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BIFFI ALGAS-MHW Installation, Operation And Maintenance Manual

Spring-return pneumatic actuator with handwheel manual override
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Installation, Operation and Maintenance Manual
MAN 604-1A Rev. 6
March 2021
Biffi ALGAS-MHW or MRHW
Spring-Return Pneumatic Actuator with Handwheel Manual Override
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

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  • Page 1 Spring-Return Pneumatic Actuator with Handwheel Manual Override 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 March 2021 MAN 604-1A Rev. 6 Revision Details Revision Date Description Prepared Checked Approved March 2021 Migration to new template December 2019 Added Declutch-able type Ermanni Orefici Vigliano March 2018 Update Data-plate Ermanni Orefici Vigliano April 2016...

  • Page 3: Table Of Contents

    Installation, Operation and Maintenance Manual Table of Contents MAN 604-1A Rev. 6 March 2021 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 Description of the Actuator ................3 Section 2: Installation Checks to be Carried Out on Receiving the Actuator ..........
  • Page 4 Table of Contents Installation, Operation and Maintenance Manual March 2021 MAN 604-1A Rev. 6 Section 5: Maintenance Routine Maintenance .................. 24 Special Maintenance ................... 25 5.2.1 Replacement of Cylinder Seals ............26 5.2.2 Replacement of the Seals of Manual Override “MHW” ...... 28 5.2.3 Replacement of the Seals of Reduced-Manual Override “MRHW”...

  • Page 5: Section 1: General Warnings

    Nevertheless Biffi Italia does not provide any guarantees for this instruction manual. Biffi Italia will not be responsible for any mistakes contained in it or for any damage either accidental or due to the use of this manual. The information herein contained is reserved property of Biffi Italia and is subject to being modified without notice.

  • 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: Description Of The Actuator

    The actuator yoke has a hole with keyways suitable for the assembly of an insert bush or a stem extension. Their internal hole is machined (by Biffi or at Customer's care), according to the shape and dimensions of the valve stem.

  • Page 8: Section 2: Installation

    Section 2: Installation Installation, Operation and Maintenance Manual March 2021 MAN 604-1A Rev. 6 Section 2: Installation Checks to be Carried Out on Receiving the Actuator If the actuator arrives already assembled onto the valve, the settings of the mechanical stops and of the microswitches (if existing) has already been made by the person who assembled the actuator onto the valve.

  • Page 9: Assembling The Actuator Onto The Valve

    Types of Assembly For coupling to the valve, the housing is provided with a flange with threaded holes according to Biffi standard tables (SCN6200; SCN6200-1; SCN6201; SCN6201-1). 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...
  • Page 10 Section 2: Installation Installation, Operation and Maintenance Manual March 2021 MAN 604-1A Rev. 6 Figure 2 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 11 Installation, Operation and Maintenance Manual Section 2: Installation MAN 604-1A Rev. 6 March 2021 Figure 3 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 12 Section 2: Installation Installation, Operation and Maintenance Manual March 2021 MAN 604-1A Rev. 6 Figure 4 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 13 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 14: Valve Stem With Vertical Axis

    Section 2: Installation Installation, Operation and Maintenance Manual March 2021 MAN 604-1A Rev. 6 2.3.2 Valve Stem with Vertical Axis NOTICE The 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.
  • Page 15 Do not use the lifting eyelets on actuator to lift valve + actuator assembly. WARNING Any lifting method different from what described above is strictly forbidden. Biffi reject any responsibility for damages to goods or injuries to persons coming from wrong lifting operations. Installation...
  • Page 16 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 The actuator can be assembled onto the valve flange either by using the actuator-housing flange with threaded holes, or by the interposition of an adaptor flange or a spool piece.

  • Page 17: Valve Stem With Horizontal Axis

    Installation, Operation and Maintenance Manual Section 2: Installation MAN 604-1A Rev. 6 March 2021 Clean the actuator flange and remove anything that might prevent a perfect adherence to the valve flange and especially all traces of grease. Lower the actuator onto the valve in such a way that the insert bush, assembled on the valve stem, enters the actuator drive sleeve.
  • Page 18 Section 2: Installation Installation, Operation and Maintenance Manual March 2021 MAN 604-1A Rev. 6 Connect properly the actuator lifting points 1 with chains, and connect by suitable slings the support brackets 2 and 3. Figure 11 Balance the weight and lift the actuator until to make possible the rotation of actuator in its final mounting position, with cylinder on top, or spring container placed on top, as showed in the following images: Figure 12...
  • Page 19 Installation, Operation and Maintenance Manual Section 2: Installation MAN 604-1A Rev. 6 March 2021 Figure 13 Clean the actuator flange and remove anything that might prevent a perfect adherence to the valve flange and especially all traces of grease. Lift the actuator near to the valve in such a way that the insert bush, assembled on the valve stem, enters the actuator drive sleeve without forcing the coupling.

