BIFFI ALGA-EAC Series Installation, Operation And Maintenance Manual
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BIFFI ALGA-EAC Series Installation, Operation And Maintenance Manual

Double-acting pneumatic actuator
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Biffi ALGA - EAC
Double-Acting Pneumatic 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 564_EAC Rev. 2
June 2020

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  • Page 1 Double-Acting Pneumatic 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 June 2020 MAN 564_EAC Rev. 2 Revision Details Rev. Date Description Prepared Checked Approved June 2020 General update (migration to new template) March 2018 Updated data-plate Ermanni Orefici Vigliano January 2017 Document release Ermanni Orefici Vigliano...

  • Page 3: Table Of Contents

    Installation, Operation and Maintenance Manual Table of Contents MAN 564_EAC Rev. 2 June 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 ................2 Data Sheet .....................
  • Page 4 Table of Contents Installation, Operation and Maintenance Manual June 2020 MAN 564_EAC Rev. 2 Section 5: Maintenance Periodic Maintenance ................... 32 5.1.1 Check and Restore Oil Level in the Hydraulic Manual Override ... 33 5.1.2 Gas Supply Dehydrating Filter Maintenance (If Foreseen) ....35 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: Data Sheet

    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 June 2020 MAN 564_EAC Rev. 2 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 Section 2: Installation Installation, Operation and Maintenance Manual MAN 564_EAC Rev. 2 June 2020 Figure 4 Lifting points for ALGA / ALGA-MHP / ALGA-MSJ actuators 1, 2 = Lifting points (obligatory) 3 = Balancing point Figure 5 Lifting points for ALGA / ALGA-MHP / ALGA-MSJ actuators 1 = Point of support 2 = Supports for lateral positioning 3 = Don’t lay the actuator on tie-rods of cylinder /s and don’t lay the actuator on...
  • Page 10 BIFFI IS NOT LIABLE FOR ANY PERSONEL INJURY DUE TO INCORRECT USE REFER TO IOM 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 11: Storage

    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 12 Installation, Operation and Maintenance Manual June 2020 MAN 564_EAC Rev. 2 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: Figure 7 Drive sleeve Ø...
  • Page 13 Section 2: Installation Installation, Operation and Maintenance Manual MAN 564_EAC Rev. 2 June 2020 Figure 8 Drive sleeve Ø Ø +0.1 Ø ±0.2 Ø N. THREADED HOLES PCD, holes, number and size according to ISO 5211 Flow line Ø +0.2 +0.1 Top view of the scotch yoke mechanism (actuator shown in closed position)
  • Page 14 264.8 264.8 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, provided its dimensions match the maximum stem acceptance of the bush according to Biffi doc.: TN1005.
  • 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

    A non-conforming assembly could be the source of serious accidents. For actuator assembly on 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).

  • Page 17: Pneumatic Connections

    Section 2: Installation Installation, Operation and Maintenance Manual MAN 564_EAC Rev. 2 June 2020 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 June 2020 MAN 564_EAC Rev. 2 Electrical Connections (If Any) NOTICE Use components appropriate as for type, material and dimensions. WARNING 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) 2014/35/EU from 20 April 2016...

  • Page 19: Commissioning

    Section 2: Installation Installation, Operation and Maintenance Manual MAN 564_EAC Rev. 2 June 2020 Commissioning Check that values of electrical supply to the control group (if foreseen) are compatible with those on the plate on the junction box (Figure 11). WARNING 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 June 2020 MAN 564_EAC Rev. 2 Section 3: Operation and Use Operation Description In the normal operating situation, the ALGA actuator is fed by pressurized gas 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”...
  • Page 21 Installation, Operation and Maintenance Manual Section 3: Operation and Use MAN 564_EAC Rev. 2 June 2020 Figure 13 Table 6. Parts list 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...
  • Page 22 Section 3: Operation and Use Installation, Operation and Maintenance Manual June 2020 MAN 564_EAC Rev. 2 For local or remote operations, please refer for information only to Section 3.1 to Section 3.4 and prior to technical documentation furnished with actuators. Typical schematics for various applications are follow attached for information only, the function described are fournished only on specific customer demand.
  • Page 23 Installation, Operation and Maintenance Manual Section 3: Operation and Use MAN 564_EAC Rev. 2 June 2020 Figure 15 ON-OFF service: air fail safe system Pressurized air Pressurized air (low pressure) Atmospheric pressure air The system allows 'fail safe' operation when the pressure in the gas supply line drops below a set value.
  • Page 24 Section 3: Operation and Use Installation, Operation and Maintenance Manual June 2020 MAN 564_EAC Rev. 2 Figure 17 Emergencency manual override The MHW - MSJ jackscrew manual override can be supplied for model up to 3. The override is mounted on the left side of the actuator, the jackscrew end is screwed into the guide block. A bronze split screw nut is mounted inside the body.
  • Page 25 Installation, Operation and Maintenance Manual Section 3: Operation and Use MAN 564_EAC Rev. 2 June 2020 Figure 19 Pneumatic operation Manual operation The diagram is drawn with actuator under pneumatic The diagram is drawn with actuator under manual operation in opening. The flow regulator Fa allows control operation towards open.

