BIFFI GIG Installation, Operation And Maintenance Manual
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BIFFI GIG Installation, Operation And Maintenance Manual

Double-acting direct gas actuator
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Biffi GIG
Double-Acting Direct Gas 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 – biffi_italia@biffi.it
Installation, Operation and Maintenance Manual
MAN 601 Rev. 7
December 2020

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  • Page 1 Double-Acting Direct Gas 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 – biffi_italia@biffi.it...
  • Page 2 Revision Details Installation, Operation and Maintenance Manual December 2020 MAN 601 Rev. 7 Revision Details Revision Date Description Prepared Checked Approved December 2020 Migration to new template April 2018 Updated Data-plate Ermanni Orefici Vigliano April 2016 Updated applicable regulation (chapter 1.1.1) Ermanni Orefici Vigliano...

  • Page 3: Table Of Contents

    Installation, Operation and Maintenance Manual Table of Contents MAN 601 Rev. 7 December 2020 Table of Contents Section 1: General Warnings Generalities ....................1 1.1.1 Applicable Regulation ................ 1 1.1.2 Terms and Conditions ................. 2 Identification Plate ..................2 Introducing the Actuator ................3 Data Sheet ....................
  • Page 4 Table of Contents Installation, Operation and Maintenance Manual December 2020 MAN 601 Rev. 7 Section 4: Operational Tests and Inspections Operational Tests and Inspections................34 Section 5: Maintenance Periodic Maintenance .................. 35 5.1.1 Check and Restore Oil Level in the Hydraulic Manual Override ..36 Extraordinary Maintenance .................

  • Page 5: Section 1: General Warnings

    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. The information contained is of exclusive reserved ownership of Biffi Italia s.r.l.

  • Page 6: Terms And Conditions

    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.

  • Page 7: Introducing The Actuator

    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.

  • Page 8: Section 2: Installation

    Section 2: Installation Installation, Operation and Maintenance Manual December 2020 MAN 601 Rev. 7 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, see Section 1.2.
  • Page 9 Section 2: Installation MAN 601 Rev. 7 December 2020 Figure 4 Lifting points for GIG / GIG-MHP / GIG-MSJ / GIG-MHW actuators 1-2 = Lifting points (obligatory) 3 = Balancing point 1 = point of support 2 = supports for lateral positioning WARNING 3 = don’t lay the actuator on tie rods of cylinder/s and don’t lay the actuator on accessories...

  • Page 10: Storage

    AND ACTUATOR TOGETHER DO NOT DISASSEMBLE TOP OR BOTTOM COVER. SPRING LOADED. POTENTIAL ELECTROSTATIC CHARGE HAZARD BIFFI IS NOT LIABLE FOR ANY PERSONNEL INJURY DUE TO INCORRECT USE REFER TO IOM Storage If the actuator needs storage, before installation follow these steps: •...

  • Page 11: Actuator Assembly On The Valve

    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. Installation...
  • Page 12 Section 2: Installation Installation, Operation and Maintenance Manual December 2020 MAN 601 Rev. 7 Figure 6 Coupling dimensions - Models 0.3 to 6 Drive sleeve +0.1 Ø d Ø d Ø d ±0.2 Ø d N. threaded holes PCD, number and size according to ISO 5211 (but the holes are on centerline instead of...
  • Page 13 Installation, Operation and Maintenance Manual Section 2: Installation MAN 601 Rev. 7 December 2020 Figure 7 Coupling dimensions - Models 14 to 42 Drive sleeve Ø Ø +0.1 Ø ±0.2 Ø N. THREADED HOLES PCD, number and size according to ISO 5211 Flow line Ø...
  • Page 14 Section 2: Installation Installation, Operation and Maintenance Manual December 2020 MAN 601 Rev. 7 Figure 8 Coupling dimensions - Models 50 and 60 Drive sleeve Ø Ø +0.1 Ø ±0.2 Ø N. THREADED HOLES Flange sizing according to ISO W D10 Flow line Ø...
  • Page 15 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.

  • Page 16: Assembly Procedure

    Section 2: Installation Installation, Operation and Maintenance Manual December 2020 MAN 601 Rev. 7 2.4.2 Assembly Procedure NOTICE Failure to comply with the following procedures may impair product warranty. WARNING Installation, commissioning and maintenance, and repair works should be carried out by qualified staff.

