BIFFI FCB Series Service Instructions Manual
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BIFFI FCB Series Service Instructions Manual

Pneumatic actuators
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FCB Series Pneumatic Actuators
Model FCBA Double-Acting Disassembly and Reassembly
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
Service Instructions
VCIOM-15380-EN Rev. 2
March 2022

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  • Page 1 Model FCBA Double-Acting Disassembly and Reassembly 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 Service Instructions Notes VCIOM-15380-EN Rev. 2 March 2022 This page is intentionally left blank...

  • Page 3: Table Of Contents

    Table of Contents Section 1: Introduction General Service Information ................. 1 Definitions ....................2 General Safety Information ................2 Biffi Reference Materials ................3 Service Support Items .................. 3 Lubrication Requirements ................3 General Tool Information ................3 Actuator Weight ................... 4 Actuator Storage ...................
  • Page 4 Service Instructions Table of Contents VCIOM-15380-EN Rev. 2 March 2022 Section 6: Troubleshooting Fault Insertion ..................... 25 Operational Test ..................26 Section 7: Removal and Decommissioning Removal and Decommissioning ..............27 Section 8: Document Revision Document Revision....................28 List of Tables List ot Tables......................29 List of Figures List of Figures......................30...

  • Page 5: Section 1: Introduction

    1.1.6 Numbers in parentheses, ( ) indicate the bubble number (reference number) used on the Biffi Assembly Drawing and Actuator Parts List. 1.1.7 This procedure is written using the serial number tag side of the housing (1-10) as a reference and this side will be considered the front side of the actuator.

  • Page 6: Definitions

    VCIOM-15380-EN Rev. 2 March 2022 CAUTION Apply the thread sealant per the manufacturer’s instructions. 1.1.10 Biffi recommends that disassembly of the actuator should be done in a clean area on a workbench. Definitions WARNING If not observed, user incurs a high risk of severe damage to actuator and/or fatal injury to personnel.

  • Page 7: Biffi Reference Materials

    Biffi Product Engineering. 1.6.2 All temperature services (-50 °F to +350 °F)/(-45.5 °C to 176.6 °C) use Biffi ESL-5 lubricant. ESL-5 lubricant is contained in the Biffi module service kit in tubes and the tubes are marked ESL-4, 5 and 10 lubricant.

  • Page 8: Actuator Weight

    Section 1: Introduction Service Instructions VCIOM-15380-EN Rev. 2 March 2022 Actuator Weight Table 2. Actuator Weight Approximate Approximate Actuator Actuator Weight (2) Weight (2) Model Model FCBA730 FCBA930 70.4 FCBA730-M3 59.4 FCBA930-M3 71.7 FCBA730-M3HW 131.5 59.6 FCBA930-M3HW 158.5 71.9 FCBA830 63.5 FCBA1030 77.1...

  • Page 9: Actuator Start-Up

    Service Instructions Section 1: Introduction VCIOM-15380-EN Rev. 2 March 2022 1.10.3 Good instrument practices are also recommended. Clean/dry regulated pneumatic pressure is essential for long service life and satisfactory operation. It should be noted that new pneumatic lines often have scale and other debris in them and these lines should be purged of all foreign material.

  • Page 10: Actuator Operation

    Section 1: Introduction Service Instructions VCIOM-15380-EN Rev. 2 March 2022 1.11.5 Due to the interaction of these variables, it is difficult to specify a “normal” operating time. Faster operating time may be obtained by using one or more of the following: Larger supply lines Larger control valve Higher supply pressure *...

  • Page 11: Section 2: Actuator Disassembly

    Service Instructions Section 2: Actuator Disassembly VCIOM-15380-EN Rev. 2 March 2022 Section 2: Actuator Disassembly General Disassembly WARNING It is possible, that the actuator may contain a dangerous gas and/or liquids. Ensure that all proper measures have been taken to prevent exposure or release of these types of contaminants before commencing any work.

  • Page 12: Pneumatic Cylinder Disassembly

    Section 2: Actuator Disassembly Service Instructions VCIOM-15380-EN Rev. 2 March 2022 Pneumatic Cylinder Disassembly NOTE: Review Section 2, steps 2.1.1 through 2.1.3 before proceeding with cylinder disassembly. 2.2.1 Remove hex nut (4-40) as follows: FCBA730 through FCBA1030 standard end cap stop screw or extended stop (ES), use step 2.2.1.1.

