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BIFFI ALGAS Installation, Operation And Maintenance Manual

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Installation, Operation and Maintenance Manual
FCIM-20197-EN Rev. 0
January 2025
Biffi ALGAS
Version: Base, QA and with Manual Operator Actuators
Copyright © Biffi. The information in this document is subject to change without notice. Updated installation, operation and maintenance manual 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' A rda (PC) – Italy PH: +39 0523 944 411 – biffi_italia@biffi.it

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  • Page 1 Copyright © Biffi. The information in this document is subject to change without notice. Updated installation, operation and maintenance manual 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’ A rda (PC) – Italy PH: +39 0523 944 411 – biffi_italia@biffi.it...
  • Page 2 ALGAS MAN 604C REV. 3 ALGAS MAN 604A_EAC REV. 5 Ermanni Orefici Vigliano ALGAS MHP MAN 689 REV. 7 Starting ALGAS MHW-MRHW MAN MAN 604-1A REV. 7 Last revision Various Data point ALGAS MHW-MRHW MAN MAN 604-1C REV. 1 Ermanni Orefici Vigliano manuals ALGAS MHW-MRHW MAN MAN 604-1A_EAC REV.

  • Page 3: Table Of Contents

    Installation, Operation and Maintenance Manual Table of Contents FCIM-20197-EN Rev. 0 January 2025 Table of Contents Section 1: General Warnings Generalities ......................1 1.1.1 Applicable Regulation ................1 1.1.2 Terms and Conditions ................2 1.1.3 Electrostatic Charge ...................2 1.1.4 Noise Emission ....................2 Identification Plate (Nameplate) ................3 Description of the Actuator ..................4 Section 2: Installation Checks to Be Carried Out Upon Receiving the Actuator .......6...
  • Page 4 5.2.2 ALGAS MHP ....................58 5.2.3 ALGAS MHW Actuator ................71 5.2.4 ALGAS-QA (with Stop Setting Screw Cover) Actuator ...... 79 5.2.5 ALGAS-QA (without Stop Setting Screw Cover) Actuator ....82 5.2.6 ALGAS with Stop Setting Screw Cover ..........85 Lubrication of Mechanism .................

  • Page 5: Section 1: General Warnings

    Nevertheless, Biffi Italia s.r.l. does not provide any guarantees for this manual. Biffi Italia s.r.l. will not be responsible for any mistakes contained in it or for any damage either accidental or due to the use of this manual. The information herein contained is reserved property of Biffi Italia s.r.l.

  • Page 6: Terms And Conditions

    1.1.4 Noise Emission The verification of the noise of the actuated valve is at valve maker care. Biffi points out that the actuator’s noise can be considered negligible since it is an equipment for regular on/off or intermittent use. If the integral quick exhaust valve is present, we recommend using ear Personal Protective Equipment (PPE) to avoid any possible acoustic discomfort.

  • Page 7: Identification Plate (Nameplate)

    Identification Plate (Nameplate) WARNING It is forbidden to modify the information and the marks without previous written authorization by Biffi Italia s.r.l. The plate fastened on the actuator contains the following information (Figures 2 and 3). Figure 2. Nameplate Base (Sample) Figure 3.

  • Page 8: Description Of The Actuator

    The actuator yoke has a hole with keyways suitable for the assembly of an insert bush or a stem extension. Their internal hole is machined (by Biffi or at customer care), according to the shape and dimensions of the valve stem.
  • Page 9 Installation, Operation and Maintenance Manual Section 1: General Warnings FCIM-20197-EN Rev. 0 January 2025 Table 1. Selection Guide Code ALGAS  XXX YYYYY ZZZZ Actuator series Scotch yoke mechanism size Yoke shape Canted Symmetric Spring cartridge size Cylinder size Internal diameter in mm...

  • Page 10: Section 2: Installation

    Section 2: Installation Installation, Operation and Maintenance Manual January 2025 FCIM-20197-EN Rev. 0 Section 2: Installation Checks to Be Carried Out Upon Receiving the Actuator If the actuator arrives already assembled onto the valve, the settings of the mechanical stops and of the microswitches (if existing) have already been made by the person who assembled the actuator onto the valve.

