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BIFFI FCBB Series Disassembly And Reassembly

Pneumatic actuators, double acting
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Service Instructions
VCIOM-15368-EN Rev. 3
August 2024
Biffi FCBB Double-Acting Series
Pneumatic Actuators
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 FCBB Series

  • Page 1 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-15368-EN Rev. 3 August 2024 This page is intentionally left blank.

  • Page 3: Table Of Contents

    Section 1: Introduction General Service Information ................. 1 Definitions ......................... 2 General Safety Information ................... 2 Biffi Actuator 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 August 2024 VCIOM-15368-EN Rev. 3 Section 7: Document Revision Document Revision ......................26 Appendix A: List of Tables List of Tables ........................27 Appendix B: List of Drawings Part Number VA001-005-72-4, FCBBXXX Assembly Drawing.......28 Part Number VA001-005-73-3, FCBBXXX-M3HW Assembly Drawing ..29 Appendix C: Safety Instructions for Use in (Potential) Explosive Atmosphere Intended Use ......................30...

  • 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 should be done in a clean area on a workbench. Introduction...

  • Page 6: Definitions

    M3: Manual jackscrew override General Safety Information Products supplied by Biffi, in its “as shipped” condition, are intrinsically safe if the instructions contained within this service instruction are strictly adhered to and executed by well-trained, equipped, prepared and competent personnel.

  • Page 7: Biffi Actuator Reference Materials

    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 item number (500).

  • Page 8: General Tool Information

    VCIOM-15368-EN Rev. 3 August 2024 General Tool Information • All threads on FCBB 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,...

  • Page 9: Actuator Start-Up

    Service Instructions Section 1: Introduction VCIOM-15368-EN Rev. 3 August 2024 NOTE: The actual “stopping” should be done by the actuator. If the valve does not have internal stops, adjust the actuator to the full open position. Using this as a reference point, rotate the valve closed and adjust to the valve manufacturer’s specifications for total rotation.

  • Page 10: Actuator Operation

    Section 1: Introduction Service Instructions VCIOM-15368-EN Rev. 3 August 2024 1.12.3 Speed of operation The actuator speed of operation is determined by a number of factors including: Power supply line length Power supply line size Power supply line pressure Control valve and fitting orifice size Torque requirements of the valve Size of the actuator Setting of speed controls...

  • Page 11: Section 2: Actuator Disassembly

    Service Instructions Section 2: Actuator Disassembly VCIOM-15368-EN Rev. 3 August 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 Section 2: Actuator Disassembly Service Instructions VCIOM-15368-EN Rev. 3 August 2024 2.2.1.2 For FCBB315/420/520/525/725-M3 or M3HW: 2.2.1.2.1 Remove retainer ring (12-30) and groove pin (12-20) from optional hex drive hub or from handwheel (12-10). 2.2.1.2.2 Remove optional hex drive hub or handwheel (12-10) from M3 jackscrew (1-70).

  • Page 13: Housing Disassembly

    Service Instructions Section 2: Actuator Disassembly VCIOM-15368-EN Rev. 3 August 2024 Housing Disassembly NOTE: Review Section 2 steps 2.1.1 through 2.1.2 before proceeding with housing disassembly. 2.3.1 Remove hex nut (1-80) as follows: FCBB315 through 725 standard housing stop screw or extended stop (ES), use step 2.3.1.1. FCBB315-M3/M3HW through FCBB725-M3/M3HW, use step 2.3.1.2.
  • Page 14 Section 2: Actuator Disassembly Service Instructions VCIOM-15368-EN Rev. 3 August 2024 2.3.4 Remove the torque shaft (1-30) by pushing it out one side of housing (1-10). 2.3.5 Remove yoke key (1-40) and yoke key spring (1-50) from torque shaft (1-30). 2.3.6 Remove yoke (1-20) from housing (1-10).

  • Page 15: Section 3: Actuator Reassembly

    Service Instructions Section 3: Actuator Reassembly VCIOM-15368-EN Rev. 3 August 2024 Section 3: Actuator Reassembly General Reassembly CAUTION Only new seals that are still within the seals expectant shelf life should be installed into the actuator being refurbished. 3.1.1 Remove and discard all old seals and gaskets. 3.1.2 All parts should be cleaned to remove all dirt and other foreign material prior to inspection.
  • Page 16 (1-10) and yoke (1-20) on the opposite side of the installed O-ring seal (2-20). NOTE: Two new retaining rings (1-60) are contained in the Biffi FCBB Service Kits. 3.2.7 Install one of the new retaining ring (1-60) and washer (1-65) onto the exposed end of the torque shaft, making certain it is properly seated in the groove of the torque shaft (1-30).
  • Page 17 Service Instructions Section 3: Actuator Reassembly VCIOM-15368-EN Rev. 3 August 2024 CAUTION Rotate the torque shaft until the yoke key snaps into the yoke keyway. 3.2.8 Rotate the torque shaft (1-30) so that the arms of yoke (1-20) point out the open end of housing (1-10).
  • Page 18 Section 3: Actuator Reassembly Service Instructions VCIOM-15368-EN Rev. 3 August 2024 3.2.23 End cap seal installation 3.2.23.1 Coat O-ring seal (5-20) with lubricant and install in the internal seal groove of end cap (4-20). 3.2.23.2 Install O-ring seal (5-15) onto outer diameter of end cap (4-20). 3.2.24 Install end cap (4-20) onto center bar (8-10) and into cylinder (4-10).

