Installation, Operation and Maintenance Manual Table of Contents MAN 606 Rev. 5 December 2020 Table of Contents Section 1: General Warnings Generalities ....................1 1.1.1 Applicable Regulation ................ 1 1.1.2 Terms and Conditions ................. 1 Identification Plate ..................2 Introducing the Actuator ................3 Data Sheet ....................
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Table of Contents Installation, Operation and Maintenance Manual December 2020 MAN 606 Rev. 5 Section 6: Troubleshooting Failure or Breakdown Research ..............37 Section 7: Layouts Spare Parts Order ..................38 Parts List for Maintenance and Replacing Procedure ........39 Section 8: Date Report for Maintenance Operations Date Report for Maintenance Operations...............47 Table of Contents...
Biffi Italia s.r.l pays the highest attention to collecting and verifying the documentation contained in this user manual. However Biffi Italia s.r.l. is not liable for any mistakes contained in this manual, for damage or accidents due to the use of the latter.
MAN 606 Rev. 5 Identification Plate WARNING It is forbidden to modify the information and the marks without previous written authorization by Biffi Italia s.r.l. The plate fastened on the actuator contains the following information (Figure 1). Figure 1 Data Plate...
The actuator yoke has a hole with keyways suitable for the assembly of an insert bush the internal hole of which is machined (by Biffi or at Customer's care), according to the shape and dimensions of the valve stem. Biffi can supply different types of control system following Customer's requirements.
Section 2: Installation Installation, Operation and Maintenance Manual December 2020 MAN 606 Rev. 5 Section 2: Installation 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).
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Installation, Operation and Maintenance Manual Section 2: Installation MAN 606 Rev. 5 December 2020 Figure 4 Lifting points for OLGA / OLGA-MHP / OLGA-MSJ 1, 2 = Lifting points (obligatory) 3 = Balancing point 1 = Point of support 2 = Supports for lateral positioning WARNING 3 = Do not lay the actuator on tie rods of cylinder/s and do not lay the actuator on accessories (manual handpump, manual jackscrew, pneumatic control group etc.).
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MHP body); remove the blind plug and restore the dipstick before operate the actuator with MHP. Biffi hydraulic manual hand-pump must be maintained with tank in upper position to operate the actuator with MHP correctly.
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Installation, Operation and Maintenance Manual Section 2: Installation MAN 606 Rev. 5 December 2020 Figure 6 Figure 7 OMFB manual hand-pump should be transported and used with MHP tank in horizontal position, but in position 3 of follow picture (extracted from OMFB technical documentation) it is necessary change the position of suction pipe and breather cap.
Section 2: Installation Installation, Operation and Maintenance Manual December 2020 MAN 606 Rev. 5 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. •...
Biffi standard tables SCN6200* and SCN6201*. If required, for the standard models size 0.3 to 6, Biffi can supply an insert bush with un-machined bore in accordance with Biffi standard table SCN6202. On request the insert bush bore can be machined by Biffi to couple the valve stem.
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.
NOTICE If necessary to mount components not in Biffi scope of supply, please check the accessories mounting hole details in the documents TN 1028 (for metric dimension) or TN 1028U (for imperial dimension).
Section 2: Installation Installation, Operation and Maintenance Manual December 2020 MAN 606 Rev. 5 Electrical Connections (If Any) WARNING Use components appropriate as for type, material and dimensions. The 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...
Installation, Operation and Maintenance Manual Section 2: Installation MAN 606 Rev. 5 December 2020 Commisioning WARNING Check that values of electrical supply to the control group (if foreseen) are compatible with those on the plate on the junction box (Figure 10). Installation, commissioning and maintenance and repair works should be made by qualified staff.
Section 3: Operation and Use Installation, Operation and Maintenance Manual December 2020 MAN 606 Rev. 5 Section 3: Operation and Use Operation Description In the normal operating situation, the double-acting actuator is fed by pressurised oil which flows into the relevant cylinder chamber (for example opening). The cylinder piston stroke causes the actuator operation and the consequent valve movement to the operational position requested (in this case to the “open”...
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Installation, Operation and Maintenance Manual Section 3: Operation and Use MAN 606 Rev. 5 December 2020 Figure 11 Table 3. Item Name Housing Yoke Yoke bushing Cover Guide block pin Sliding block Guide block Guide bar Guide block bushing Travel stop screw Cylinder head flange Piston rod bushing Piston rod O-ring...
Section 3: Operation and Use Installation, Operation and Maintenance Manual December 2020 MAN 606 Rev. 5 Residual Risks WARNING The actuator has parts under pressure. Use the due caution. Use individual protections provided for by the laws and provisions in force. Operations Refer to specific document: Operating Diagram Furnished.