  • Page 11: Assembling The Actuator Onto The Valve

    For the biggest actuator models, the actuator flange can be machined in accordance with the valve flange dimensions. The yoke is bored with keyways for coupling to the valve stem, the dimensions of which are according to Biffi base tables SCN2600 and SCN2601 (Tables 2 to 8). Installation...
  • Page 12 Section 2: Installation Installation, Operation and Maintenance Manual January 2025 FCIM-20197-EN Rev. 0 Figure 4. Coupling Dimensions - Actuator Model 0.1 (SCN6200-1 - Rev. 15/10/19) DRIVE SLEEVE Ød ØM Ød ±0.2 Ød N. THREADED HOLES PCD, HOLES, NUMBER AND SIZE ACCORDING TO ISO 5211 FLOW LINE 45°...
  • Page 13 Installation, Operation and Maintenance Manual Section 2: Installation FCIM-20197-EN Rev. 0 January 2025 Figure 5. Coupling Dimensions - Actuator Models 0.3 to 6 (SCN6200E - Rev. 15/10/19) DRIVE SLEEVE Ød +0.1 Ød Ød ±0.2 Ød N. THREADED HOLES PCD, HOLES, NUMBER AND SIZE ACCORDING TO ISO 5211 (BUT THE HOLES ARE ON CENTERLINE INSTEAD OF...
  • Page 14 Section 2: Installation Installation, Operation and Maintenance Manual January 2025 FCIM-20197-EN Rev. 0 Figure 6. Coupling Dimensions - Actuator Model 14 (SCN6201E - Rev. 16/06/20) DRIVE SLEEVE Ød +0.1 Ød Ød ±0.2 Ød N. THREADED HOLES PCD, HOLES, NUMBER AND SIZE ACCORDING TO ISO 5211 FLOW LINE Ø...
  • Page 15 Installation, Operation and Maintenance Manual Section 2: Installation FCIM-20197-EN Rev. 0 January 2025 Figure 7. Coupling Dimensions - Actuator Models 18 and 32 (SCN6201E - Rev. 16/06/20) DRIVE SLEEVE Ød +0.1 Ød Ød ±0.2 Ød N. THREADED HOLES P.C.D. AND HOLES SIZE ACCORDING TO ISO (NUMBER AND THREAD DEPTH IS W D10 NOT ACCORDING TO ISO 5211)
  • Page 16 Section 2: Installation Installation, Operation and Maintenance Manual January 2025 FCIM-20197-EN Rev. 0 Figure 8. Coupling Dimensions - Actuator Model 50 (SCN62011 - Rev. 15/10/19) DRIVE SLEEVE Ød +0.1 Ød Ød ±0.2 Ød N. THREADED HOLES FLOW LINE Ød +0.2 +0.1 TOP VIEW OF THE SCOTCH YOKE MECHANISM (ACTUATOR SHOWN IN CLOSED POSITION)
  • Page 17 Installation, Operation and Maintenance Manual Section 2: Installation FCIM-20197-EN Rev. 0 January 2025 Figure 9. Coupling Dimensions - Actuator Models 65 and 80 (SCN62013 - Rev. 19/06/20) DRIVE SLEEVE Ød +0.1 Ød Ød ±0.2 Ød N. THREADED HOLES P.C.D. AND HOLES SIZE ACCORDING TO ISO 5211 (NUMBER AND THREAD DEPTH IS NOT ACCORDING TO ISO 5211) FLOW LINE...
  • Page 18 Section 2: Installation Installation, Operation and Maintenance Manual January 2025 FCIM-20197-EN Rev. 0 Figure 10. Coupling Dimensions - Actuator Model 100 (SCN62015 - Rev. 22/07/22) DRIVE SLEEVE Ød +0.1 Ød Ød ±0.2 Ød N. THREADED HOLES P.C.D. NUMBER AND HOLES SIZE ACCORDING TO ISO (BUT THE HOLES ARE ON CNTERLINE AND THREAD DEPTH IS NOT ACCORDING TO ISO 5211)
  • Page 19 2.3.1.2 Coupling with Insert Bush If required, for the base models size 0.3 to 6, Biffi can supply an insert bush with unmachined bore in accordance with Biffi base 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 table TN1005 (ask factory or refer to TDS), and refer to Figure 11.

  • Page 20: Valve Stem With Vertical Axis

    Section 2: Installation Installation, Operation and Maintenance Manual January 2025 FCIM-20197-EN Rev. 0 2.3.2 Valve Stem with Vertical Axis NOTICE The lifting and handling of the actuator must be done by qualified personnel and in accordance with the laws and regulations in force. Avoid hanging the lifted actuator above any personnel.
  • Page 21 FCIM-20197-EN Rev. 0 January 2025 Lift  ALGAS actuators (pneumatic spring-return) by means of the proper lifting points represented and indicated on actuator by sticking labels. Refer to the figures in this section to understand the lifting points position of the actuator model.
  • Page 22 Section 2: Installation Installation, Operation and Maintenance Manual January 2025 FCIM-20197-EN Rev. 0 The actuator can be assembled onto the valve flange either by using the actuator-housing flange with threaded holes or by the interposition of an adaptor flange or a spool-piece. The actuator drive sleeve is generally connected to the valve stem by an insert bush or a stem extension.
  • Page 23 ACTUATOR ONLY. DO NOT LIFT VALVE AND ACTUATOR TOGETHER. DO NOT DISASSEMBLE TOP OR BOTTOM COVER. SPRING LOADED. POTENTIAL ELECTROSTATIC CHARGE HAZARD Biffi IS NOT LIABLE FOR ANY PERSONNEL INJURY DUE TO INCORRECT USE. REFER TO IOM Table 10. Bolts Recommended Torque...
  • Page 24 January 2025 FCIM-20197-EN Rev. 0 Refer to the figures below to understand the lifting points position of the actuator model. Lifting points for ALGAS and ALGAS-QA with or without stop setting screw. Figure 15. Lifting Eyelet Locations LIFTING EYELET LIFTING EYELET...
  • Page 25 Installation, Operation and Maintenance Manual Section 2: Installation FCIM-20197-EN Rev. 0 January 2025 Lifting points for ALGAS MHP. Figure 17. Lifting Eyelet Locations LIFTING LIFTING EYELET POINT LIFTING EYELET LIFTING POINT LIFTING POINT APPLICABLE FOR   LIFTING POINT APPLICABLE MODELS: 3-6-14-18-32-50-80 FOR MODELS: 0.3-0.9-1.5...

