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BIFFI GIGS Series Installation, Operation And Maintenance Manual

Spring-return hydraulic actuator
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Biffi GIGS
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 – biffi_italia@biffi.it
Installation, Operation and Maintenance Manual
MAN 611 Rev. 6
February 2021

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  • Page 1 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 – biffi_italia@biffi.it...
  • Page 2 Revision Details Installation, Operation and Maintenance Manual February 2021 MAN 611 Rev. 6 Revision Details Rev. Date Description Prepared Checked Approved February 2021 Migration to new template April 2018 Updated Data-plate Ermanni Orefici Vigliano April 2018 Revised data-plate Ermanni Orefici Vigliano Updated applicable regulation April 2018...

  • Page 3: Table Of Contents

    3.3.4 Emergency Manual Operation by MHP ..........22 Calibration of the Angular Stroke ..............23 Calibration of Micro-switches (Biffi Limit Switch Box Only) ......28 Calibration of the Operation Time ............... 31 Section 4: Operational Tests and Inspections Operational Tests and Inspections.................32 Section 5: Maintenance Periodic Maintenance ..................
  • Page 4 Table of Contents Installation, Operation and Maintenance Manual February 2021 MAN 611 Rev. 6 Section 6: Troubleshooting Failure or Breakdown Research ..............43 Section 7: Layouts Spare Parts Order ..................44 Parts List for Maintenance and Replacing Procedure ........45 Section 8: Date Report for Maintenance Operations Date Report for Maintenance Operations...............54 Table of Contents...

  • 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.

  • Page 6: Identification Table

    MAN 611 Rev. 6 Identification Table 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...

  • 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 February 2021 MAN 611 Rev. 6 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).
  • Page 9 Installation, Operation and Maintenance Manual Section 2: Installation MAN 611 Rev. 6 February 2021 Figure 4 Lifting points for GIGS Actuators 1, 2 = Lifting points (obligatory) 3 = Balancing point 1 = Point of support 2 = Supports for lateral positioning 3 = Do not lay the actuator on tie rods of cylinder/s and do not lay the actuator on accessories (manual override, pneumatic control group etc.).
  • Page 10 LIFTING LUGS TO BE USED FOR THE ACTUATOR ONLY. DO NOT LIFT VALVE AND ACTUATOR TOGETHER DO NOT DISASSEMBLE TOP OR BOTTOM COVER. SPRING LOADED. POTENTIAL ELECTROTASTIC CHARGE HAZARD BIFFI IS NOT LIABLE FOR ANY PERSONEL INJURY DUE TO INCORRECT USE REFER TO IOM Installation...

  • Page 11: Storage

    For coupling to the valve, the housing is provided with a flange with threaded holes according to Biffi standard tables (SCN6200 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...
  • Page 12 Section 2: Installation Installation, Operation and Maintenance Manual February 2021 MAN 611 Rev. 6 Figure 6 Actuator Models from 0.3 to 6 Drive sleeve +0.1 Ø d Ø ±0.2 Ø d Ø d N. threaded holes PCD, number and size according to ISO 5211 (but the holes are on centerline instead of straddle the centerline) Flow line...
  • Page 13 Installation, Operation and Maintenance Manual Section 2: Installation MAN 611 Rev. 6 February 2021 Figure 7 Actuator Models from 14 to 42 Drive sleeve + 01 Ø Ø ±0.2 Ø Ø d N. threaded holes PCD, number and size according to ISO 5211 Flow line +0.2 Ø...
  • Page 14 Section 2: Installation Installation, Operation and Maintenance Manual February 2021 MAN 611 Rev. 6 Figure 8 Actuator Models from 50 and 60 Drive sleeve Ø +0.1 Ø ±0.2 Ø Ø d N. threaded holes Flange sizing according to ISO 5211 Flow line +0.2 Ø...
  • Page 15 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.

  • Page 16: Assembly Procedure

    Section 2: Installation Installation, Operation and Maintenance Manual February 2021 MAN 611 Rev. 6 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

    Installation, Operation and Maintenance Manual Section 2: Installation MAN 611 Rev. 6 February 2021 Table 5. Nuts Tightening Torque Threading Tightening Torque (Nm) 1100 1400 1700 The screwing values in Table 5 were calculated considering the materials ASTM A320 L7 for screws or tie rods and ASTM A194 gr.2H for the nuts.

