BIFFI HLAS Installation, Operation And Maintenance Manual
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BIFFI HLAS Installation, Operation And Maintenance Manual

Single acting spring-return hydraulic linear actuator
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Biffi HLAS
Single Acting Spring-Return Hydraulic Linear 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 620 Rev. 5
February 2022

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  • Page 1 Single Acting Spring-Return Hydraulic Linear 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 2022 MAN 620 Rev. 5 Revision Details Rev. Date Description Prepared Checked Approved February 2022 General update (Migration to new template) February 2019 Updated data plate Sassi Orefici Vigliano April 2016 Updated applicable regulation (chapter 1.1.1) Ermanni Orefici Vigliano...

  • Page 3: Table Of Contents

    3.3.2 Remote Control Operations ..............14 Calibration of the Angular Stroke ..............15 Calibration of Microswitches (Biffi Limit Switch Box Only) ......18 Calibration of the Operation Time .............. 20 Section 4: Operational Tests and Inspections Operational Tests and Inspections ................. 21 Section 5: Maintenance Periodic Maintenance .................
  • Page 4 Table of Contents Installation, Operation and Maintenance Manual February 2022 MAN 620 Rev. 5 Section 6: Troubleshooting Failure or Breakdown Research ..............30 Section 7: Layouts Spare Parts Order ..................31 Parts List for Maintenance and Replacing Procedure ........32 Section 8: Date Report for Maintenance Operations Date Report for Maintenance Operations ..............

  • Page 5: Section 1: General Warnings

    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 6: Identification Plate

    Figure 1 Data plate Introducing the Actuator HLAS single acting hydraulic linear actuators are suitable for the operation of linear valves (wedge gate valves through conduit gate valves) for ON-OFF and modulating heavy-duty service. The actuator is made up of a hydraulic cylinder, a spring cartridge and a mounting pedestal complete with a joint for the coupling to the valve stem of actuator output stem.

  • Page 7: Data Sheet

    Identification of actuator parts Lifting eyelets Hydraulic cylinder Spring cartridge Manual handpump MHP (optional) Valve position indicator Valve coupling HLAS 250 k 100 k Manual override Spring action Stroke (mm) Spring ending thrust (N) Cylinder diameter (mm) Max. allowable thrust (N)

  • Page 8: Section 2: Installation

    Installation, Operation and Maintenance Manual Section 2: Installation February 2022 MAN 620 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).
  • Page 9 Installation, Operation and Maintenance Manual Section 2: Installation February 2022 MAN 620 Rev. 5 Figure 3 Lifting points for HLAS actuators 1 = Lifting points (obligatory) Figure 4 Positioning by chains 1 = point of support WARNING 2 = don’t lay the actuator on tie rods of cylinder 3 = don’t lay the actuator on accessories (manual handpump, hydraulic control system, etc.)

  • Page 10: Storage

    Installation, Operation and Maintenance Manual Section 2: Installation February 2022 MAN 620 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. •...
  • Page 11 Installation, Operation and Maintenance Manual Section 2: Installation February 2022 MAN 620 Rev. 5 To assemble the actuator onto the valve by bracket with threaded joint, proceed as follows: Figure 5 Pedestal with threaded coupling joint Table 1. Parts list Item Description Stud bolt...
  • Page 12 Installation, Operation and Maintenance Manual Section 2: Installation February 2022 MAN 620 Rev. 5 To assemble the actuator onto the valve by bracket with shell joint, perform the following operations: Figure 6 Pedestal with shell coupling joint Table 2. Parts list Item Description Stud bolt...
  • Page 13 Installation, Operation and Maintenance Manual Section 2: Installation February 2022 MAN 620 Rev. 5 Check that the coupling dimensions of the valve flange and stem, or of the relevant extension, meet the actuator coupling dimensions (valve stem and flange). Lubricate the valve stem with grease in order to make the assembly easier. To make the assembly easier, the valve stem has to be in perfect vertical position.

  • Page 14: Hydraulic Connections

    Installation, Operation and Maintenance Manual Section 2: Installation February 2022 MAN 620 Rev. 5 Hydraulic Connections WARNING Check that the values of hydraulic supply available are compatible with those reported on the identification plate of the actuator. NOTICE The connections should be made by qualified staff. Use pipes and connections appropriate as for type, material and dimensions.