  • Page 26: Valve Stem With Horizontal Axis

    Figure 19 to understand the lifting point position of the actuator model that the user own: If the user have ALGAS MHW or MRHW, remove the manual override (unscrewing the 4 fixing screws with its washers) to make the lifting operations easier.
  • Page 27 Installation, Operation and Maintenance Manual Section 2: Installation FCIM-20197-EN Rev. 0 January 2025 Figure 20. For All Types of Actuator SUPPORT BRACKETS (2) LIFTING EYELETS (1) LIFTING EYELETS (1) SUPPORT BRACKETS (3) Installation...
  • Page 28 Section 2: Installation Installation, Operation and Maintenance Manual January 2025 FCIM-20197-EN Rev. 0 Figure 21. For All Types of Actuator Installation...

  • Page 29: Section 3: Operation And Use

    Section 3: Operation and Use NOTICE Do not change the setting in case of disassembly of the actuator of the valve. Section 3.1 to 3.4.1 refers only to ALGAS-QA with or without stop setting screw cover. Operation Description The actuator is operated by: Pressurized motor fluid.
  • Page 30 Section 3: Operation and Use Installation, Operation and Maintenance Manual January 2025 FCIM-20197-EN Rev. 0 Figure 22. Angular Stroke/Quick Operation Time Diagram QUICK OPERATION QUICK TIME OPERATION SIGNAL DAMPER ACTION TIME (ms) Figure 23. Generic Operating Diagram PNEUMATIC SUPPLY CONNECTION LEGENDS: E.M.

  • Page 31: Residual Risks

    (Figure 24). The calibration of the operation time is made by Biffi according to customer requirements and to technical data sheet included in technical documentation.
  • Page 32 Section 3: Operation and Use Installation, Operation and Maintenance Manual January 2025 FCIM-20197-EN Rev. 0 Figure 25. Integral Quick-Acting Detail MAXIMUM UNSCREWING FOR SETTING-SCREW DUMP VALVE MODELS: FLOW DIAMETER 40 mm - SCREW M12X50, X= 38 mm FLOW DIAMETER 70 mm - SCREW M16X70, X= 59 mm FLOW DIAMETER 100 mm - SCREW M16X80, X= 59 mm Figure 26.

  • Page 33: Bypass Adjustment

    Installation, Operation and Maintenance Manual Section 3: Operation and Use FCIM-20197-EN Rev. 0 January 2025 3.4.1 Bypass Adjustment Figure 27. Bypass Action to Angular Stroke/Quick Operation Time Diagram TWO BYPASS VALVES OPEN ONE BYPASS VALVE OPEN TWO BYPASS VALVES CLOSED TIME (ms) Remove the protection cap from adjusting needle-valve and turn it clockwise to increase throttling-action and consequently to slow the last part of cylinder stroke.

  • Page 34: Setting Of The Angular Stroke

    3.5.1 Travel Stop Screw Screwed at the End Flange of Pneumatic Cylinder 3.5.1.1 ALGAS and ALGAS-QA For the adjustment of the travel stop screws, proceed as follows: See Figure 28. Loosen the lock nut (2) with a proper wrench (C2).
  • Page 35 Installation, Operation and Maintenance Manual Section 3: Operation and Use FCIM-20197-EN Rev. 0 January 2025 Figure 28. Travel Stop Detail Table 11. Travel Stop Adjustment Tools Size Pneumatic Cylinder Size Wrench C1 (mm) Wrench C2 (mm) Table 12. Travel Stop Adjustment Tools Size Pneumatic Cylinder Size Wrench C1 (mm) Wrench C2 (mm)
  • Page 36 3.5.1.1.1 Angular Stroke Setting in Case of Two Travel Stop Screws in the End Flange of Pneumatic Cylinder for ALGAS-QA To set the two travel stop screws in the flange of the pneumatic cylinder, proceed as follows (see Figure 29 and refer to Table 13): Supply pressure to the cylinder to reduce trust on the stop screws.
  • Page 37 Installation, Operation and Maintenance Manual Section 3: Operation and Use FCIM-20197-EN Rev. 0 January 2025 Table 13. Travel Stop Adjustment Tools Size Pneumatic Cylinder Size Wrench C1 (mm) Wrench C2 (mm) 0100 0150 0200 0350 0400 0700 1100 1200 2000 2500 3800 5100...
  • Page 38 Installation, Operation and Maintenance Manual January 2025 FCIM-20197-EN Rev. 0 3.5.1.2 ALGAS with MHP For the adjustment of the travel stop screws, proceed as follows: Remove the protection plug (T) with proper wrench (C1). Loosen the stopper-protection with a proper wrench (C3).