  • Page 17: Pneumatic Connections

    Check the absence of leakages from pneumatic connections. 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).

  • Page 18: Electrical Connections (If Any)

    Section 2: Installation Installation, Operation and Maintenance Manual December 2020 MAN 601 Rev. 7 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 (until 19 April 2016)

  • Page 19: Commissioning

    Installation, Operation and Maintenance Manual Section 2: Installation MAN 601 Rev. 7 December 2020 Commissioning 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.

  • Page 20: Section 3: Operation And Use

    (see Section 3.5) is adjustable by bidirectional flow regulators (item 276) for GIG and GIG with manual jackscrew or handwheel (refer to follow GIG-1 typical control schematic); for models with manual handpump, speed is adjusted by unidirectional flow regulators (item Fa –...
  • Page 21 Installation, Operation and Maintenance Manual Section 3: Operation and Use MAN 601 Rev. 7 December 2020 Typical Control Schematics Figure 12 Direct gas actuator local and remote control with "MSJ" (GIG-1) Open Close Pneumatic supply E.M. to open optional Gas exhaust T.E.
  • Page 22 Section 3: Operation and Use Installation, Operation and Maintenance Manual December 2020 MAN 601 Rev. 7 Figure 13 Direct gas actuator local and remote control with "MHP" (GIG-2) Open Close E.M. Gas exhaust T.E. Auxiliary gas supply Electric connection connection...
  • Page 23 Installation, Operation and Maintenance Manual Section 3: Operation and Use MAN 601 Rev. 7 December 2020 Figure 14 Direct gas actuator local and remote control - twin gas cylinder (GIG-3) Open Close E.M. T.E. Electric exhaust connections Gas supply connection...

  • Page 24: Residual Risks

    Section 3: Operation and Use Installation, Operation and Maintenance Manual December 2020 MAN 601 Rev. 7 Residual Risks WARNING It is recommended to pipe exhaust gas. The actuator has parts under pressure. Use the due caution. Use individual protections provided for by the laws and provisions in force. Operations 3.3.1 Local Pneumatic Operation...

  • Page 25: Electric Remote Control To Open And To Close

    Solenoid valves must be de-energized at the end of actuator operation. 3.3.3 Emergency Manual Operation by MSJ / MHW (see GIG-1 typical control schematic – when sufficient line pressure is not available). Figure 16 The MSJ (jackscrew manual override with removable lever) or the MHW (jackscrew manual override with handwheel), can be supplied for GIG actuators up to model 3.
  • Page 26 Section 3: Operation and Use Installation, Operation and Maintenance Manual December 2020 MAN 601 Rev. 7 • Engage the manual override by rotating it’s handle. • Turn by the lever (or the hand-wheel) the manual override clockwise to close, or counter-clockwise to open •...

  • Page 27: Emergency Manual Operation By Mhp

    MAN 601 Rev. 7 December 2020 3.3.4 Emergency Manual Operation by MHP (see GIG-2 or GIG-3 schematics – when sufficient line pressure is not available). Figure 18 Figure 19 • Select by the lever 5-D the manual opening or manual closing operation.
  • Page 28 Section 3: Operation and Use Installation, Operation and Maintenance Manual December 2020 MAN 601 Rev. 7 WARNING If no other manual operation is carried out, the lever 5-D must be in “remote operation” position to allow the operations with gas supply. To ensure that the manual override has been correctly disengaged after a manual override operation, the following actions must be done: •...
  • Page 29 Installation, Operation and Maintenance Manual Section 3: Operation and Use MAN 601 Rev. 7 December 2020 Figure 21 MHP with lockable handpump and signalling switch (Please see also Section 7.2, Figure 44: sectional drawing for hydraulic control unit MHP). NOTICE Assemble the MHP in vertical position (as shown in Figure 22) to work properly the actuator, any other mounting position is strictly forbidden Figure 22...