  • Page 15: Electrical Connections (If Any)

    Installation, Operation and Maintenance Manual Section 2: Installation February 2022 MAN 620 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 as per CEI 64-8 regulation should be complied with (same as IEC 60364).

  • Page 16: Section 3: Operation And Use

    Section 3: Operation and Use Installation, Operation and Maintenance Manual February 2022 MAN 620 Rev. 5 Section 3: Operation and Use Operation Description The supply fluid pressurizes the hydraulic cylinder chamber relevant to the operation to carry out (opening or closing) (see following pages). This pressure starts the linear motion of the piston and the consequent motion of the valve stem that is coupled.

  • Page 17: Residual Risks

    WARNING Refer to applicable control schematic in supplied documentation. The HLAS actuators can have an emergency manual override in addition to the local and/or remote control system, which controls the oil supplied by a power pack for the “normal” actuator operation.

  • Page 18: Remote Control Operations

    Section 3: Operation and Use Installation, Operation and Maintenance Manual February 2022 MAN 620 Rev. 5 3.3.2 Remote Control Operations Figure 9 Example of control schematics for spring-to-close HLAS actuator Connection at customer care Oil supply line Oil return line Electric connection to microswitches...

  • Page 19: Calibration Of The Angular Stroke

    Installation, Operation and Maintenance Manual Section 3: Operation and Use MAN 620 Rev. 5 February 2022 3.4. Calibration of the Angular Stroke It is important that the mechanical stops of the actuator (and not those of the valve) stop the linear stroke at both extreme valve position (fully open and fully closed), except when this is required by the valve operation.
  • Page 20 Section 3: Operation and Use Installation, Operation and Maintenance Manual February 2022 MAN 620 Rev. 5 For the adjustment of the mechanical stop on the end flange of cylinder, follow these steps (Figure 11): • Remove the plug (t) with the specific wrench (c1). •...
  • Page 21 Installation, Operation and Maintenance Manual Section 3: Operation and Use MAN 620 Rev. 5 February 2022 For high pressure cylinder models, the mechanical stop is internal (without protection cover). Proceed at the same way: (1) remove the plug and (2) operate the adjusting screw. Figure 12 Operation and Use...

  • Page 22: Calibration Of Microswitches (Biffi Limit Switch Box Only)

    Installation, Operation and Maintenance Manual February 2022 MAN 620 Rev. 5 Calibration of Microswitches (Biffi Limit Switch Box Only) NOTICE Operate only the microswitch corresponding to the direction of operation being carried out, as clearly reported on the microswitch. WARNING If different microswitches assembly or limit switch box is supplied, please refer to the specific documentation.
  • Page 23 Installation, Operation and Maintenance Manual Section 3: Operation and Use MAN 620 Rev. 5 February 2022 Figure 14 Cam adjustment If the index (Figure 15) 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 24: Calibration Of The Operation Time

    For actuator models with control system, it’s possible to regulate the speed of actuator operations. 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.

  • Page 25: Section 4: Operational Tests And Inspections

    Installation, Operation and Maintenance Manual Section 4: Operational Tests and Inspections MAN 620 Rev. 5 February 2022 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 26: Section 5: Maintenance

    Installation, commissioning and maintenance and repair works should be carried out by qualified staff. Periodic Maintenance HLAS 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 27: Check And Restore Oil Level In The Manual Handpump

    The cleanliness level for actuator without control system is NAS 8 minimum. For actuator with control system, the cleanliness level is that required by singles components. In any case, Biffi Italia s.r.l. respects the customer requirements to scope of supply. For applicable cleanliness level, refer to document: technical data sheet for actuators.
  • Page 28 Section 5: Maintenance Installation, Operation and Maintenance Manual February 2022 MAN 620 Rev. 5 Table 6. Features of hydraulic oil suggested by Biffi Italia s.r.l. for refilling in different working conditions Standard temperature conditions (-30 °C/+85 °C): Producer AGIP Name ARNICA 22 Viscosity at 40 °C...

  • Page 29: Extraordinary Maintenance

    5.2.1 Lubrication of Mechanism For normal duty, the HLAS actuator is lubricated "for life". In case of high load and high frequency of operation, it may be necessary to periodically restore the lubrication; it is advisable to apply a generous coating of grease on the contact surfaces of moving parts.