  • Page 39: Screw Cover

    FCIM-20197-EN Rev. 0 January 2025 3.5.1.3 ALGAS, ALGAS with MHW Or MRHW with Stop Setting Screw Cover For the adjustment of the travel stop screws proceed as follows (see Figure 32): Unscrew the protection plugs (1) with Allen wrench (C3).
  • Page 40 January 2025 FCIM-20197-EN Rev. 0 3.5.1.4 ALGAS MHW or MRHW without Stop Setting Screw Cover For the adjustment of the travel stop screws proceed as follows (see figures below): Loosen the locknut (2). If the actuator angular stroke is stopped before reaching the end...
  • Page 41 Wrench C1 (mm) Wrench C2 (mm) 3.5.1.5 ALGAS-QA To set the two travel stop screws in the flange of the pneumatic cylinder, proceed as follows, see Figure 35: Supply pressure to the cylinder to reduce trust on the stop screws.
  • Page 42 Section 3: Operation and Use Installation, Operation and Maintenance Manual January 2025 FCIM-20197-EN Rev. 0 Figure 35. Travel Stop Adjustment Warning (BOTH STOP SCREWS MUST REST AGAINST THE PISTON) Figure 36. Travel Stop Adjustment Warning Operation and Use...

  • Page 43: Stop Screw Screwed On The End Flange Of Spring Container

    Stop Screw Screwed on the End Flange of Spring Container 3.5.2.1 ALGAS, ALGAS with MHW, MRHW or MHP, ALGAS-QA, without Stop Setting Screw Cover For the adjustment of the travel stop screw for models 006 to 150, proceed as follows: Figure 37.
  • Page 44 Section 3: Operation and Use Installation, Operation and Maintenance Manual January 2025 FCIM-20197-EN Rev. 0 For the adjustment of the travel stop screw for models 200 to 19600, proceed as follows: Figure 38. Travel Stop Detail Loosen the lock nut (D). If the actuator angular stroke is stopped before reaching the end position, unscrew the stop screw (V) by turning it counterclockwise until the valve reaches the correct position.
  • Page 45 Installation, Operation and Maintenance Manual Section 3: Operation and Use FCIM-20197-EN Rev. 0 January 2025 Table 18. Travel Stop Adjustment Tools Size Spring Container Size Wrench C1 (mm) Wrench C2 (mm) 0200 0250 0300 0350 0400 0420 0700 0800 0850 0950 1100 1200...
  • Page 46 Installation, Operation and Maintenance Manual January 2025 FCIM-20197-EN Rev. 0 3.5.2.2 ALGAS MHW or MRHW and ALGAS-QA with Stop Setting Screw Cover Figure 39. Travel Stop Detail For the adjustment of the travel stop screw, proceed as follows (see Figure 39): Unscrew the protection plugs (1) with an Allen wrench (C1).

  • Page 47: Calibration Of Microswitches (Sample)

    Installation, Operation and Maintenance Manual Section 3: Operation and Use FCIM-20197-EN Rev. 0 January 2025 Calibration of Microswitches (Sample) Refer to the dedicated Safety Instructions Manual for limit switch box different from the sample proposed. WARNING Refer only to technical documentation related to installed switch box model. If different microswitches assembly or limit switch box is supplied, please refer to the specific documentation.
  • Page 48 Section 3: Operation and Use Installation, Operation and Maintenance Manual January 2025 FCIM-20197-EN Rev. 0 Figure 40. Microswitches Box Figure 41. Cam Adjustment Box Operation and Use...
  • Page 49 Installation, Operation and Maintenance Manual Section 3: Operation and Use FCIM-20197-EN Rev. 0 January 2025 If the index (Figure 42), 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 50: Calibration Of Operating Time

    FCIM-20197-EN Rev. 0 Calibration of Operating Time The calibration of the operation time is made by Biffi according to customer requirements and to technical data sheet included in technical documentation. If necessary, it is possible to modify or to reset the operating time through the flow regulation valve placed between the control system and the pneumatic cylinder (Figure 43).

  • Page 51: Preparation For Start-Up

    NOTICE If necessary to mount components not in Biffi scope of supply, please check the accessories mounting hole details in the documents TN1028 (for metric dimension) or TN1028U (for imperial dimension).

  • Page 52: Start-Up

    Section 3: Operation and Use Installation, Operation and Maintenance Manual January 2025 FCIM-20197-EN Rev. 0 3.8.2 Electrical Connections Connect the electrical feed, control and signal lines to the actuator by linking them up with the terminal blocks of the electrical components. In order to do this, the housing covers must be removed without damaging the coupling surfaces, the O-rings or the gaskets.

  • Page 53: Local Control

    FCIM-20197-EN Rev. 0 January 2025 FOR MHP ACTUATOR: NOTICE If necessary to mount components not in Biffi scope of supply, please check the accessories mounting hole details in the documents TN1028 (for metric dimension) or TN1028U (for imperial dimension). Figure 44.

  • Page 54: Section 4: Operational Tests And Inspections

    Section 4: Operational Tests and Inspections Installation, Operation and Maintenance Manual January 2025 FCIM-20197-EN Rev. 0 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.

  • Page 55: Section 5: Maintenance

    Installation, commissioning and maintenance, and repair works should be carried out by qualified staff. Routine Maintenance ALGAS  actuators have been designed to work for long periods in the most severe conditions. NOTICE The periodicity and regularity of the inspection plan are particularly influenced by, but not limited to, specific environmental working conditions and the number of cycles performed.

