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BIFFI F01-3000 Installation, Operation And Maintenance Manual

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Installation, Operation and Maintenance Manual  
FCIM-20206-EN Rev. 0
February 2025
Biffi F01-3000
Electric Actuator
Copyright © Biffi. The information in this document is subject to change without notice. Updated installation, operation and maintenance 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 F01-3000

  • Page 1 Copyright © Biffi. The information in this document is subject to change without notice. Updated installation, operation and maintenance 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 Installation, Operation and Maintenance Manual FCIM-20206-EN Rev. 0 February 2025 This page is intentionally left blank...

  • Page 3: Table Of Contents

    Installation, Operation and Maintenance Manual Table of Contents FCIM-20206-EN Rev. 0 February 2025 Table of Contents Section 1: General Safety Instructions Range of Application ..................... 1 Safety Instructions for Installation in Hazardous Area ........1 1.2.1 Marking....................2 Applicable Standards and Regulations ............. 2 Terms and Conditions ...................
  • Page 4 Output Contacts ..................32 5.7.3 ESD Operation ..................32 5.7.4 ESD Operation ..................33 5.7.5 Interlock Inputs ...................33 Operating the F01-3000 for the First Time ............35 Optional Modules ....................35 5.9.1 Fieldbus Interface for Remote Control via Fieldbus ....36 5.9.2 Ain/Aout Card ..................36 5.10 Base Card of the F01-3000 ................39...
  • Page 5 Installation, Operation and Maintenance Manual Table of Contents FCIM-20206-EN Rev. 0 February 2025 Maintenance ......................78 9.3.1 Set Password ..................79 9.3.2 Clear Alarm Log ...................79 9.3.3 Set Torque Reference .................79 9.3.4 Set Curve Reference ................80 9.3.5 Clear Recent Data Log................80 9.3.6 Configuration (Backup/Restore) ............81 9.3.7 Set PST Reference ................82...
  • Page 6 Notes Installation, Operation and Maintenance Manual February 2025 FCIM-20206-EN Rev. 0 This page is intentionally left blank...

  • Page 7: Section 1: General Safety Instructions

    F01-3000 electric actuators covered in this Installation, Operation and Maintenance Manual are designed for the operation of industrial valves used in heavy industrial, chemical and petrochemical plants. Biffi will not be liable for any possible damage resulting from use in other than the designated applications. Such risk lies entirely with the user.

  • Page 8: Marking

    Section 1: General Safety Instructions Installation, Operation and Maintenance Manual FCIM-20206-EN Rev. 0 February 2025 1.3.1 Marking IECEx INE XX.ZZZZ IECEx reference certificate (CoC) XX ATEX ZZZZ ATEX reference certificate 0080 Notified body for ATEX quality assurance (INERIS) Group II (surface industries) Category 2 apparatus Explosive atmospheres caused by gas, mists or vapors Explosive atmospheres caused by gas dusts...

  • Page 9: Terms And Conditions

    February 2025 Terms and Conditions Biffi Italia s.r.l. guarantees every product to be free from defects and to conform to industry standards. The warranty period is one year from the date of installation by the first user or eighteen (18) months from the date of shipment to the first user, whichever occurs first.

  • Page 10: Section 2: Storage And Pre-Installation

    Section 2: Storage and Pre-Installation Installation, Operation and Maintenance Manual FCIM-20206-EN Rev. 0 February 2025 Section 2: Storage and Pre-Installation Tests to be Carried Out When the Actuator is Received If the actuator is received already mounted on the valve, all operations should have already been performed during valve/actuator assembly.

  • Page 11: General

    In order to maintain these characteristics until the actuator is installed on site, proper procedures must be taken for preservation during the storage period. F01-3000 actuators are weatherproof to IP66/68; this condition can only be maintained if the unit is correctly installed on-site and if the actuator was correctly stored.

  • Page 12: Long-Term Storage (More Than One Year)

    Section 2: Storage and Pre-Installation Installation, Operation and Maintenance Manual FCIM-20206-EN Rev. 0 February 2025 2.2.3 Long-term Storage (More Than One Year) 2.2.3.1 Indoor Storage In addition to the instructions at Section 2.2.2.1. • If the actuators are supplied with standard plastic plugs, replace them with weatherproof plugs.

  • Page 13: Section 3: Installation

    Installation, Operation and Maintenance Manual Section 3: Installation FCIM-20206-EN Rev. 0 February 2025 Section 3: Installation Working Condition The standard actuators are suitable for the following environment temperatures: • -20 to +85 °C / -4 to +185 °F Special versions are available for extreme environment temperatures: •...