  • Page 20: Section 3: Operation And Use

    Section 3: Operation and Use Installation, Operation and Maintenance Manual March 2021 MAN 604-1A Rev. 6 Section 3: Operation and Use Setting of the Angular Stroke It is important that the mechanical stops of the actuator (and not those of the valve) stop the angular stroke at both extreme valve position (fully open and fully closed), except when this is required by the valve operation (e.g.

  • Page 21: Travel Stop-Screw Screwed On The End Of Mechanical Manual Override

    Installation, Operation and Maintenance Manual Section 3: Operation and Use MAN 604-1A Rev. 6 March 2021 3.1.2 Travel Stop-screw Screwed on the End of Mechanical Manual Override Figure 14 Table 7. ALGAS actuator size Wrench C1 (mm) Wrench C2 (mm) Figure 15 Table 8.

  • Page 22: Travel Stop-Screw Screwed On The End Flange Of Spring Container

    Section 3: Operation and Use Installation, Operation and Maintenance Manual March 2021 MAN 604-1A Rev. 6 3.1.3 Travel Stop-screw Screwed on the End Flange of Spring Container For the adjustment of the travel stop-screw, proceed as follows: Figure 16 For model from 006 to 150 For the adjustment of the travel stop screw, proceed as follows: Figure 17 For model from 200 to 19600...
  • Page 23 Installation, Operation and Maintenance Manual Section 3: Operation and Use MAN 604-1A Rev. 6 March 2021 To operate the adjustments, refer to following tables: Table 9. Spring container size Wrench C1 (mm) Wrench C2 (mm) 0100 0150 Table 10. Spring container size Wrench C1 (mm) Wrench C2 (mm) 0200...

  • Page 24: Calibration Of Microswitches (If Foreseen)

    Calibration of Operating Time in Supply Operation 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 to re-set the operating time through the flow regulation valve placed between the control system and the pneumatic cylinder (Figure 18).

  • Page 25: Preparation For Start-Up

    Installation, Operation and Maintenance Manual Section 3: Operation and Use MAN 604-1A Rev. 6 March 2021 To carry out the adjustment, use an adequate Allen wrench and follow these steps (Figure 18): • Loosen the locknut • Screw with a screwdriver the setting screw to increase the operation time •...

  • Page 26: Electrical Connections

    Section 3: Operation and Use Installation, Operation and Maintenance Manual March 2021 MAN 604-1A Rev. 6 3.4.2 Electrical Connections Connect the electrical feed, control and signal lines to the actuator, by linking them up with the terminal blocks of the electrical components. In order to do this, the housing covers must be removed without damaging the coupling surfaces, the O-rings or the gaskets.

  • Page 27: Section 4: Operational Tests And Inspections

    Installation, Operation and Maintenance Manual Section 4: Operational Tests and Inspections MAN 604-1A Rev. 6 March 2021 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 28: Section 5: Maintenance

    Section 5: Maintenance Installation, Operation and Maintenance Manual March 2021 MAN 604-1A Rev. 6 Section 5: Maintenance NOTE: Before carrying out any maintenance operation, it is necessary to close the pneumatic feed line and exhaust the pressure from the actuator cylinder and from the control unit, to ensure safety of maintenance staff.

  • Page 29: Special Maintenance

    Section 5: Maintenance Installation, Operation and Maintenance Manual MAN 604-1A Rev. 6 March 2021 Special Maintenance If there are leaks in the cylinder/manual override or a malfunction in the mechanical components, or in case of scheduled preventive maintenance, the actuator must be disassembly and seals must be replaced with reference to the follow general sectional drawing and adopting the following procedures.

  • Page 30: Replacement Of Cylinder Seals

    Section 5: Maintenance Installation, Operation and Maintenance Manual March 2021 MAN 604-1A Rev. 6 5.2.1 Replacement of Cylinder Seals Measure the protrusion of the stop screw (52) with reference to the protection tube (51) surface, so as to be able to easily restore the setting of the actuator mechanical stop, once the maintenance procedures have been completed.
  • Page 31 Section 5: Maintenance Installation, Operation and Maintenance Manual MAN 604-1A Rev. 6 March 2021 Figure 20 ALGAS - MHW spring-return pneumatic actuator Table 11. Parts list Item Description Item Description Item Description Stop setting screw Protection tube Spring container Guide rod Stop setting screw Spring Spring thrust flange...

  • Page 32: Replacement Of The Seals Of Manual Override "Mhw

    Section 5: Maintenance Installation, Operation and Maintenance Manual March 2021 MAN 604-1A Rev. 6 5.2.2 Replacement of the Seals of Manual Override “MHW” NOTICE Before any operation, you must keep the actuator in release position to allow the air and spring stroke.