  • Page 56: Extraordinary Maintenance

    Section 5: Maintenance Installation, Operation and Maintenance Manual January 2025 FCIM-20197-EN Rev. 0 Extraordinary Maintenance If there are leaks in the hydraulic or pneumatic cylinders, a malfunction in the mechanical components, or scheduled preventive maintenance, the actuator must be disassembled, and the seals must be replaced by referring to the general sectional drawing and following the prescribed procedures.
  • Page 57 Installation, Operation and Maintenance Manual Section 5: Maintenance FCIM-20197-EN Rev. 0 January 2025 Figure 46. Only for ALGAS Table 19. Travel Stops Free Space for Setting Dimension "X" (Spring Side) Dimension "Y" (Cylinder Side) Model size (mm) (mm) 32 to 42...

  • Page 58: Algas Actuator

    Section 5: Maintenance Installation, Operation and Maintenance Manual January 2025 FCIM-20197-EN Rev. 0 5.2.1 ALGAS Actuator 5.2.1.1 Replacement of Cylinder Seals Refer to Figure 47. Measure the protrusion of the stop screw (26) with reference to the end flange (22) surface, to be able to easily restore the setting of the actuator mechanical stops, once the maintenance procedures have been completed.
  • Page 59 Installation, Operation and Maintenance Manual Section 5: Maintenance FCIM-20197-EN Rev. 0 January 2025 5.2.1.1.2 Cylinder Reassembling Carefully clean the inside of the tube (19) and check that the entire surface, particularly that of the bevels, is not damaged. Lubricate the inside surface of the tube and the bevels at the ends.
  • Page 60 Section 5: Maintenance Installation, Operation and Maintenance Manual January 2025 FCIM-20197-EN Rev. 0 Figure 47. ALGAS General Drawing 15 16 Table 20. Item Description Item Description Stop setting screw Spring container Spring Shoulder washer Rod bushing Screw Housing Guide bar...
  • Page 61 Installation, Operation and Maintenance Manual Section 5: Maintenance FCIM-20197-EN Rev. 0 January 2025 Table 21. Item Description (Continued) Item Description Cylinder tube Piston rod Piston End flange Lifting eyelet Spring washer Stop setting screw Guide rod Spring thrust flange Rod bushing Container rod Adaptor bush Washer...

  • Page 62: Algas Mhp

    Section 5: Maintenance Installation, Operation and Maintenance Manual January 2025 FCIM-20197-EN Rev. 0 5.2.2 ALGAS MHP 5.2.2.1 Replacement of Cylinder Seals Refer to Figure 48. Measure the protrusion of the stop screw (26) with reference to the end flange (22) surface, to be able to easily restore the setting of the actuator mechanical stops, once the maintenance procedures have been completed.
  • Page 63 Installation, Operation and Maintenance Manual Section 5: Maintenance FCIM-20197-EN Rev. 0 January 2025 5.2.2.1.2 Reassembly 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 and tighten the screws (15) to the recommended torque.
  • Page 64 Section 5: Maintenance Installation, Operation and Maintenance Manual January 2025 FCIM-20197-EN Rev. 0 Figure 48. ALGAS with MHP General Drawing Table 22. Item Description Item Description Cover Screw Guide block pin Vent valve Sliding block Screw Screw Housing Guide bar...
  • Page 65 Installation, Operation and Maintenance Manual Section 5: Maintenance FCIM-20197-EN Rev. 0 January 2025 Table 23. Item Description (Continued) Item Description Cylinder tube Piston rod Piston End flange Lifting eyelet Spring washer Gasket Screw Stopper bush Container rod Adaptor bush Washer O-ring Yoke bushing Retainer ring...
  • Page 66 Section 5: Maintenance Installation, Operation and Maintenance Manual January 2025 FCIM-20197-EN Rev. 0 5.2.2.2.1 Seals Replacement Prior to reassembly, check that the actuator components are in good condition and clean. Lubricate all the surfaces of the parts, that move in contact with other components, with recommended grease (Molykote 2003 or Lubcon Turmoplex LTA 2 if seals are NBR/Viton or neoprene rubber, with Mobilgrease 33 if the seals are in fluorosilicone rubber).

  • Page 67: Cylinder Reassembly

    Installation, Operation and Maintenance Manual Section 5: Maintenance FCIM-20197-EN Rev. 0 January 2025 5.2.2.2.2 Cylinder Reassembly Assemble the new gasket (25, Figure 48) after cleaning the surfaces of pneumatic cylinder end flange (22, Figure 48) and head flange (2) which are in contact.
  • Page 68 Section 5: Maintenance Installation, Operation and Maintenance Manual January 2025 FCIM-20197-EN Rev. 0 Figure 49. Cylinder Table 24. Item Description Item Quantity Description Material Piston rod bushing Steel + Bronze + PTFE Head flange Carbon steel O-ring * NBR Piston rod seal ring * PTFE + Graphite O-ring * NBR...