  • Page 30: Calibration Of The Angular Stroke

    Section 3: Operation and Use Installation, Operation and Maintenance Manual December 2020 MAN 601 Rev. 7 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) by means the mechanical stops screwed into the left side of the housing (open valve) and into the end flange of the hydraulic cylinder (closing) (Figure 23).
  • Page 31 Installation, Operation and Maintenance Manual Section 3: Operation and Use MAN 601 Rev. 7 December 2020 For the adjustment of the mechanical stop on the end flange of cylinder, follow these steps (Figure 25): • Remove with the specific wrench (c1) the plug (t). •...
  • Page 32 Turn counterclockwise to increase the angular stroke, turn clockwise to decrease it. • When the adjustment is over tighten the locknut (d). Figure 26 Mechanical stop on the housing Table 12. GIG actuator model Wrench C1 (mm) Wrench C2 (mm) Operation and Use...
  • Page 33 MAN 601 Rev. 7 December 2020 Figure 27 Mechanical stop on the housing Table 13. GIG actuator model Wrench c1 (mm) Wrench c2 (mm) Figure 28 (Optional - if foreseen) For the adjustment of the mechanical stop screwed on the end flange of manual override (see Section 7.2, Figure 46: sectional drawing for manual jackscrew MSJ or MHW).
  • Page 34 December 2020 MAN 601 Rev. 7 Figure 29 Mechanical stop on the end flange of manual override Table 14. GIG actuator size Wrench C1 (mm) Wrench C2 (mm) Figure 30 Mechanical stop on the end flange of manual override Table 15.

  • Page 35: Calibration Of Micro-Switches (If Foreseen)

    Installation, Operation and Maintenance Manual Section 3: Operation and Use MAN 601 Rev. 7 December 2020 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).

  • Page 36: Calibration Of The Operation Time

    MAN 601 Rev. 7 Calibration of the Operation Time 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 placed between the control valves enclosure and the pneumatic cylinder (Figure 34).
  • Page 37 Section 3: Operation and Use MAN 601 Rev. 7 December 2020 For GIG actuator models with Manual Handpump, the operating time is adjustable through two regulation valves placed on manual handpump body (see Section 7.2, Figure 44: sectional drawing for hydraulic control unit MHP).

  • Page 38: Section 4: Operational Tests And Inspections

    Section 4: Operational Tests and Inspections Installation, Operation and Maintenance Manual December 2020 MAN 601 Rev. 7 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...

  • Page 39: Section 5: Maintenance

    Installation, commissioning and maintenance, and repair works should be carried out by qualified staff. Periodic Maintenance GIG actuators are designed to operate long-term in heavy-duty operating conditions, without maintenance needs. NOTICE Periodicity and regularity of inspections is particularly influenced by specific environmental and working conditions.

  • Page 40: Check And Restore Oil Level In The Hydraulic Manual Override

    Section 5: Maintenance Installation, Operation and Maintenance Manual December 2020 MAN 601 Rev. 7 Figure 36 Level measuring stick Maximum level Minimum level 5.1.1 Check and Restore Oil Level in the Hydraulic Manual Override Operate the distributor lever to “closing manual operation”. Figure 37 Move the actuator into his “fail to close”...
  • Page 41 December 2020 NOTICE For refill use oil of the same brand as previous, refer to related technical documentation. Table 16. Features of hydraulic oil used by Biffi Italia s.r.l. for refilling different working condition: Standard temperature conditions (-30 °C/+85 °C): Producer...
  • Page 42 Section 5: Maintenance Installation, Operation and Maintenance Manual December 2020 MAN 601 Rev. 7 Gas supply dehydrating filter maintenance (if foreseen) The gas supply filter is fitted with a mechanical filter and a drain valve to discharge periodically the water generated by the condensation of the humidity inside the gas supply. During the routine maintenance it is recommended to check and clean the mechanical filter and replace it in case of heavy dirty conditions.

  • Page 43: Extraordinary Maintenance

    Section 5: Maintenance Installation, Operation and Maintenance Manual MAN 601 Rev. 7 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.
  • Page 44 Section 5: Maintenance Installation, Operation and Maintenance Manual December 2020 MAN 601 Rev. 7 Seals Replacement Prior to reassemble check that the actuator components are in good conditions and clean. Lubricate all the surfaces of the parts, which move in contact with other components, by recommended grease (AGIP-ENI LCX 2/32 if seals are in NBR/Viton or Neoprene rubber, or with Aeroshell Grease 7 if the seals are in Fluorosilicon rubber).
  • Page 45 Section 5: Maintenance Installation, Operation and Maintenance Manual MAN 601 Rev. 7 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.
  • Page 46 Section 5: Maintenance Installation, Operation and Maintenance Manual December 2020 MAN 601 Rev. 7 Figure 39 GIG-MHP double-acting pneumatic actuator Table 17. Parts List Item Description Item Description Cover Spring washer Screw Guide block pin Plug Vent valve Sliding block...