  • Page 26: Residual Risks

    Section 3: Operation and Use Installation, Operation and Maintenance Manual June 2020 MAN 564_EAC Rev. 2 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.
  • Page 27 Installation, Operation and Maintenance Manual Section 3: Operation and Use MAN 564_EAC Rev. 2 June 2020 For the adjustment of the travel stop screws proceed as follows: (see Figures 22 and 23). Loosen the lock nut (2) with a proper wrench (c2). If the actuator angular stroke is stopped before reaching the end position (fully open or closed), unscrew the stop screw (1) by turning it anticlockwise with a proper wrench (c1), until the valve reaches the right position.
  • Page 28 Section 3: Operation and Use Installation, Operation and Maintenance Manual June 2020 MAN 564_EAC Rev. 2 Figure 23 Table 8. Pneumatic cylinder size Wrench c1 (mm) Wrench c2 (mm) 1000 1100 1200 1300 1450 For the adjustment of the mechanical stop screwed into the left side of housing, follow these steps (Figure 22 and 24): •...
  • Page 29 Installation, Operation and Maintenance Manual Section 3: Operation and Use MAN 564_EAC Rev. 2 June 2020 Figure 24 Mechanical stop on the housing Table 9. Actuator model Wrench c1 (mm) Wrench c2 (mm) Figure 25 Mechanical stop on the housing Table 10.
  • Page 30 Section 3: Operation and Use Installation, Operation and Maintenance Manual June 2020 MAN 564_EAC Rev. 2 Figure 26 Optional (if foreseen) For the adjustment of the mechanical stop screwed on the end flange of manual override (see Section 7.2 Table 26: sectional drawing for manual jackscrew MSJ – MHW). Figure 27 Mechanical stop on the end flange of manual override Table 11.
  • Page 31 Installation, Operation and Maintenance Manual Section 3: Operation and Use MAN 564_EAC Rev. 2 June 2020 Figure 28 Mechanical stop on the end flange of manual override Table 12. GIG actuator size Wrench c1 (mm) Wrench c2 (mm) Figure 29 Optional (if foreseen) For the adjustment of the mechanical stop on the end flange of hydraulic cylinder of MHP, follow these steps (Figure 30):...

  • Page 32: Calibration Of Micro-Switches (If Foreseen)

    Section 3: Operation and Use Installation, Operation and Maintenance Manual June 2020 MAN 564_EAC Rev. 2 Figure 30 Mechanical stop of the MHP cylinder Table 13. Hydraulic cylinder size Wrench c1 (mm) Wrench c2 (mm) Wrench c3 (mm) 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.

  • Page 33: Calibration Of The Operation Time (Optional - If Foreseen)

    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 placed between the control valves enclosure and the pneumatic cylinder (Figure 34).
  • Page 34 Section 3: Operation and Use Installation, Operation and Maintenance Manual June 2020 MAN 564_EAC Rev. 2 For ALGA actuator models with Manual Handpump, the operating time is adjustable through two regulation valves placed on manual handpump body (see Section 7.2 Table 24: sectional drawing for hydraulic control unit MHP).

  • Page 35: Section 4: Operational Tests And Inspections

    Installation, Operation and Maintenance Manual Section 4: Operational Tests and Inspections MAN 564_EAC Rev. 2 June 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...

  • Page 36: Section 5: Maintenance

    Section 5: Maintenance Installation, Operation and Maintenance Manual June 2020 MAN 564_EAC Rev. 2 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 37: Check And Restore Oil Level In The Hydraulic Manual Override

    Section 5: Maintenance Installation, Operation and Maintenance Manual MAN 564_EAC Rev. 2 June 2020 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 MANUAL CLOSING MANUAL OPENING...
  • Page 38 Section 5: Maintenance Installation, Operation and Maintenance Manual June 2020 MAN 564_EAC Rev. 2 Table 14. Features of hydraulic oil suggested by Biffi Italia s.r.l. for refilling in different working condition: Standard temperature conditions (-30 °C/+85 °C) Producer AGIP Name ARNICA 22 Viscosity at 40 °C...