  • Page 69: Manual Operation

    Installation, Operation and Maintenance Manual Section 5: Maintenance FCIM-20197-EN Rev. 0 January 2025 5.2.2.3 MHP Hydraulic Manual Override Maintenance and Troubleshooting 5.2.2.4 Operation Refer to Figure 50. The “MHP” hydraulic manual override is utilized, in connection with the actuator hydraulic cylinder, for the manual operation of the actuators. 5.2.2.5 Manual Operation The hand-operated directional control valve (D) must be in its "MANUAL"...
  • Page 70 Equivalent oils: Use an equivalent or better product in compliance with the oil proposed in the actual scope of supply by Biffi. Your oil supplier can verify and propose an alternative product at your responsibility. Low Temperature Conditions (Until -46 °C):...
  • Page 71 Installation, Operation and Maintenance Manual Section 5: Maintenance FCIM-20197-EN Rev. 0 January 2025 5.2.2.8 Maintenance for MHP NOTICE Before carrying out any maintenance operation, it is necessary to close the pneumatic feed line and exhaust the pressure from the actuator cylinder and from the control unit, to provide the proper safety conditions for the staff.
  • Page 72 Section 5: Maintenance Installation, Operation and Maintenance Manual January 2025 FCIM-20197-EN Rev. 0 Figure 50. (MAN686-A) ALGAS with MHP General Arrangement LEGENDS: 1 - SCOTCH YOKE MECHANISM 2 - SPRING CARTRIDGE 3 - HYDRAULIC CYLINDER R - RELIEF VALVE P - HAND PUMP...
  • Page 73 Installation, Operation and Maintenance Manual Section 5: Maintenance FCIM-20197-EN Rev. 0 January 2025 Figure 51. Hydraulic Manual Hand Pump OIL TANK RELIEF VALVE RELIEF VALVE FOR AUTOMATIC OPERATION FLOW REGULATOR RELIEF VALVE FOR MANUAL OPERATION Table 26. Item Description Item Quantity Description Material...
  • Page 74 Section 5: Maintenance Installation, Operation and Maintenance Manual January 2025 FCIM-20197-EN Rev. 0 Table 27. Item Description (Continued) Item Quantity Description Material Flange Aluminum Check valve body Carbon steel Plug Carbon steel Flow control valve setting screw Stainless steel Spring pin Stainless steel Carbon steel Flange...

  • Page 75: Algas Mhw Actuator

    Section 5: Maintenance FCIM-20197-EN Rev. 0 January 2025 5.2.3 ALGAS MHW Actuator 5.2.3.1 Replacement of Cylinder Seals Measure the protrusion of the stop screw (52) with reference to the protection tube (51) surface, to easily restore the setting of the actuator mechanical stop, once the maintenance procedures have been completed.

  • Page 76: Item Description

    Section 5: Maintenance Installation, Operation and Maintenance Manual January 2025 FCIM-20197-EN Rev. 0 Figure 52. ALGAS-MHW Spring-Return Pneumatic Actuator NOTE: IF STOP SETTING SCREW IS REQUIRED, REFER TO ITEMS 62 AND 63. 15 16 57 58 56 Table 28. Item Description...
  • Page 77 Installation, Operation and Maintenance Manual Section 5: Maintenance FCIM-20197-EN Rev. 0 January 2025 5.2.3.2 Replacement of the Seals of Manual Override “MHW” NOTICE Before any operation, you must keep the actuator in release position to allow the air and spring stroke. Measure the protrusion of the stop screw (52) with reference to the surface of the protection tube (51) end flange, to easily restore the setting of the actuator mechanical stop, once the maintenance procedures have...
  • Page 78 Section 5: Maintenance Installation, Operation and Maintenance Manual January 2025 FCIM-20197-EN Rev. 0 5.2.3.3 Replacement of the Seals of Reduced-Manual Override “MRHW” NOTICE Before any operation, you must keep the actuator in release position to allow the air and spring stroke. Measure the protrusion of the stop screw (19) with reference to the surface of the protection tube (6) end flange, to easily restore the setting of the actuator mechanical stop, once the maintenance procedures have been completed.
  • Page 79 Installation, Operation and Maintenance Manual Section 5: Maintenance FCIM-20197-EN Rev. 0 January 2025 Figure 53. Mechanical Manual Override “MRHW” Worm Gear Reduction Unit 10 11 12 13 14 15 16 17 18 19 20 36 21 25 26 34 35 Table 29.
  • Page 80 Section 5: Maintenance Installation, Operation and Maintenance Manual January 2025 FCIM-20197-EN Rev. 0 Table 30. Item Description (Continued) Item Quantity Description Material Equivalence to USA Standards O-ring * NBR Drive sleeve Carbon steel API 5LX Grade X52 Jackscrew Alloy steel + Bronze AISI SAE 9840 + ASTM B427 Alloy 908 Stop setting screw Carbon steel...
  • Page 81 Installation, Operation and Maintenance Manual Section 5: Maintenance FCIM-20197-EN Rev. 0 January 2025 Figure 54. Mechanical Manual Override “MRHW” Bevel Gear Reduction Unit 1 2 3 4 5 6 18 13 9 31 11 17 14 19 15 16 35 34 20 28 29 21 Table 31.
  • Page 82 Section 5: Maintenance Installation, Operation and Maintenance Manual January 2025 FCIM-20197-EN Rev. 0 Table 32. Item Description (Continued) Item Quantity Description Material Equivalence to USA Standards O-ring * NBR Drive sleeve * Carbon steel API 5LX Grade X52 Jackscrew Alloy steel + Bronze AISI SAE 9840 + ASTM B427 Alloy 908 Stop setting screw Carbon steel...