  • Page 13: Housing Disassembly

    Service Instructions Section 2: Actuator Disassembly VCIOM-15380-EN Rev. 2 March 2022 2.2.6 On actuator models FCBA830, FCBA930 and FCBA1030, remove cylinder adapter (4-15) from flange of housing (1-10). Model FCBA730 is not equipped with a cylinder adapter (4-15). 2.2.7 M3 JACKSCREW REMOVAL FROM END CAP (4-20). 2.2.7.1 Remove retainer ring (5-60) from M3 adapter (4-55).
  • Page 14 Section 2: Actuator Disassembly Service Instructions VCIOM-15380-EN Rev. 2 March 2022 NOTE: For FCBA730 through FCBA1030-M3/M3HW models, the M3 jackscrew (4-30) cannot be removed now. The M3 used in these models can be removed later in this procedure using step 2.3.10. 2.3.2 Remove center bar (8-10) from housing adapter (6-10).

  • Page 15: Section 3: Actuator Reassembly

    3.1.4.2 Coat all seals with lubricant, before installing into seal grooves. 3.1.5 Torque shaft upper bearing and the lower bearing are not recommended as parts that require field replacement. Consult Houston, Texas Biffi Service Coordinator for “torque shaft upper or lower bearing” replacement information. 3.1.6 FCBA double-acting actuator construction as follows: 3.1.6.1 STANDARD CONSTRUCTION - Cylinder (4-10) or cylinder adapter...

  • Page 16: Housing Reassembly

    Section 3: Actuator Reassembly Service Instructions VCIOM-15380-EN Rev. 2 March 2022 Housing Reassembly NOTE: Review Section 3, steps 3.1.1 through 3.1.6 before proceeding with actuator reassembly. In Section 3.2, where the step indicates to “lubricate, coat or apply lubricant”, use lubricant as identified in Section 1, step 1.6 for lubricating the part being installed.
  • Page 17 Service Instructions Section 3: Actuator Reassembly VCIOM-15380-EN Rev. 2 March 2022 NOTE: Move the O-ring seal (7-30) down the ES or stop screw until it is next to the housing adapter (6-10). 3.2.2.3 Install washer (6-90) onto ES or stop screw (6-30). NOTE: Push the washer down the ES or stop screw until it is next to the housing adapter (6-10).
  • Page 18 3.2.11 Install thrust washer (2-80) onto the upper area of torque shaft (1-30) on top of thrust bearing (2-70). NOTE: A new retaining ring (2-90) is provided in the Biffi FCBA Service Kit. 3.2.12 Install the new retaining ring (2-90) into the groove located on the upper area of torque shaft (1-30).

  • Page 19: Pneumatic Cylinder Reassembly

    Service Instructions Section 3: Actuator Reassembly VCIOM-15380-EN Rev. 2 March 2022 Pneumatic Cylinder Reassembly NOTE: Review Section 3, steps 3.1.1 through 3.1.6 before proceeding with cylinder reassembly. In Section 3.3, where the step indicates to “lubricate, coat or apply lubricant”, use lubricant as identified in Section 1, step 1.6 for lubricating the part being installed.
  • Page 20 Section 3: Actuator Reassembly Service Instructions VCIOM-15380-EN Rev. 2 March 2022 3.3.9 With the piston head facing away from housing (1-10), install piston assembly (4-50) onto center bar assembly (8-10). 3.3.10 Carefully slide piston assembly (4-50) along center bar assembly (8-10) until the yoke pin engages the slots of yoke (1-20).
  • Page 21 Service Instructions Section 3: Actuator Reassembly VCIOM-15380-EN Rev. 2 March 2022 3.3.14.6 Install retainer ring (5-60) into exposed outer diameter groove in M3 jackscrew adapter (4-55). 3.3.14.7 Install O-ring seal (5-30) onto M3 jackscrew (4-30). NOTE: Move the O-ring seal (5-30) down the M3 jackscrew until it is next to the M3 jackscrew adapter. 3.3.14.8 Install hex nut (4-40) onto M3 jackscrew (4-30).
  • Page 22 Section 3: Actuator Reassembly Service Instructions VCIOM-15380-EN Rev. 2 March 2022 NOTE: Move the O-ring seal (5-30) down the ES or stop screw until it is next to the end cap (4-20). 3.3.19.3 Install washer (4-90) onto ES or stop screw (4-30). NOTE: Push the washer down the ES or stop screw until it is next to the end cap (4-20).

  • Page 23: Section 4: Actuator Testing

    Service Instructions Section 4: Actuator Testing VCIOM-15380-EN Rev. 2 March 2022 Section 4: Actuator Testing Actuator Testing 4.1.1 Leak Test - General - A small amount of leakage may be tolerated. Generally, a small bubble which breaks about three seconds after starting to form is considered acceptable.
  • Page 24 PED by pressuring both sides of the piston to avoid damage and over torquing of the actuator components. If further future testing in the field is necessary, Biffi should be contacted for guidance. 4.1.11 After the actuator is installed back on the valve, all accessories should be hooked up and tested for proper operation and replaced, if found defective.