  • Page 14: Heater Options

    Section 3: Installation Installation, Operation and Maintenance Manual February 2025 FCIM-20206-EN Rev. 0 3.1.1 Heater Options Actuators are suitable for ambient temperature range as per Product Data Sheet. Heater options are available for specific application. Table 2. Heaters Model Ambient Temperature Range Control Type Power ON and OFF managed by thermostat...

  • Page 15: Coupling Block: Disassembly From The Actuator

    Installation, Operation and Maintenance Manual Section 3: Installation FCIM-20206-EN Rev. 0 February 2025 Coupling Block: Disassembly from the Actuator The bushing is delivered already assembled to the drive sleeve, even when it is unmachined. In order to perform the necessary machining, remove the bushing from its housing.
  • Page 16 Section 3: Installation Installation, Operation and Maintenance Manual February 2025 FCIM-20206-EN Rev. 0 Figure 4. Drive Sleeve Removed Figure 5. Handwheel Operation Installation...

  • Page 17: Manual Operation

    Installation, Operation and Maintenance Manual Section 3: Installation FCIM-20206-EN Rev. 0 February 2025 Manual Operation To manually operate the actuator, it is sufficient to turn the handwheel in the desired direction. WARNING Do not manually operate the actuator with devices other than the handwheel. Using cheater bars, wheel wrenches, pipe wrenches or other such devices on the actuator handwheel may cause serious personal injury and/or damage to the actuator or valve.

  • Page 18: Electrical Connections

    Access to terminals for electrical connections and commissioning is through the terminal cover since all settings are non-intrusive. The removal of any other covers without Biffi’s approval will invalidate the warranty. Biffi will not accept any responsibility for any damage or deterioration that may be caused.

  • Page 19: Identification Of Entries

    FCIM-20206-EN Rev. 0 February 2025 3.5.1 Identification of Entries Electric actuators series F01-3000 are equipped with 4 entries (3 are standard, the fourth is supplied when requested). With reference to Figure 7, the thread form/size for entry is as follows: Figure 7.

  • Page 20: Plants Requirements

    Section 3: Installation Installation, Operation and Maintenance Manual February 2025 FCIM-20206-EN Rev. 0 3.5.2 Plants Requirements Protection devices (overcurrent breakers, magneto-thermal switches or fuses) should be provided on the plant at Customer care, to protect the mains line in case of motor overcurrent or loss of insulation between phases and earth.

  • Page 21: Cable Entries

    Installation, Operation and Maintenance Manual Section 3: Installation FCIM-20206-EN Rev. 0 February 2025 Cable Entries The sealing of cables and conduit entries should be carried out in accordance with National Standards or the Regulatory Authorities that have certified the actuators. This is particularly true for units that are certified for use in hazardous areas where the method of sealing must be to an approved standard and cable glands, reducers, plugs and adapters must be approved and separately certified.

  • Page 22: Terminal Board

    NOTICE The removal of any other covers without Biffi’s approval will invalidate the warranty. Biffi will not accept any responsibility for any damage or deterioration that may occur as a result of cover removal. Terminate the ground connections to the ground stud marked , one internal and one external ground studs are provided.
  • Page 23 Installation, Operation and Maintenance Manual Section 3: Installation FCIM-20206-EN Rev. 0 February 2025 Connect the motor supply cable previously sized in accordance with: • The absorbed current correspondent to the actuator nominal torque with the torque limiting device set at 100 percent (see the test certificate attached to the actuator).
  • Page 24 Section 3: Installation Installation, Operation and Maintenance Manual February 2025 FCIM-20206-EN Rev. 0 Figure 10. Wiring Terminals Figure 11. Terminal Indication Installation...
  • Page 25 Installation, Operation and Maintenance Manual Section 3: Installation FCIM-20206-EN Rev. 0 February 2025 Connections for Ex e terminals enclosure The wires must be terminated in accordance with the following method (see connection in Table 6): Table 6. Connection Table Power Cables Control Cables Type of terminal Insulated ring tongue...

  • Page 26: Instructions For The Explosion-Proof Enclosures

    Instructions for the Explosion-Proof Enclosures NOTICE Electric actuator F01-3000 shall be installed and maintained according to the applicable rules regarding the electrical installations in hazardous area (other than mines) classified as zone 1 (gas); example: EN 60079-10 (hazardous area classification), EN 60079-14 (electrical installation), EN 60079-17 (maintenance) and/or other national standards.

  • Page 27: Installation In Environment With Explosive Dusts

    Installation in Environment with Explosive Dusts NOTICE Electric actuator F01-3000 shall be installed and maintained according to the applicable rules regarding the electrical installations in hazardous area (other than mines) classified as zone 21 (dust); example: EN 61241-14 (dust) and/or other national standards.