  • Page 19: Actuator Reassembly Per Fcbb Models Listed In Step 3.1.5.2

    Service Instructions Section 3: Actuator Reassembly VCIOM-15368-EN Rev. 3 August 2024 NOTE: Leave hex nut hand tight. 3.2.31 If removed, install ES or stop screw (1-70) into housing (1-10). 3.2.32 Install O-ring seal (2-30) and CSK washer (2-35) onto the ES or stop screw (1-70).
  • Page 20 Section 3: Actuator Reassembly Service Instructions VCIOM-15368-EN Rev. 3 August 2024 NOTE: Rotate the hex nut down the M3 jackscrew until it is next to the housing (1-10). 3.3.1.5 Continue reassembly at step 3.3.3. 3.3.2 M3 Jackscrew Housing Installation for FCBB420-M3 through FCBB725-M3 Model Actuators (includes M3HW models).
  • Page 21 CAUTION Rotate the torque shaft until the yoke key snaps into the yoke keyway. NOTE: Two new retaining rings (1-60) and washers (1-65) are contained in the Biffi FCBB Service Kits. 3.3.8 Install one of the new retaining ring (1-60) and washer (1-65) onto the exposed end of the torque shaft, making certain it is properly seated in the groove of the torque shaft (1-30).
  • Page 22 Section 3: Actuator Reassembly Service Instructions VCIOM-15368-EN Rev. 3 August 2024 3.3.16 Install bushing (4-80) between the two arms of yoke (1-20). 3.3.17 With the piston head facing away from housing (1-10) and with yoke pin up, install center bar (8-10) in the open end of housing (1-10) and push the center bar through the center bar “hole”...
  • Page 23 Service Instructions Section 3: Actuator Reassembly VCIOM-15368-EN Rev. 3 August 2024 NOTE: Rotate the M3 jackscrew into the end cap (4-20) until the inboard end of the M3 jackscrew is up against the end cap (4-20). 3.3.25.3 Install seal (5-30) onto M3 jackscrew (1-70). NOTE: Move the O-ring seal (2-30) down the M3 jackscrew until it is next to the end cap (4-20).
  • Page 24 Section 3: Actuator Reassembly Service Instructions VCIOM-15368-EN Rev. 3 August 2024 NOTE: Position the end cap (4-20) so that the inlet port is at the bottom and the M3 jackscrew (4-30) is at the top of the actuator. 3.3.28 Install end cap (4-20) onto center bar (8-10) and cylinder (4-10). WARNING If step 3.3.29 is not completed as described, the center bar O-ring seals (5-20) may become a source of pressure leakage and cause the actuator to fail.

  • Page 25: Section 4: Actuator Testing

    Service Instructions Section 4: Actuator Testing VCIOM-15368-EN Rev. 3 August 2024 Section 4: Actuator Testing Actuator Testing 4.1.1 Leak Test: 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 26 The actuator’s main pressure bearing parts will be tested in controlled conditions 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.

  • Page 27: Section 5: Troubleshooting

    In the unlikely event of a fault developing, the following Symptoms and Solutions Table is provided to assist the service engineer. This table is designed to cover a wide a range of Biffi actuators as possible. Reference to equipment not supplied should be ignored.

  • Page 28: Operational Test

    Section 5: Troubleshooting Service Instructions VCIOM-15368-EN Rev. 3 August 2024 Operational Test 5.2.1 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 29: Section 6: 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 the actuator is isolated before removing from valve. Turn OFF the power medium and bleed off all pressure first, including storage tank (if present).

  • Page 30: Section 7: Document Revision

    MarCom use only Massimiliano Franco Added ATEX Safety Instructions for Use July 2024 Massimiliano Franco in (Potential) Explosive Atmosphere Note: * Signatures on file at Biffi Italia s.r.l. The data in this table refers to the parent document (VCIOM-13250-EN). Document Revision...

  • Page 31: Appendix A: List Of Tables

    Service Instructions Appendix VCIOM-15368-EN Rev. 3 August 2024 Appendix A: List of Tables Table 1. FCBB Model Numbers ...................1 Table 2. Actuator Weight ......................4 Table 3. Tightening Torque Center Bar (1) ..............14 Table 4. Tightening Torque Center Bar (2) ..............20 Table 5.

  • Page 32: Appendix B: List Of Drawings

    Appendix Service Instructions VCIOM-15368-EN Rev. 3 August 2024 Appendix B: List of Drawings Part Number VA001-005-72-4, FCBBXXX Assembly Drawing Appendix...

  • Page 33: Part Number Va001-005-73-3, Fcbbxxx-M3Hw Assembly Drawing

    Service Instructions Appendix VCIOM-15368-EN Rev. 3 August 2024 Part Number VA001-005-73-3, FCBBXXX-M3HW Assembly Drawing Appendix...

  • Page 34: Appendix C: Safety Instructions For Use In (Potential) Explosive Atmosphere

    Appendix Service Instructions VCIOM-15368-EN Rev. 3 August 2024 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 35: Safety Instructions

    VCIOM-15368-EN Rev. 3 August 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 instructions contained in such 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 36: Maximum Temperatures

    EPL and range of temperature. 17. 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 37 Service Instructions Notes VCIOM-15368-EN Rev. 3 August 2024 This page is intentionally left blank.
  • Page 38 VCIOM-15368-EN (CP-13250) © 2020, 2024 Biffi. All rights reserved. Biffi Italia s.r.l. Strada Biffi 165 The contents of this publication are presented for informational 29017 Fiorenzuola d’Arda (PC) purposes only, and while every effort has been made to ensure their...

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