  • Page 18: Electrical Connections (If Any)

    Section 2: Installation Installation, Operation and Maintenance Manual February 2021 MAN 611 Rev. 6 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...

  • Page 19: Commisioning

    Installation, Operation and Maintenance Manual Section 2: Installation MAN 611 Rev. 6 February 2021 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.

  • Page 20: Section 3: Operation And Use

    Section 3: Operation and Use Installation, Operation and Maintenance Manual February 2021 MAN 611 Rev. 6 Section 3: Operation and Use Operation Description In the normal operating situation, the direct gas actuator is fed by pressurised gas which flows into pneumatic cylinder. The cylinder piston stroke causes the actuator operation and the consequent valve movement to the operational position requested (for example to the “open”...
  • Page 21 Installation, Operation and Maintenance Manual Section 3: Operation and Use MAN 611 Rev. 6 February 2021 Typical control schematics Figure 12 Spring-return direct gas actuator with local/remote controls E.M. 278B 278A Electric connection to micro-switches Gas exhaust T.E. Electric connection Auxiliary gas to solenoid valve supply connection...
  • Page 22 Section 3: Operation and Use Installation, Operation and Maintenance Manual February 2021 MAN 611 Rev. 6 Figure 13 Spring-return direct gas actuator with manual override-local/remote controls 278B 278A E.M. Electric connection to microswitches T.E. Gas exhaust Electric connection to solenoid valve Auxiliary gas supply connection Gas supply...
  • Page 23 Installation, Operation and Maintenance Manual Section 3: Operation and Use MAN 611 Rev. 6 February 2021 Figure 14 Spring-return direct gas actuator with hydraulic manual override - local/remote controls E.M. Electric connection 278B to microswitches 278A Gas exhaust T.E. Electric connection Auxiliary gas to solenoid valve supply connection...

  • Page 24: Residual Risks

    Section 3: Operation and Use Installation, Operation and Maintenance Manual February 2021 MAN 611 Rev. 6 Electric remote control to open Energize permanently the solenoid valve 704-P. The opening time is adjustable by the flow regulator 278B. Electric remote control to close De-energize the solenoid valve 704-P.

  • Page 25: Operations

    Installation, Operation and Maintenance Manual Section 3: Operation and Use MAN 611 Rev. 6 February 2021 Operations 3.3.1 Local Pneumatic Operation WARNING Use the proper safety measures to protect from any pressurised gas not piped and from excessive and harmful noise. Figure 15 GIGS-MHW with local/remote pneumatic control group Solenoid valve with manual...

  • Page 26: Emergency Manual Operation By Mhw Or Mrhw

    Section 3: Operation and Use Installation, Operation and Maintenance Manual February 2021 MAN 611 Rev. 6 3.3.3 Emergency Manual Operation by MHW or MRHW See GIGS-MHW typical control schematic – when sufficient line pressure is not available. • Turn the jackscrew until actuator complete operation •...