  • Page 28: Section 4: Lubrication

    AGIP GREASE MU EP 2 or equivalent Ambient temperature from -40 to +85 °C • Molykote 33M or equivalent ® Ambient temperature from -60 to +65 °C • Molykote 33M or equivalent Table 8. Oil Fill Volume Actuator Size Oil Quantity (l) F01-3000/150 F01-3000/300 F01-3000/600 Lubrication...

  • Page 29: Section 5: Operating The F01-3000

    Installation, Operation and Maintenance Manual Section 5: Operating the F01-3000 FCIM-20206-EN Rev. 0 February 2025 Section 5: Operating the F01-3000 Operation by Handwheel To manually operate the actuator, it is sufficient to turn the handwheel in the desired direction. The manual operation is always possible without any clutching mechanism.

  • Page 30: Setting Of Mechanical Stops

    Section 5: Operating the F01-3000 Installation, Operation and Maintenance Manual FCIM-20206-EN Rev. 0 February 2025 Setting of Mechanical Stops Necessary equipment: a 3 mm hexagonal key. According to the type of valve to be operated, the actuator can be stopped by means...
  • Page 31 Installation, Operation and Maintenance Manual Section 5: Operating the F01-3000 FCIM-20206-EN Rev. 0 February 2025 Hold the lock nut and remove the mechanical stop protection by unscrewing it. Remove the seal washer. Figure 16. Stop Screw Adjustment Hold the mechanical stop by means of a suitable Allen key and in the same time loosen the lock nut by one turn.

  • Page 32: Electrical Operation

    Section 5: Operating the F01-3000 Installation, Operation and Maintenance Manual FCIM-20206-EN Rev. 0 February 2025 Electrical Operation Before connecting power to the actuator, check that the voltage is correct and according to the indications on the nameplate. Wrong power supply could cause a permanent damage to the electrical components.

  • Page 33: Local Indication

    Installation, Operation and Maintenance Manual Section 5: Operating the F01-3000 FCIM-20206-EN Rev. 0 February 2025 Figure 18. Local User Interface OPEN/YES STOP CLOSE/NO Local Indication By default, the upper display indicates the valve position as a percentage of opening (open = 100%). The lower display in the upper part shows icons that indicate the actuator status or the Menu, where the user is operating.
  • Page 34 Section 5: Operating the F01-3000 Installation, Operation and Maintenance Manual FCIM-20206-EN Rev. 0 February 2025 Figure 20. Pushbuttons OPEN/YES STOP CLOSE/NO Figure 21. Display Operation Local selector Status or Position position request R% Operating the F01-3000...

  • Page 35: Lock Of The 3-Position Selector

    Installation, Operation and Maintenance Manual Section 5: Operating the F01-3000 FCIM-20206-EN Rev. 0 February 2025 Lock of the 3-Position Selector The 3-position selector can be locked in any of its three positions by means of a padlock. Figure 22. Lockable Selector...
  • Page 36 Section 5: Operating the F01-3000 Installation, Operation and Maintenance Manual FCIM-20206-EN Rev. 0 February 2025 3 WIRES (see the remote connections diagram) With option “3 wires” (OPEN, CLOSE, COMMON), the actuator can be driven in either “push-to- run” or “latched with instant reverse”...
  • Page 37 Installation, Operation and Maintenance Manual Section 5: Operating the F01-3000 FCIM-20206-EN Rev. 0 February 2025 Figure 23. Wiring Diagram OPTION A1 OPTION B1 (-Ve) (+Ve) OPTION A2 OPTION B2 (-Ve) (+Ve) OPTION A3 OP/CL OPTION B3 OP/CL (-Ve) (+Ve) Operating the F01-3000...

  • Page 38: Output Contacts

    Section 5: Operating the F01-3000 Installation, Operation and Maintenance Manual FCIM-20206-EN Rev. 0 February 2025 5.7.2 Output Contacts • Monitor relay: on the terminal board, the voltage-free, change-over contacts of the monitor relay are available. The monitor relay indicates that the actuator can be remotely controlled or that there is a problem or condition which prevents remote control of the valve.

  • Page 39: Esd Operation

    Installation, Operation and Maintenance Manual Section 5: Operating the F01-3000 FCIM-20206-EN Rev. 0 February 2025 5.7.4 ESD Operation An ESD (Emergency Shut Down) signal can be sent to the actuator to override any existing command and to drive the valve to a predetermined position. The control is not self-maintained, that is, the ESD action continues until the relevant signal is present.
  • Page 40 Section 5: Operating the F01-3000 Installation, Operation and Maintenance Manual FCIM-20206-EN Rev. 0 February 2025 Figure 24. Wiring Diagram OPTION D1 OPTION D2 (-Ve) (+Ve) OPTION E1 OPTION E2 (-Ve) (+Ve) Operating the F01-3000...