  • Page 83: Algas-Qa (With Stop Setting Screw Cover) Actuator

    Section 5: Maintenance FCIM-20197-EN Rev. 0 January 2025 5.2.4 ALGAS-QA (with Stop Setting Screw Cover) Actuator 5.2.4.1 Replacement of Cylinder Seals Refer to Figure 55 for sectional drawing. Measure the protrusion of the stop screw (26) with reference to the end flange (22) surface, to easily restore the setting of the actuator mechanical stop, once the maintenance procedures have been completed.

  • Page 84: Cylinder Reassembly

    Figure 55. ALGAS-QA “Quick-Acting” Spring-Return Pneumatic Actuator 15 16 70 72 66 62 65...
  • Page 85 Installation, Operation and Maintenance Manual Section 5: Maintenance FCIM-20197-EN Rev. 0 January 2025 Table 33. Item Description Item Description Item Description Stop setting screw Plug Spring container Stop setting screw cover Spring O-ring Gasket Shoulder washer Piston rod bushing Rod bushing O-ring Screw O-ring...

  • Page 86: Algas-Qa (Without Stop Setting Screw Cover) Actuator

    Installation, Operation and Maintenance Manual January 2025 FCIM-20197-EN Rev. 0 5.2.5 ALGAS-QA (without Stop Setting Screw Cover) Actuator 5.2.5.1 Replacement of Cylinder Seals Refer to Figure 56 for sectional drawing. Measure the protrusion of the stop screw (26), with reference to the end flange (22) surface, to easily restore the setting of the actuator mechanical stop, once the maintenance procedures have been completed.
  • Page 87 Figure 56. ALGAS-QA “Quick-Acting” Spring-Return Pneumatic Actuator 15 16 71 70 72 66 62 65...
  • Page 88 Section 5: Maintenance Installation, Operation and Maintenance Manual January 2025 FCIM-20197-EN Rev. 0 Table 34. Item Description Item Description Item Description Stop setting screw Retainer ring Spring container Spring Washer Sealing washer Shoulder washer Gasket Rod bushing piston rod bushing Screw O-ring Housing...

  • Page 89: Algas With Stop Setting Screw Cover

    Installation, Operation and Maintenance Manual Section 5: Maintenance FCIM-20197-EN Rev. 0 January 2025 5.2.6 ALGAS with Stop Setting Screw Cover 5.2.6.1 Replacement of Cylinder Seals Refer to Figure 57. Measure the protrusion of the stop screw (26) with reference to the...
  • Page 90 Figure 57. ALGAS Spring-Return Pneumatic Actuator 15 16 41 42 Maintenance...
  • Page 91 Installation, Operation and Maintenance Manual Section 5: Maintenance FCIM-20197-EN Rev. 0 January 2025 Table 35. Item Description Item Description Item Description Stop setting screw Guide rod Spring container Spring thrust flange Spring Rod bushing Container rod Shoulder washer Adaptor bush Rod bushing Washer Screw...

  • Page 92: Lubrication Of Mechanism

    If the service is not special (i.e., oxygen, hydrogen or other mentioned during the offer stage). Use an equivalent or better product in compliance with the grease proposed in the actual scope of supply by Biffi. Your grease supplier can verify and propose an alternative product at your responsibility. Maintenance...

  • Page 93: Dismantling And Tear Down

    Installation, Operation and Maintenance Manual Section 5: Maintenance FCIM-20197-EN Rev. 0 January 2025 Dismantling and Tear Down Before starting the disassembly, a large area should be created around the actuator 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...

  • Page 94: Section 6: Troubleshooting

    Restore correct position manual hydraulic group Actuator does not work Failure of the spring Call Biffi Italia s.r.l. customer service Failure of the control group Call Biffi Italia s.r.l. customer service Unexpected intervention of torque Call Biffi Italia s.r.l. customer service...

