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

Pneumatic actuators
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Service Instructions
VCIOM-15405-EN Rev. 3
July 2024
Biffi FCB Series Pneumatic Actuators
Model FCBA Spring-Return Disassembly and Reassembly
Copyright © Biffi. The information in this document is subject to change without notice. Updated service instruction manuals 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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Summary of Contents for BIFFI FCB Series

  • Page 1 Model FCBA Spring-Return Disassembly and Reassembly Copyright © Biffi. The information in this document is subject to change without notice. Updated service instruction manuals 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 Notes Service Instructions VCIOM-15405-EN Rev. 3 July 2024 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 Operating Media ...................... 3 Lubrication Requirements ..................3 General Tool Information ..................4 Actuator Weight .......................
  • Page 4 Table of Contents Service Instructions July 2024 VCIOM-15405-EN Rev. 3 Section 6: Troubleshooting Fault Insertion ......................19 Operational Test .....................20 Section 7: Removal and Decommissioning Removal and Decommissioning ..................21 Section 8: Document Revision Document Revision ......................22 Appendix A: List of Tables List of Tables ........................23 Appendix B: List of Drawings Part Number VA129743, FCBA300-SRX Assembly Drawing .......

  • Page 5: Section 1: Introduction

    • Use a non-hardening thread sealant on all pipe threads. CAUTION Apply the thread sealant per the manufacturer’s instructions. • Biffi recommends that disassembly of the actuator components should be done in a clean area on a workbench. Introduction...

  • Page 6: Definitions

    M3HW: Jackscrew assembly with handwheel ES: Extended stop(s) General Safety Information Products supplied by Biffi, in its “as shipped” condition, are intrinsically safe if the instructions within this Service Instruction are strictly adhered to and executed by well-trained, equipped, prepared and competent personnel.

  • Page 7: Biffi Reference Materials

    NOTE: Lubricants other than those listed below should not be used without prior written approval of Biffi Product Engineering. The lubricant item number on some assembly drawings is item (5) while the service kits lubricant item number is (500). All temperature services -45.5 to 176.6 °C / -50 to +350 °F use ESL-5 lubricant. ESL-5 lubricant is contained in the module service kit in tubes and the tubes are marked ESL-4, 5 and 10 lubricant.

  • Page 8: General Tool Information

    Section 1: Introduction Service Instructions July 2024 VCIOM-15405-EN Rev. 3 General Tool Information All threads on FCBAX30-SR Series actuators are Inch Unified and NPT. All tools/Hexagons are American Standard inch. Two adjustable wrenches, Allen wrench set, small standard screwdriver with sharp edges rounded off, medium size standard screwdriver, diagonal cutting pliers, external snap ring pliers, flat file, drive ratchet/deep well socket set and torque wrench (up to 226 Nm / 2,000 in-lb).

  • Page 9: Actuator Installation

    Service Instructions Section 1: Introduction VCIOM-15405-EN Rev. 3 July 2024 1.11 Actuator Installation Since there are many valve and actuator combinations, it is not practical to include detailed instructions for each type. Mountings are designed to be as simple as possible to keep the guess work out of the installation.

  • Page 10: Actuator Operation

    Section 1: Introduction Service Instructions July 2024 VCIOM-15405-EN Rev. 3 NOTE: When actuator is first placed into service, it should be cycled with regulated pneumatic pressure. This is necessary because the seals have been stationary, causing them to take a “set”.

  • Page 11: Section 2: Actuator Disassembly

    Service Instructions Section 2: Actuator Disassembly VCIOM-15405-EN Rev. 3 July 2024 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: Spring Cylinder Disassembly

    Section 2: Actuator Disassembly Service Instructions July 2024 VCIOM-15405-EN Rev. 3 Spring Cylinder Disassembly NOTE: Review Section 2, steps 2.1.1 through 2.1.5 before proceeding with spring cylinder disassembly. The spring in FCBAX30 Series spring-return actuators are preloaded. Actuator must be disassembled in the following manner: 2.2.1 Loosen and remove hex nut (4-40) from stop screw (4-30) or from ES (4-30).

  • Page 13: Housing Disassembly

    Service Instructions Section 2: Actuator Disassembly VCIOM-15405-EN Rev. 3 July 2024 Housing Disassembly 2.3.1 Remove center bar assembly (8-10) housing adapter (6-10). 2.3.2 Remove housing adapter (6-10) from housing (1-10). 2.3.3 Remove the position indicator (1-50) from torque shaft (1-30). 2.3.4 Remove retaining ring (2-90) from torque shaft (1-30).