  • Page 39: Gas Supply Dehydrating Filter Maintenance (If Foreseen)

    Section 5: Maintenance Installation, Operation and Maintenance Manual MAN 564_EAC Rev. 2 June 2020 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 40: Extraordinary Maintenance

    Section 5: Maintenance Installation, Operation and Maintenance Manual June 2020 MAN 564_EAC Rev. 2 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.
  • Page 41 Installation, Operation and Maintenance Manual Section 5: Maintenance MAN 564_EAC Rev. 2 June 2020 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 oil (SHELL OMALA S4 WE or equivalent).
  • Page 42 Section 5: Maintenance Installation, Operation and Maintenance Manual June 2020 MAN 564_EAC Rev. 2 Reassemble Assemble the new gasket (36) after cleaning the surfaces of housing (8) and head flange (17), which are in contact. Assemble the head flange (17), replace the washers (37) if damaged, tighten the screws (15) to the recommended torque.
  • Page 43 Installation, Operation and Maintenance Manual Section 5: Maintenance MAN 564_EAC Rev. 2 June 2020 Figure 39 ALGA double-acting pneumatic actuator Table 15. Parts list Item Name Cover Screw Guide block pin Vent valve Sliding block Screw Screw Housing Guide bar Cover gasket Yoke Plug...
  • Page 44 Section 5: Maintenance Installation, Operation and Maintenance Manual June 2020 MAN 564_EAC Rev. 2 Item Name Head flange Tie rod Cylinder tube Piston rod Piston End flange Lifting eyelet Spring washer Stop setting screw Stopper bush Adaptor bush Washer O-ring Yoke bushing Retainer ring Flange...
  • Page 45 Installation, Operation and Maintenance Manual Section 5: Maintenance MAN 564_EAC Rev. 2 June 2020 Replacement of hydraulic cylinder seals (see Figure 40) only for ALGA-MHP hydraulic handpump manual override 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 sectional drawing and adopting the following procedures:...
  • Page 46 Section 5: Maintenance Installation, Operation and Maintenance Manual June 2020 MAN 564_EAC Rev. 2 To replace the piston seal ring (9) and the O-ring (19) proceed as follows: Remove the existing Teflon seal ring (9) and the O-ring (19) from their groove. Clean the groove carefully and lubricate it with a protective oil film.
  • Page 47 Installation, Operation and Maintenance Manual Section 5: Maintenance MAN 564_EAC Rev. 2 June 2020 Carefully clean the inside of the tube (item 12) and check that the entire surface, particularly that of the bevels, is not damaged. Lubricate with protective oil film the tube inside surface and the bevels at the ends.
  • Page 48 Section 5: Maintenance Installation, Operation and Maintenance Manual June 2020 MAN 564_EAC Rev. 2 Figure 40 Hydraulic cylinder Table 16. Parts list Item Name Piston rod bushing Head flange O-ring Piston rod seal ring O-ring Piston rod Piston Guide sliding ring for piston Piston seal ring Tie rod Stop setting screw...

  • Page 49: Mhp Hydraulic Manual Override Maintenance And Trouble Shooting

    Installation, Operation and Maintenance Manual Section 5: Maintenance MAN 564_EAC Rev. 2 June 2020 MHP Hydraulic Manual Override Maintenance and Trouble Shooting 5.3.1 Operation (see the attached operating diagram MAN 562-A) The “MHP” hydraulic manual override and speed control unit is utilized, in connection with the actuator hydraulic cylinder, for the manual operation and for the speed control during the pneumatic operation of pneumatic double-acting actuators.

  • Page 50: Setting

    B) Settings of relief valves (see the attached sectional drawings) The relief valve (item Ra of operating diagram MAN562-A) is set at Biffi factory at a proper value and there is no reason to change the setting on the field.
  • Page 51 Installation, Operation and Maintenance Manual Section 5: Maintenance MAN 564_EAC Rev. 2 June 2020 Figure 41 Hydraulic cylinder Oil tank relief valve Relief valve for automatic operation Flow regulator Relief valve for manual operation Table 17. Parts list Item Description Material Dipstick Carbon steel + Aluminium...