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Installation, Operation and Maintenance Manual Section 3: Operation and Use MAN 606 Rev. 5 December 2020 Figure 13 Figure 14 OLGA with hydraulic manual hand-pump Table 4. Item Name Scotch yoke mechanism Hydraulic cylinder Hydraulic manual override Directional control valve Handpump Relief valve Oil tank...
Section 3: Operation and Use Installation, Operation and Maintenance Manual December 2020 MAN 606 Rev. 5 3.3.2 Emergency Manual Operation by MHP The OLGA actuators can have an emergency manual override in addition to the local and/or remote control panel which controls the oil supplied by a power pack for the “normal”...
Installation, Operation and Maintenance Manual Section 3: Operation and Use MAN 606 Rev. 5 December 2020 3.3.3 Emergency Manual Operation by MSJ - MHW The MSJ jackscrew manual override can be supplied for OLGA actuators from model 0.3 to model 3. The override is mounted on the left side of the actuator, the jackscrew end is screwed into the guide block.
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Section 3: Operation and Use Installation, Operation and Maintenance Manual December 2020 MAN 606 Rev. 5 In case of an actuator with two cylinders (Figure 18), both mechanical stops are screwed on the end flanges of the cylinders. Figure 18 Actuator with two cylinders For the adjustment of the mechanical stop on the end flange of cylinder, follow these steps (Figure 18):...
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Installation, Operation and Maintenance Manual Section 3: Operation and Use MAN 606 Rev. 5 December 2020 Figure 19 Table 6. Hydraulic cylinder size Wrench c1 (mm) Wrench c2 (mm) Wrench c3 (mm) Operation and Use...
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Section 3: Operation and Use Installation, Operation and Maintenance Manual December 2020 MAN 606 Rev. 5 For the adjustment of the mechanical stop screwed into the left side of housing, follow these steps (Figure 20 and Figure 21): • Loosen the locknut (d) with the specific wrench (c2). •...
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Installation, Operation and Maintenance Manual Section 3: Operation and Use MAN 606 Rev. 5 December 2020 For the adjustment of the mechanical stop screwed on the end flange of manual override (see Section 7.2, Figure 36). Figure 22 Table 9. Mechanical stop on the end flange of manual override Hydraulic cylinder size Wrench c1 (mm)
Section 3: Operation and Use Installation, Operation and Maintenance Manual December 2020 MAN 606 Rev. 5 Calibration of Micro-switches (If Foreseen) (Refer to Safety Instructions Manual for limit switch box). WARNING Refer only to technical documentation related to installed switch-box model. NOTICE For mounting interface dimension of the Limit Switch box on the cover of the actuator, please refer to TN1163V (for metric dimension) or TN1163VU (for imperial dimension).
Calibration of the Operation Time (Optional – If Foreseen) The calibration of the operation time is made by Biffi Italia s.r.l according to customer requirements and to technical data-sheet included in technical documentation. If necessary it’s possible to modify or reset the operating time through two flow regulation valves (optional) placed on inlets of hydraulic cylinder (see Figure 24 and the applicable operating diagram).
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Section 3: Operation and Use Installation, Operation and Maintenance Manual December 2020 MAN 606 Rev. 5 To carry out the adjustment, operate the handwheel (turn clockwise the handwheel to increase the operating time or turn the handwheel counterclockwise to decrease the operation time).
Installation, Operation and Maintenance Manual Section 4: Operational Tests and Inspections MAN 606 Rev. 5 December 2020 Section 4: Operational Tests and Inspections NOTICE To ensure the guaranteed SIL grade, according to IEC 61508, the functionality of actuator must be checked with regular intervals of time, as described in the Safety Manual. Operational Tests and Inspections...
Section 5: Maintenance Installation, Operation and Maintenance Manual December 2020 MAN 606 Rev. 5 Section 5: Maintenance NOTICE Before carrying out any maintenance operation, it is necessary to close the hydraulic feed line and exhaust the pressure from the actuator cylinder and from the control unit, to ensure safety of maintenance staff.
Installation, Operation and Maintenance Manual Section 5: Maintenance MAN 606 Rev. 5 December 2020 Figure 26 Level measuring stick Maximum level Minimum level 5.1.1 Check and Restore Oil Level in the Hydraulic Control Unit Operate the distributor lever to “closing manual operation”. Figure 27 Move the actuator into his “fail to close”...
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Section 5: Maintenance Installation, Operation and Maintenance Manual December 2020 MAN 606 Rev. 5 NOTICE For refill use oil of the same brand as previous, refer to related technical documentation. Table 12. Features of hydraulic oil suggested for refilling in different working conditions Standard temperature conditions (-30 °C/+85°): Producer...
Installation, Operation and Maintenance Manual Section 5: Maintenance MAN 606 Rev. 5 December 2020 Extraordinary Maintenance If there are leaks in the hydraulic cylinder, or a malfunction in the mechanical components, or in case of scheduled preventive maintenance, the actuator must be disassembled and seals must be replaced with reference to the follow general sectional drawing and adopting the following procedures.