  • Page 14: 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 (2-20) and lower bearing (2-50) are not recommended as parts that require field replacement. Contact your local Biffi service center for torque shaft upper or lower bearing replacement information. Housing Reassembly NOTE: Review Section 3, steps 3.1.1 through 3.1.5 before proceeding with housing reassembly.
  • Page 15 Service Instructions Section 3: Actuator Reassembly VCIOM-15405-EN Rev. 3 July 2024 3.2.1 M3 jackscrew installation: 3.2.1.1 Apply a coating of lubricant to outer diameter and inner diameter threads of M3 jackscrew adapter (6-55). 3.2.1.2 Coat O-ring seal (7-65) with lubricant and install into outer diameter seal groove located in the M3 jackscrew adapter (6-55).
  • Page 16 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 17: Spring Cylinder Reassembly

    Service Instructions Section 3: Actuator Reassembly VCIOM-15405-EN Rev. 3 July 2024 WARNING Care should be taken during installation of center bar assembly so as to not scratch it or damage the housing adapter O-ring seal (5-20). NOTE: Rotate the hex nut down the M3 jackscrew until it is next to the M3 adapter. 3.2.18 Recoat center bar assembly (8-10) with lubricant.
  • Page 18 Section 3: Actuator Reassembly Service Instructions July 2024 VCIOM-15405-EN Rev. 3 NOTE: While holding the center bar assembly flush against the housing adapter (6-10), push piston assembly (4-50) into housing (1-10) as far as the piston will go. 3.3.9 Apply a coating of lubricant to entire bore of spring cylinder (4-10). 3.3.10 Spring cylinder (4-10) installation: 3.3.10.1 For FCBA830-SR, FCBA930-SR and FCBA1030-SR models, install the lubricated...
  • Page 19 Service Instructions Section 3: Actuator Reassembly VCIOM-15405-EN Rev. 3 July 2024 3.3.22 Install O-ring seal (5-30) onto ES or stop screw (4-30) until it is flush with the end cap (4-20). 3.3.23 Install hex nut (4-40) and washer (4-90) onto ES or stop screw (4-30) do not tighten.

  • Page 20: Section 4: Actuator Testing

    Section 4: Actuator Testing Service Instructions July 2024 VCIOM-15405-EN Rev. 3 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 21: Return To Service

    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. Return to Service 4.2.1...

  • Page 22: Section 5: Field Conversions

    Section 5: Field Conversions Service Instructions July 2024 VCIOM-15405-EN Rev. 3 Section 5: Field Conversions Fail Mode Reversal (CW to CCW or CCW to CW) 5.1.1 Disassemble actuator, refer to Section 2. 5.1.2 Converting to CCW: Assemble actuator with spring cylinder assembly on the right side of housing and housing adapter assembly on left side using the orientation below, refer to Section 3.

  • Page 23: 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. This table is designed to cover as wide a range of Biffi actuators as possible. Reference to equipment not supplied should be ignored. Table 3.

  • Page 24: Operational Test

    Section 6: Troubleshooting Service Instructions July 2024 VCIOM-15405-EN Rev. 3 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 25: 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 a customer’s authorized 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 26: Section 8: Document Revision

    By * July 2020 Released Updated March 2022 Added Warnng for Electrostatic Charge July 2024 Added Appendix C Massimiliano Franco Notes: * Signatures on file Biffi Italia s.r.l. The data in this table refers to the parent document (VCIOM-13247-EN). Document Revision...

  • Page 27: Appendix A: List Of Tables

    Service Instructions Appendix VCIOM-15405-EN Rev. 3 July 2024 Appendix A: List of Tables Table 1. FCBAX30-SR Model Numbers ................1 Table 2. Actuator Weight ....................4 Table 3. Fault Location Table ..................19 Table 4. Revision Overview ................... 22 Table C-1. Ambient and ATEX Temperatures ..............28 Appendix...

  • Page 28: Appendix B: List Of Drawings

    Appendix Service Instructions July 2024 VCIOM-15405-EN Rev. 3 Appendix B: List of Drawings Part Number VA129743, FCBA300-SRX Assembly Drawing Appendix...

  • Page 29: Part Number 129745, Fcba300-Srx-M3Hw Assembly Drawing

    Service Instructions Appendix VCIOM-15405-EN Rev. 3 July 2024 Part Number 129745, FCBA300-SRX-M3HW Assembly Drawing Appendix...

  • Page 30: Appendix C: Safety Instructions For Use In (Potential) Explosive Atmosphere

    Appendix Service Instructions July 2024 VCIOM-15405-EN Rev. 3 Appendix C: Safety Instructions for Use in (Potential) Explosive Atmosphere Intended Use The actuator series have been designed to comply with the explosion safety requirements in the Ex-standards EN IEC 60079-0:2018, EN ISO 80079-36, EN ISO 80079-37:2016 and EN 1127-1:2019.

  • Page 31: Safety Instructions

    July 2024 Safety Instructions Before the installation, please carefully read the service instructions. Biffi is not responsible for damages caused by operations not complying with the instruction manuals. All the operations shall be done by a trained and qualified operator. All maintenance operations must be performed in accordance with the instructions detailed in the maintenance manual.

  • Page 32: Maximum Temperatures

    EPL and range of temperature. It is forbidden to use this equipment in a different way if it is not included in the instruction manual. Biffi is not responsible for damages caused by an improper and/or dangerous use.
  • Page 33 Service Instructions Notes VCIOM-15405-EN Rev. 3 July 2024 This page is intentionally left blank.
  • Page 34 VCIOM-15405-EN (CP-13247) © 2024 Biffi. All rights reserved. Biffi Italia s.r.l. The contents of this publication are presented for informational 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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