  • Page 52: Lubrication Of Mechanism

    Section 5: Maintenance Installation, Operation and Maintenance Manual June 2020 MAN 564_EAC Rev. 2 Item Description Material Tank gasket * Fiber Tank cover Carbon steel Tie rod Carbon steel Screw Carbon steel Flange Aluminium Check valve body Carbon steel Plug Carbon steel Flow control valve setting screw Stainless steel...

  • Page 53: Dismantling And Demolition

    Installation, Operation and Maintenance Manual Section 5: Maintenance MAN 564_EAC Rev. 2 June 2020 The following grease is used by BIFFI for standard working temperature and suggested for re-lubrication: Table 18. AGIP MU/EP/2 AEROSHELL GREASE 7 or equivalent To be used in standard (-30 °C/+85 °C)

  • Page 54: Section 6: Troubleshooting

    Wrong position of the distributor not work Restore correct position of the manual hydraulic group Failure of the control group Call Biffi Italia s.r.l. Customer Service Low supply pressure Restore (Section 1.4) Low supply pressure Restore (Section 1.4) Actuator too slow Wrong calibration of flow regulator valves Restore (Section 3.6)

  • Page 55: 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 56: Parts List For Maintenance And Replacing Procedure

    Section 7: Layouts Installation, Operation and Maintenance Manual June 2020 MAN 564_EAC Rev. 2 Parts List for Maintenance and Replacing Procedure Figure 42 Scotch yoke mechanism Table 20. Parts list Item Description Material O-ring * Fluorosilicon rubber Yoke bushing Bronze Retainer ring Stainless steel Housing...
  • Page 57 Installation, Operation and Maintenance Manual Section 7: Layouts MAN 564_EAC Rev. 2 June 2020 Figure 43 Pneumatic cylinder Table 21. Parts list Item Description Material Piston rod bushing Steel + Bronze + PTFE O-ring * Fluorosiliconic rubber Gasket * NBR 870260 Head flange Carbon steel P355NL1 UNI EN 10028-1 Carbon steel ASTM A194 gr.
  • Page 58 Section 7: Layouts Installation, Operation and Maintenance Manual June 2020 MAN 564_EAC Rev. 2 Figure 44 Hydraulic cylinder (optional: only for ALGA-MHP hydraulic handwheel manual override) Table 22. Parts list Item Description Material Piston rod bushing Steel + Bronze + PTFE Head flange Carbon steel O-ring...
  • Page 59 Installation, Operation and Maintenance Manual Section 7: Layouts MAN 564_EAC Rev. 2 June 2020 Figure 45 Assembly kit Table 23. Parts list Item Description Material Screw Alloy steel Carbon steel Carbon steel Screw Alloy steel Flange Carbon steel Gasket * SBR + Cellulose + Fillers Stopper bush Alloy steel Plug...
  • Page 60 Section 7: Layouts Installation, Operation and Maintenance Manual June 2020 MAN 564_EAC Rev. 2 Figure 46 Hydraulic control unit MHP Oil tank relief valve Relief valve for automatic operation Flow regulator Relief valve for manual operation Table 24. Parts list Item Description Material...
  • Page 61 Installation, Operation and Maintenance Manual Section 7: Layouts MAN 564_EAC Rev. 2 June 2020 Item Description Material O-ring * Fluorosilicon rubber Tank cover Carbon steel Tie rod Carbon steel Screw Carbon steel Flange Aluminium Check valve body Aluminium Plug Carbon steel Flow control valve setting screw Stainless steel Spring pin...
  • Page 62 Section 7: Layouts Installation, Operation and Maintenance Manual June 2020 MAN 564_EAC Rev. 2 Figure 47 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 63 Installation, Operation and Maintenance Manual Section 7: Layouts MAN 564_EAC Rev. 2 June 2020 Figure 48 Jackscrew manual override MSJ or MHW ENGAGED TO OPEN TO CLOSE DISENGAGED Table 26. Parts list Item Description Material Protection pipe Carbon steel Jackscrew Carbon steel Engagement lever pin Stainless steel...

  • Page 64: Section 8: Date Report For Maintenance Operations

    Section 8: Date Report for Maintenance Operations Installation, Operation and Maintenance Manual June 2020 MAN 564_EAC Rev. 2 Section 8: Date Report for Maintenance Operations Last maintenance operation date: (in factory, on delivery): ……… exec. by : ………… ……… exec. by : ………… ………...
  • Page 65 Installation, Operation and Maintenance Manual Notes MAN 564_EAC Rev. 2 June 2020 This page intentionally left blank...
  • Page 66 VCIOM-15305-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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