ACTUATOR INSTALLATION, OPERATION AND MAINTENANCE MANUAL FIGURE 32A Hand pump PARTS LIST Item Q.ty Description Material Ball Stainless steel Delivery valve bush Carbon steel Suction valve bush Carbon steel Spring Stainless steel Suction valve ring...
  • Page 30 BIFFI OLGA-H HIGH PRESSURE DOUBLE ACTING HYDRAULIC ACTUATOR INSTALLATION, OPERATION AND MAINTENANCE MANUAL FIGURE 33 Jackscrew manual override MSJ ENGAGED TO OPEN TO CLOSE DISENGAGED PARTS LIST Item Q.ty Description Material Protection pipe Carbon steel Jackscrew Carbon steel Engagement lever pin...
  • Page 31: Date Report For Maintenance Operations

    (in factory, on delivery): �……………………���������������� (on plant): …������������������������������������� Biffi reserves the the right to change product designs and specifications without notice� Biffi Italia S.r.L. Località Caselle San Pietro, 420, 29017 Fiorenzuola d’Arda (PC) ITALY Ph: +39 (0)523 944 411 E-mail: biffi_italia@biffi�it www.biffi.it...