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Section 5: Maintenance Installation, Operation and Maintenance Manual December 2020 MAN 606 Rev. 5 If the actuator control unit requires the cylinder chamber head flange side to be also filled with oil, and the piston rod seal ring (40) to be replaced, remove the screw (2) and the cover (1).
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Installation, Operation and Maintenance Manual Section 5: Maintenance MAN 606 Rev. 5 December 2020 Reassemble: Assemble the new gasket (37-39) after cleaning the surfaces of housing (8), the flange (38) and head flange (42), which are in contact. Assemble the head flange (42), replace the washers if damaged, tighten the screws (31) to the recommended torque.
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Section 5: Maintenance Installation, Operation and Maintenance Manual December 2020 MAN 606 Rev. 5 Figure 29 OLGA Double-Acting Hydraulic Actuator Table 13. Parts list Item Description Item Description Cover Plug Screw Guide block pin Vent valve Stopper bush Sliding block Adaptor bush Screw Screw...
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 relubrication: Table 14.
Section 5: Maintenance Installation, Operation and Maintenance Manual December 2020 MAN 606 Rev. 5 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. WARNING Before disassembling the actuator it is necessary to close the hydraulic feed line and discharge oil pressure from the cylinder of the actuator, from the control unit and from the...
Repair or replace Wrong position of the distributor of the Restore correct position Actuator does not work manual hydraulic group Call Biffi Italia s.r.l. Failure of the control group Customer Service Unexpected intervention of torque Call Biffi Italia s.r.l. limit-device...
Section 7: Layouts Spare Parts Order For spare parts order to the relevant Biffi office please make reference to Biffi order confirmation concerning all the supply, and serial number of the actuator (Section 1.2) for any specific spare part for a specific actuator model.
Installation, Operation and Maintenance Manual Section 7: Layouts MAN 606 Rev. 5 December 2020 Parts List for Maintenance and Replacing Procedure Figure 30 Scotch Yoke Mechanism Table 16. Parts List Item Description Material O-ring * NBR Yoke bushing Bronze Retainer ring Stainless steel Housing Carbon steel...
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Section 7: Layouts Installation, Operation and Maintenance Manual December 2020 MAN 606 Rev. 5 Figure 31 Hydraulic Cylinder Table 17. Parts List Item Description Material Piston rod bushing Steel + BZ + Teflon Head flange Carbon steel O-ring * NBR rubber Piston rod seal ring * Teflon + graphite O-ring...
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Installation, Operation and Maintenance Manual Section 7: Layouts MAN 606 Rev. 5 December 2020 Figure 32 Hydraulic Cylinder for MHP (Optional) Table 18. Parts List Item Description Material Piston rod bushing Steel + BZ + Teflon Head flange Carbon steel O-ring * NBR rubber Piston rod seal ring...
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Section 7: Layouts Installation, Operation and Maintenance Manual December 2020 MAN 606 Rev. 5 Figure 33 Assembly Kit Table 19. Parts List Item Description Material Screw Alloy Steel Carbon steel Carbon steel Screw Alloy Steel Flange Carbon steel Gasket * Fiber Stopper bush Alloy Steel Plug...
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Installation, Operation and Maintenance Manual Section 7: Layouts MAN 606 Rev. 5 December 2020 Figure 34 Hydraulic Control Unit MHP Layouts...
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Section 7: Layouts Installation, Operation and Maintenance Manual December 2020 MAN 606 Rev. 5 Table 20. Parts List Item Description Material Dipstick Cap nut Carbon steel Washer Carbon steel + rubber Hydraulic tank Carbon steel Handpump See attached table O-ring * Fluorosilicon rubber Ball Stainless steel...
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Installation, Operation and Maintenance Manual Section 7: Layouts MAN 606 Rev. 5 December 2020 Figure 35 Handpump Table 21. Parts List Item Description Material Ball Stainless steel Delivery valve bush Carbon steel Suction valve bush Carbon steel Spring Stainless steel Suction valve ring Carbon steel Spring retainer ring...
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Section 7: Layouts Installation, Operation and Maintenance Manual December 2020 MAN 606 Rev. 5 Figure 36 Jackscrew manual override MSJ ENGAGED TO OPEN DISENGAGED TO CLOSE Table 22. Parts List Item Description Material Protection pipe Carbon steel Jackscrew Carbon steel Engagement lever pin Stainless steel O-ring...
Installation, Operation and Maintenance Manual Section 8: Date Report for Maintenance Operations MAN 606 Rev. 5 December 2020 Section 8: Date Report for Maintenance Operations Last maintenance operation date: (in factory, on delivery): ……… exec. by: ………… ……… exec. by: ………… ………...
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