  • Page 95: Section 7: Layouts And Sectional Drawings

    Recommended spare parts Cycles performed by actuator in a 25 years expected lifetime - the minimum performed cycles are guarantied by Biffi based on service conditions listed: – All the valve required torques have to be lower than actuator max operating torque (design torque).
  • Page 96 Installation, Operation and Maintenance Manual January 2025 FCIM-20197-EN Rev. 0 NOTICE For special scotch yoke mechanism version or heavy-duty service application, refer to Fiorenzuola plant. Figure 59. ALGAS MHW with Screw Protection Table 38. Item Description Item Quantity Description Material...
  • Page 97 Installation, Operation and Maintenance Manual Section 7: Layouts and Sectional Drawings FCIM-20197-EN Rev. 0 January 2025 Figure 60. ALGAS-QA with Screw Protection Table 39. Item Description Item Quantity Description Material Piston rod bushing Steel + Bronze + PTFE O-ring * Viton...
  • Page 98 Section 7: Layouts and Sectional Drawings Installation, Operation and Maintenance Manual January 2025 FCIM-20197-EN Rev. 0 Figure 61. ALGAS-QA without Screw Protection Table 40. Item Description Item Quantity Description Material Piston rod bushing Steel + Bronze + PTFE O-ring * NBR...
  • Page 99 Installation, Operation and Maintenance Manual Section 7: Layouts and Sectional Drawings FCIM-20197-EN Rev. 0 January 2025 Figure 62. ALGAS and ALGAS MHP without Screw Protection Table 41. Item Description Item Quantity Description Material Piston rod bushing Steel + Bronze + PTFE...
  • Page 100 Section 7: Layouts and Sectional Drawings Installation, Operation and Maintenance Manual January 2025 FCIM-20197-EN Rev. 0 Figure 63. All Configurations without Screw Protection Table 42. Item Description Item Quantity Description Material Carbon steel Washer Carbon steel Sealing washer * PVC Stop setting screw Carbon steel Spring container...
  • Page 101 Installation, Operation and Maintenance Manual Section 7: Layouts and Sectional Drawings FCIM-20197-EN Rev. 0 January 2025 Figure 64. Spring Cartridge with Setting Screw Protection Table 43. Item Description Item Quantity Description Material Stop setting screw cover Carbon steel Plug with gasket Stainless steel + Viton O-ring * NBR...
  • Page 102 Section 7: Layouts and Sectional Drawings Installation, Operation and Maintenance Manual January 2025 FCIM-20197-EN Rev. 0 Figure 65. All Configurations - Assembly Kit SPRING TO CLOSE ASSEMBLY SPRING TO OPEN ASSEMBLY Table 44. Item Description Item Quantity Description Material Screw Alloy steel Gasket * SBR + Cellulose + fillers...
  • Page 103 Installation, Operation and Maintenance Manual Section 7: Layouts and Sectional Drawings FCIM-20197-EN Rev. 0 January 2025 Figure 66. ALGAS-QA Quick Exhaust Valve PART A 18+10 PART A Table 45. Item Description Item Quantity Description Material Spacer Stainless steel O-ring * Viton...
  • Page 104 Section 7: Layouts and Sectional Drawings Installation, Operation and Maintenance Manual January 2025 FCIM-20197-EN Rev. 0 Figure 67. Hydraulic Control Unit MHP Layouts and Sectional Drawings...
  • Page 105 Installation, Operation and Maintenance Manual Section 7: Layouts and Sectional Drawings FCIM-20197-EN Rev. 0 January 2025 Table 46. Parts List Item Quantity Description Material Dipstick Cap nut Carbon steel Washer Carbon steel + rubber Hydraulic tank Carbon steel Hand pump Refer to Table 32 O-ring * Fluorosilicon rubber...
  • Page 106 Section 7: Layouts and Sectional Drawings Installation, Operation and Maintenance Manual January 2025 FCIM-20197-EN Rev. 0 Table 47. Parts List (Continued) Item Quantity Description Material O-ring * Fluorosilicon rubber Spring Spring steel Plug Stainless steel Retainer ring Spring steel Spring pin Carbon steel Screw Carbon steel...
  • Page 107 Installation, Operation and Maintenance Manual Section 7: Layouts and Sectional Drawings FCIM-20197-EN Rev. 0 January 2025 Figure 68. Hand Pump Table 48. Parts List Item Quantity Description Material Ball Stainless steel Delivery valve bush Carbon steel Suction valve bush Carbon steel Spring Stainless steel Suction valve ring...
  • Page 108 Section 7: Layouts and Sectional Drawings Installation, Operation and Maintenance Manual January 2025 FCIM-20197-EN Rev. 0 Figure 69. Jackscrew Manual Override MSJ or MHW ENGAGED TO OPEN TO CLOSE DISENGAGED Table 49. Parts List Item Quantity Description Material Item Quantity Description Material Protection pipe Carbon steel Screw...

  • Page 109: Section 8: Spare Parts

    January 2025 Section 8: Spare Parts For spare parts orders to the relevant Biffi  o ffice, please make reference to Biffi    order confirmation concerning all the supply and serial number of the actuator (Section 1.2) for any specific spare parts for a specific actuator model.

  • Page 110: Date Report For Maintenance Operations

    Section 9: Maintenance Operations Installation, Operation and Maintenance Manual January 2025 FCIM-20197-EN Rev. 0 Section 9: Date Report for Maintenance Operations Last maintenance operation date: (in factory, on delivery): ……… exec. by : ………… ……… exec. by : ………… ……… exec. by : ………… Next maintenance operation date: ………...
  • Page 111 Installation, Operation and Maintenance Manual Notes FCIM-20197-EN Rev. 0 January 2025 This page is intentionally left blank.
  • Page 112 FCIM-20197-EN © 2025 Biffi. All rights reserved. Biffi Italia s.r.l. Strada Biffi 165 The contents of this publication are presented for informational purposes 29017 Fiorenzuola d’Arda (PC) only, and while every effort has been made to ensure their accuracy, Italy...

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