  • Page 25: Section 5: Field Conversions

    Service Instructions Section 5: Field Conversions VCIOM-15380-EN Rev. 2 March 2022 Section 5: Field Conversions High Temperature Service (-10 TRIM) 5.1.1 Disassemble and reassemble actuator per Sections 1 through Section 4 using new -10 (high temperature) Service Kit. Low Temperature Service (-11 TRIM) 5.2.1 Disassemble and reassemble actuator per Section 1 through Section 4 using new -11 (low temperature) Service Kit.

  • Page 26: Add An Extended Stop (Es) To Cylinder End Cap (4-20)

    Section 5: Field Conversions Service Instructions VCIOM-15380-EN Rev. 2 March 2022 5.3.2.4 Install hex nut (6-40) onto ES (6-30). NOTE: Rotate the hex nut down the ES until it is next to housing adapter (6-10). Add an Extended Stop (ES) to Cylinder End Cap (4-20) NOTE: Prior to disassembly review all of Section 1 Introduction and Section 2 - Actuator...

  • Page 27: Add An M3 Jackscrew To Housing Adapter (6-10)

    Service Instructions Section 5: Field Conversions VCIOM-15380-EN Rev. 2 March 2022 Add an M3 Jackscrew to Housing Adapter (6-10) NOTE: This section can also be used to add an M3 to the cylinder end cap (4-20) at the same time as the M3 is added to the housing adapter (6-10). When a M3 is only being installed into housing adapter (6-10), skip step 3.3.14 during installation.

  • Page 28: Add An M3 Jackscrew To Cylinder Outer End Cap (4-20)

    Section 5: Field Conversions Service Instructions VCIOM-15380-EN Rev. 2 March 2022 Add an M3 Jackscrew to Cylinder Outer End Cap (4-20) 5.6.1 Prior to disassembly, review all of Section 1 - Introduction. 5.6.2 Disassemble the actuator per Section 2.1 - General Disassembly, Section 2.2 - Pneumatic Cylinder Disassembly steps 2.2 .2 through step 2.2.5.

  • Page 29: Section 6: Troubleshooting

    In the unlikely event of a fault developing, the following Fault Location Table is provided to assist the service engineer to perform troubleshooting. Table 3 is designed to cover as wide a range of Biffi FCBA actuators as possible. Reference to equipment not supplied should be ignored.

  • Page 30: Operational Test

    Section 6: Troubleshooting Service Instructions VCIOM-15380-EN Rev. 2 March 2022 Operational Test 6.2.1 Full Stroke Test The “Full Stroke Test” (“On-line”) must be performed to satisfy the PFD (average probability of failure on demand) value. The full stroke test frequencies will be defined by the final installer to achieve the defined SIL level.

  • Page 31: Section 7: Removal And Decommissioning

    If a conflict arises between this procedure and the customer’s procedures, the differences should be resolved in writing between an authorized customer’s representative and an authorized Biffi representative. CAUTION Make sure actuator is isolated before removing from valve. Turn OFF the power medium and bleed off all pressure first, including storage tank (if present).

  • Page 32: Section 8: Document Revision

    Section 8: Document Revision Service Instructions VCIOM-15380-EN Rev. 2 March 2022 Section 8: Document Revision Table 4. Revision Overview Date Description By * July 2020 Released Updated March 2022 Added Warning for Electrostatic Charge * Signatures on file Biffi Italia s.r.l. Document Revision...

  • Page 33: List Of Tables

    Service Instructions List of Tables VCIOM-15380-EN Rev. 2 March 2022 List of Tables Table 1 FCBA Model Numbers ................... 1 Table 2 Actuator Weight ................... 4 Table 3 Fault Location Table ..................25 Table 4 Revision Overview ..................28 List of Tables...

  • Page 34: List Of Figures

    List of Figures Service Instructions VCIOM-15380-EN Rev. 2 March 2022 List of Figures Figure 1 Bushing Installation ..................15 Figure 2 M3 Targets ....................23 List of Figures...

  • Page 35: Appendix A: List Of Drawings

    Service Instructions Appendix VCIOM-15380-EN Rev. 2 March 2022 Appendix A: List of Drawings Part No. 129742, FCBA300 Assembly Drawing Appendix...

  • Page 36: Part No. 129744, Fcba300-M3Hw Assembly Drawing

    Appendix Service Instructions VCIOM-15380-EN Rev. 2 March 2022 Part No. 129744, FCBA300-M3HW Assembly Drawing Appendix...
  • Page 37 Service Instructions Notes VCIOM-15380-EN Rev. 2 March 2022 This page is intentionally left blank...
  • Page 38 VCIOM-15380-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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