  • Page 27: Calibration Of The Angular Stroke

    Installation, Operation and Maintenance Manual Section 3: Operation and Use MAN 611 Rev. 6 February 2021 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 at the end of spring cartridge, and into the end flange of the pneumatic cylinder (Figure 17).
  • Page 28 Section 3: Operation and Use Installation, Operation and Maintenance Manual February 2021 MAN 611 Rev. 6 Figure 19 Table 9. Pneumatic cylinder size Wrench c1 (mm) Wrench c2 (mm) Wrench c3 (mm) For the adjustment of the travel stop screw, proceed as follows. See Figures 20 and 21. Figure 20 Spring cartridge model from 006 to 150 Operation and Use...
  • Page 29 Installation, Operation and Maintenance Manual Section 3: Operation and Use MAN 611 Rev. 6 February 2021 Figure 21 Spring cartridge model from 200 to 15600 Loosen the lock nut “d”. If the actuator angular stroke is stopped before reaching the end position, unscrew the stop screw “v”...
  • Page 30 Section 3: Operation and Use Installation, Operation and Maintenance Manual February 2021 MAN 611 Rev. 6 Table 11. Spring container size Wrench c1 (mm) Wrench c2 (mm) 1100 1200 2000 2500 3800 5100 5400 8300 9600 9800 11000 15000 15600 For the adjustment of the mechanical stop screwed on the end flange of manual override proceed as follow.
  • Page 31 Installation, Operation and Maintenance Manual Section 3: Operation and Use MAN 611 Rev. 6 February 2021 Figure 23 Table 13. Mechanical stop on the end flange of manual override GIGS actuator size Wrench c1 (mm) Wrench c2 (mm) Loosen the lock nut (item 2). If the actuator angular stroke is stopped before reaching the end position (fully open or closed), unscrew the stop screw (item 1) by turning it anticlockwise, and actuate the handwheel of manual override until the valve reaches the right...

  • Page 32: Calibration Of Micro-Switches (Biffi Limit Switch Box Only)

    Installation, Operation and Maintenance Manual February 2021 MAN 611 Rev. 6 Calibration of Micro-switches (Biffi Limit Switch Box Only) NOTICE Operate only the micro-switch corresponding to the direction of operation being carried out, as clearly reported on the micro-switch. WARNING If different micro-switches assembly or limit switch box is supplied, please refer to the specific documentation.
  • Page 33 Installation, Operation and Maintenance Manual Section 3: Operation and Use MAN 611 Rev. 6 February 2021 Figure 24 Micro-switches box Figure 25 Cam adjustment Operation and Use...
  • Page 34 Section 3: Operation and Use Installation, Operation and Maintenance Manual February 2021 MAN 611 Rev. 6 If the index (Figure 26), does not signal the proper position of the valve but is turned by 90°: • Remove the roll pin placed on the position indicator (index). •...

  • Page 35: Calibration Of The Operation Time

    February 2021 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 27).

  • Page 36: Section 4: Operational Tests And Inspections

    Section 4: Operational Tests and Inspections Installation, Operation and Maintenance Manual February 2021 MAN 611 Rev. 6 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 37: Section 5: Maintenance

    Installation, Operation and Maintenance Manual Section 5: Maintenance MAN 611 Rev. 6 February 2021 Section 5: Maintenance NOTICE Before executing any maintenance operation, it is necessary to close the pneumatic supply line and discharge pressure from the cylinder of the actuator and from the control unit (if foreseen).

  • Page 38: Check And Restore Oil Level In The Hydraulic Control Unit

    Section 5: Maintenance Installation, Operation and Maintenance Manual February 2021 MAN 611 Rev. 6 Figure 28 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 “manual operation” to operate valve and to compress completely the actuator spring.
  • Page 39 February 2021 NOTICE For refill use oil of the same brand as previous, refer to related technical documentation. Table 14. Features of Hydraulic Oil Suggested by Biffi Italia s.r.l. for Refilling Different Working Condition: Standard temperature conditions (-30 °C/+85°): Producer...

  • Page 40: Gas Supply Dehydrating Filter Maintenance (If Foreseen)

    Section 5: Maintenance Installation, Operation and Maintenance Manual February 2021 MAN 611 Rev. 6 5.1.2 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 41: Extraordinary Maintenance

    Installation, Operation and Maintenance Manual Section 5: Maintenance MAN 611 Rev. 6 February 2021 Extraordinary Maintenance If there are leaks in the hydraulic cylinder, pneumatic 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: WARNING...

  • Page 42: Replacement Of Cylinder Seal

    Section 5: Maintenance Installation, Operation and Maintenance Manual February 2021 MAN 611 Rev. 6 5.2.1 Replacement of Cylinder Seal Unscrew the plug (26) from the cylinder end flange. Measure the distance of the stop screw (20) with reference to the end flange (22) surface, so as to be able to easily restore the setting of the actuator mechanical stop, once the maintenance procedures have been completed.
  • Page 43 Installation, Operation and Maintenance Manual Section 5: Maintenance MAN 611 Rev. 6 February 2021 To replace the piston seal ring (53) proceed as follows: Remove the existing Teflon seal ring (47) with its O-ring from their groove. Clean the groove carefully and lubricate it with a protective oil film. Assemble the new O-ring into its groove and lubricate it with a protective oil film.
  • Page 44 Section 5: Maintenance Installation, Operation and Maintenance Manual February 2021 MAN 611 Rev. 6 Figure 32 Table 15. Parts list Item Description Item Description Item Description Stop setting screw Piston Sliding block Spring container Stop setting screw O-ring Spring Cylinder tube Yoke bushing End flange Retainer ring...