  • Page 30: Replacement Of Cylinder Seals

    Section 5: Maintenance Installation, Operation and Maintenance Manual February 2022 MAN 620 Rev. 5 5.2.2 Replacement of Cylinder Seals (refer to Figure 18) WARNING 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.
  • Page 31 Installation, Operation and Maintenance Manual Section 5: Maintenance MAN 620 Rev. 5 February 2022 To replace the piston seal ring (8), proceed as follows: Remove the existing Teflon seal ring (8) with its O-ring from their groove. Clean the groove carefully and lubricate it with a protective oil or grease film. Assemble the new O-ring into its groove and lubricate it with a protective oil or grease film.
  • Page 32 Section 5: Maintenance Installation, Operation and Maintenance Manual February 2022 MAN 620 Rev. 5 Figure 18 Single acting spring-return hydraulic linear actuator sectional drawing Table 8. Parts list Item Description Item Description Head flange Lower spring flange O-ring Piston rod guide tube Piston rod seal ring Stem Back-up ring...

  • Page 33: Dismantling And Demolition

    Installation, Operation and Maintenance Manual Section 5: Maintenance MAN 620 Rev. 5 February 2022 Dismantling and Demolition Before starting the disassembly, a large area should be created around the actuator so as 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 34: Section 6: Troubleshooting

    Handle positioned on indication of the operation remote control to make Hydraulic manual pump does not work Leakages on the check Call Biffi Italia s.r.l. Customer valve of the hydraulic Service control group Wrong adjustment of Reset (Section 3.4) mechanical stops...

  • Page 35: 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 36: Parts List For Maintenance And Replacing Procedure

    Section 7: Layouts Installation, Operation and Maintenance Manual February 2022 MAN 620 Rev. 5 Parts List for Maintenance and Replacing Procedure Figure 19 Pedestal with coupling joint Table 10. Parts list Item Description Material Pedestal Carbon steel Antirotation shaft Stainless steel Scraper ring flange Stainless steel Plate...
  • Page 37 Installation, Operation and Maintenance Manual Section 7: Layouts February 2022 MAN 620 Rev. 5 Figure 20 Spring cartridge Table 11. Parts list Item Description Material Closing flange Carbon steel External tube Carbon steel Upper spring flange Carbon steel Lower spring flange Carbon steel Piston rod guide tube Carbon steel...
  • Page 38 Section 7: Layouts Installation, Operation and Maintenance Manual February 2022 MAN 620 Rev. 5 Figure 21 Hydraulic cylinder Table 12. Parts list Item Description Material Head flange Carbon steel O-ring *NBR Piston rod seal ring Teflon + graphite + NBR Back-up ring *NBR Joint...
  • Page 39 Installation, Operation and Maintenance Manual Section 7: Layouts February 2022 MAN 620 Rev. 5 Figure 22 Hydraulic control unit MHP Oil Tank Relief Valve Relief Valve for Automatic Operation Flow Regulator Relief Valve for Manual Operation Layouts...
  • Page 40 Section 7: Layouts Installation, Operation and Maintenance Manual February 2022 MAN 620 Rev. 5 Table 13. Parts list Item Description Material Dipstick Carbon steel + Aluminum Plug Carbon steel Washer Copper Hydraulic tank Carbon steel Handpump See Table 14 O-ring *Fluorosilicon rubber Ball Stainless steel...
  • Page 41 Installation, Operation and Maintenance Manual Section 7: Layouts February 2022 MAN 620 Rev. 5 Figure 23 Hydraulic control unit handpump Table 14. 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 42: Section 8: Date Report For Maintenance Operations

    Section 8: Date Report for Maintenance Operations Installation, Operation and Maintenance Manual February 2022 MAN 620 Rev. 5 Section 8: Date Report for Maintenance Operations Last maintenance operation date: (in factory, on delivery ): ……… exec. by : ………… ……… exec. by : ………… ………...
  • Page 43 Installation, Operation and Maintenance Manual Notes MAN 620 Rev. 5 February 2022 This page is intentionally left blank...
  • Page 44 VCIOM-04482-EN ©2022 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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