  • Page 33: Replacement Of The Seals Of Reduced-Manual Override "Mrhw

    Section 5: Maintenance Installation, Operation and Maintenance Manual MAN 604-1A Rev. 6 March 2021 5.2.3 Replacement of the Seals of Reduced-Manual Override “MRHW” NOTICE Before any operation , you must keep the actuator in release position to allow the air and spring stroke.
  • Page 34 Section 5: Maintenance Installation, Operation and Maintenance Manual March 2021 MAN 604-1A Rev. 6 Figure 21 Mechanical manual override "MRHW" worm gear reduction unit Table 12. Parts List Item Description Material Equivalence to USA standards O-ring Thrust bearing washer Alloy steel AISI SAE 9840 Sliding washer Bronze...
  • Page 35 Section 5: Maintenance Installation, Operation and Maintenance Manual MAN 604-1A Rev. 6 March 2021 Figure 22 Mechanical manual override "MRHW" bevel gear reduction unit Table 13. Parts List Item Description Material Equivalence to USA standards O-ring Thrust bearing washer Alloy steel AISI SAE 9840 Sliding washer Bronze...
  • Page 36 Section 5: Maintenance Installation, Operation and Maintenance Manual March 2021 MAN 604-1A Rev. 6 Figure 23 Mechanical manual override "DMHW" (Declutch-able) Cyliner End-Flange Table 14. Parts List Item Description Material Flange Aluminum Carbon steel Scraper ring * Rubber Protection tube Carbon steel Stop setting screw Alloy steel...
  • Page 37 Section 5: Maintenance Installation, Operation and Maintenance Manual MAN 604-1A Rev. 6 March 2021 Figure 24 Mechanical manual override "DMRHW" (Declutch-able / Reduced) Maintenance...
  • Page 38 Section 5: Maintenance Installation, Operation and Maintenance Manual March 2021 MAN 604-1A Rev. 6 Table 15. Parts List Item Description Material O-ring * NBR rubber Thrust bearing washer Alloy steel Sliding washer Bronze O0ring * Viton Spacer bracket Carbon steel Protection tube Carbon steel Jackscrew...

  • Page 39: Lubrication Of Mechanism

    It’s also necessary 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 re-lubrication: Table 16.

  • Page 40: Dismantling And Demolition

    Section 5: Maintenance Installation, Operation and Maintenance Manual March 2021 MAN 604-1A Rev. 6 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 41: Section 6: Troubleshooting

    Restore correct position Actuator does manual hydraulic group not work Failure of the spring Call Biffi Italia s.r.l. Customer Service Failure of the control group Call Biffi Italia s.r.l. Customer Service Unexpected intervention of torque limit-device Call Biffi Italia s.r.l. Customer Service Low supply pressure Restore (Section 1.4)

  • Page 42: Section 7: Parts List

    Section 7: Parts List 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 43: Parts List For Maintenance And Replacing Procedure

    1. Cycles performed by actuator in 25 years expected lifetime - the minimum performed cycles are guaranteed by Biffi based on service conditions listed: - All the valve required torques have to be lower than the actuator Max Operating Torque (MOT) - The ratio betweem valve required running torque and actuator Max Operating Torque (MOT) has to be >...
  • Page 44 Section 7: Parts List Installation, Operation and Maintenance Manual March 2021 MAN 604-1A Rev. 6 Figure 26 Pneumatic cylinder Table 19. Parts List Item Description Material Piston rod bushing Steel + Bz + Teflon O-ring * NBR O-ring * NBR Head flange Carbon steel Carbon steel...
  • Page 45 Section 7: Parts List Installation, Operation and Maintenance Manual MAN 604-1A Rev. 6 March 2021 Figure 27 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...
  • Page 46 Section 7: Parts List Installation, Operation and Maintenance Manual March 2021 MAN 604-1A Rev. 6 Figure 28 Assembly kit Table 21. Parts List Item Description Material Screw Alloy steel Gasket * Fiber Side plate Carbon steel Gasket * Fiber Washer Carbon steel Adoptor bush Alloy steel...

  • Page 47: Section 8: Date Report For Maintenance Operations

    Installation, Operation and Maintenance Manual Section 8: Date Report for Maintenance Operations MAN 604-1A Rev. 6 March 2021 Section 8: Date Report for Maintenance Operations Last maintenance operation date: (in factory, on delivery): ……… exec. by: ………… ……… exec. by: ………… ………...
  • Page 48 VCIOM-03200-EN ©2021 Biffi. All rights reserved. Biffi Italia s.r.l. The contents of this publication are presented for information Strada Biffi 165 purposes only, and while every effort has been made to ensure their 29017 Fiorenzuola d’Arda (PC) accuracy, they are not to be construed as warranties or guarantees,...

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