  • Page 45: Dismantling And Demolition

    Installation, Operation and Maintenance Manual Section 5: Maintenance MAN 611 Rev. 6 February 2021 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 pressure from the cylinder of the actuator, from the control unit and from the...

  • Page 46: Lubrication Of Mechanism

    It is necessary to restore the grease into spring cartridge (for this operation remove the plug on end-flange of spring cartridge and restore a generous coating of grease). The following grease is used by Biffi for standard working temperature and suggested for relubrication: Table 16.

  • Page 47: Section 6: Troubleshooting

    Actuator does not work 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 48: 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 49: Parts List For Maintenance And Replacing Procedure

    Installation, Operation and Maintenance Manual Section 7: Layouts MAN 611 Rev. 6 February 2021 Parts List for Maintenance and Replacing Procedure Figure 33 Scotch Yoke Mechanism Table 18. Parts List Item Description Material O-ring * NBR Yoke bushing Bronze Retainer ring Stainless steel Housing Carbon steel...
  • Page 50 Section 7: Layouts Installation, Operation and Maintenance Manual February 2021 MAN 611 Rev. 6 Figure 34 Pneumatic Cylinder Table 19. 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...
  • Page 51 Installation, Operation and Maintenance Manual Section 7: Layouts MAN 611 Rev. 6 February 2021 Figure 35 Spring Cartridge Table 20. Parts List Item Description Material Carbon steel Washer Carbon steel Sealing washer * PVC Stop setting screw Carbon steel Spring container Carbon steel Spring Carbon steel...
  • Page 52 Section 7: Layouts Installation, Operation and Maintenance Manual February 2021 MAN 611 Rev. 6 Figure 36 Assembly Kit Table 21. Parts List Item Description Material Screw Teflon coated alloy steel Gasket * Fiber Plug Carbon steel Washer Carbon steel Screw Alloy steel Gasket * Fiber...
  • Page 53 Installation, Operation and Maintenance Manual Section 7: Layouts MAN 611 Rev. 6 February 2021 Figure 37 Hydraulic Control Unit MHP Layouts...
  • Page 54 Section 7: Layouts Installation, Operation and Maintenance Manual February 2021 MAN 611 Rev. 6 Table 22. 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...
  • Page 55 Installation, Operation and Maintenance Manual Section 7: Layouts MAN 611 Rev. 6 February 2021 Figure 38 Hydraulic Control Unit Handpump Table 23. Parts List Item Description Material Ball Stainless steel Delivery valve bush Carbon steel Suction valve bush Carbon steel Spring Stainless steel Suction valve seat...
  • Page 56 Section 7: Layouts Installation, Operation and Maintenance Manual February 2021 MAN 611 Rev. 6 Figure 39 Mechanical Manual Override "MHW" Table 24. Parts List Item Description Material Equivalence to USA Standards Flange Aluminum ASTM B221 Alloy 6351 Carbon steel AISI SAE 1040 Retainer ring Stainless steel Protection tube...
  • Page 57 Installation, Operation and Maintenance Manual Section 7: Layouts MAN 611 Rev. 6 February 2021 Figure 40 MRHW Mechanical Manual Override 15 16 17 18 21 22 23 24 25 26 27 28 29 30 31 32 33 34 Table 25. Parts List Item Description...

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

    Section 8: Date Report for Maintenance Operations Installation, Operation and Maintenance Manual February 2021 MAN 611 Rev. 6 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 611 Rev. 6 February 2021 This page is intentionally left blank...
  • Page 60 VCIOM-03743-EN ©2021 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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