  • Page 47: Dismantling And Demolition

    Section 5: Maintenance Installation, Operation and Maintenance Manual MAN 601 Rev. 7 December 2020 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 pneumatic feed line and discharge oil pressure from the cylinder of the actuator, from the control unit and from the...

  • Page 48: Lubrication Of Mechanism

    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: Table 18.

  • Page 49: Section 6: Troubleshooting

    Repair or replace Wrong position of the distributor of the Restore correct position manual hydraulic group Failure of the control group Call Biffi Italia s.r.l. Customer Service Unexpected intervention of torque Call Biffi Italia s.r.l. Customer Service limit-device Low supply pressure Restore (Section 1.4)

  • Page 50: Section 7: Layouts

    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.

  • Page 51: Parts List For Maintenance And Replacing Procedure

    Installation, Operation and Maintenance Manual Section 7: Layouts MAN 601 Rev. 7 December 2020 Parts List for Maintenance and Replacing Procedure Figure 40 Scotch yoke mechanism Table 20. Parts List Item Description Material O-ring * NBR Yoke bushing Bronze Retainer ring Stainless steel Housing Carbon steel...
  • Page 52 Section 7: Layouts Installation, Operation and Maintenance Manual December 2020 MAN 601 Rev. 7 Figure 41 Pneumatic cylinder Table 21. Parts List Item Description Material Piston rod bushing Steel + bronze + Teflon Head flange Carbon steel O-ring * NBR rubber Piston rod seal ring * Teflon + graphite O-ring...
  • Page 53 Installation, Operation and Maintenance Manual Section 7: Layouts MAN 601 Rev. 7 December 2020 Figure 42 Hydraulic cylinder Table 22. Parts List Item Description Material Piston rod bushing Steel + bronze + Teflon Head flange Carbon steel O-ring * NBR rubber Piston rod seal ring * Teflon + graphite O-ring...
  • Page 54 Section 7: Layouts Installation, Operation and Maintenance Manual December 2020 MAN 601 Rev. 7 Figure 43 Assembly kit Table 23. 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...
  • Page 55 Installation, Operation and Maintenance Manual Section 7: Layouts MAN 601 Rev. 7 December 2020 Figure 44 Hydraulic control unit MHP Relief valve Oil tank relief valve Relief valve for automatic operation Flow regulator Relief valve for manual operation Table 24. Parts List Item Description...
  • Page 56 Section 7: Layouts Installation, Operation and Maintenance Manual December 2020 MAN 601 Rev. 7 Figure 45 Handpump Table 25. 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...
  • Page 57 Installation, Operation and Maintenance Manual Section 7: Layouts MAN 601 Rev. 7 December 2020 Figure 46 Jackscrew manual override MSJ or MHW Table 26. Parts List Item Description Material Protection pipe Carbon steel Jackscrew Carbon steel Engagement lever pin Stainless steel O-ring * Fluorosilicon rubber Cover gasket...

  • Page 58: Section 8: Date Report For Maintenance Operations

    Section 8: Date Report for Maintenance Operations Installation, Operation and Maintenance Manual December 2020 MAN 601 Rev. 7 Section 8: Date Report for Maintenance Operations Last maintenance operation date: (in factory, on delivery): ……… exec. by: ………… ……… exec. by: ………… ………...
  • Page 59 Installation, Operation and Maintenance Manual Notes MAN 601 Rev. 7 December 2020 This page is intentionally left blank...
  • Page 60 VCIOM-03401-EN ©2020 Biffi. All rights reserved. Biffi Italia s.r.l. Strada Biffi 165 The contents of this publication are presented for information purposes only, 29017 Fiorenzuola d’Arda (PC) and while every effort has been made to ensure their accuracy, they are not...

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Gig-mhpGig-msjGig-mhw

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