  • Page 41: Operating The F01-3000 For The First Time

    The actuator contains parts and assemblies susceptible to damage via Electrostatic Discharge. Prior to performing work, use protection or discharge static electricity by touching grounded metal. Additional modules can be plugged in the base card of the F01-3000 to provide the following functions: Operating the F01-3000...

  • Page 42: Fieldbus Interface For Remote Control Via Fieldbus

    5.9.2 Ain/Aout Card With the above card, the F01-3000 is provided with a 4 to 20 mA analog input and a 4 to 20 mA analog output. This card should be plugged on the base card, replacing the “TERMINAL BOARD ADAPTOR” card supplied as standard. A Hardware alarm is generated if the F01-3000 was set to be equipped with an Ain/Aout card and the card is damaged or missing.
  • Page 43 Installation, Operation and Maintenance Manual Section 5: Operating the F01-3000 FCIM-20206-EN Rev. 0 February 2025 Figure 25. Wiring Diagram EXTERNAL POWER SUPPLY ACTIVE LOOP ACTUATOR TERMINALS 20 TO 30 V DC CABLE 4 TO 20 mA LOAD: MAXIMUM 300 ohm...
  • Page 44 4 to 20 mA analog input The 4 to 20 mA analog input is the position request R% signal and is used by the F01-3000 to position the valve in inching and modulating actuators. The “POSITIONER” routine processes the input signal, compares the present actuator position % with the position request R% and if the difference is greater than the dead band, the actuator is driven to reach the requested position.

  • Page 45: Base Card Of The F01-3000

    Installation, Operation and Maintenance Manual Section 5: Operating the F01-3000 FCIM-20206-EN Rev. 0 February 2025 5.10 Base Card of the F01-3000 Figure 28. Bottom View of Base Card Terminal Board Adaptor card (TBA) Top view of base card Base card equipped with fieldbus interface card and Terminal Board Adaptor card.
  • Page 46 Section 5: Operating the F01-3000 Installation, Operation and Maintenance Manual FCIM-20206-EN Rev. 0 February 2025 Fieldbus interface card The type of card depends on the fieldbus present in the plant. Figure 30. Fieldbus Interface Card Figure 31. Logic Card Operating the F01-3000...
  • Page 47 This optional card is used in place of the Terminal Board Adaptor (TBA) card when an analog 4 to 20 mA input and output signal is requested. This card cannot be used in the actuators with terminal board series F01-3000 (see Section 5.8, Operating the F01-3000 for the First Time).

  • Page 48: Section 6: Local Controls

    Section 6: Local Controls Installation, Operation and Maintenance Manual February 2025 FCIM-20206-EN Rev. 0 Section 6: Local Controls Description of the Local Operator Interface The following functions are available by the F01-3000 local operator interface: • Actuator control • Actuator configuration •...
  • Page 49 — REMOTE: for remote control only The F01-3000 can be provided with a radiofrequency wireless connection based on a qualified Bluetooth class 1 module. This allows to establish a connection and exchange data with a PDA or PC with built-in Bluetooth technology.
  • Page 50 Section 6: Local Controls Installation, Operation and Maintenance Manual February 2025 FCIM-20206-EN Rev. 0 Three LED’s to indicate the actuator status according to the following logic: — green ON / red OFF: the actuator is stopped in open position — green OFF / red ON: the actuator is stopped in closed position —...
  • Page 51 Installation, Operation and Maintenance Manual Section 6: Local Controls FCIM-20206-EN Rev. 0 February 2025 Description of Variables and Reports torque output torque in % of the nominal torque stated in the NAMEPLATE menu motor speed RPM of electrical motor main voltage voltage (V) and frequency (Hz) of mains current current (A) absorbed by the motor...
  • Page 52 Section 6: Local Controls Installation, Operation and Maintenance Manual February 2025 FCIM-20206-EN Rev. 0 Figure 35 shows the use of the OPEN/YES, CLOSE/NO and STOP pushbuttons in function of the local selector position. Figure 35. Main Menu LOCAL REMOTE 3-POSITION SELECTOR = OPEN/YES PUSH-BUTTON = CLOSE/NO PUSH-BUTTON = STOP PUSH-BUTTON...

  • Page 53: Configuration Options

    February 2025 Configuration Options The F01-3000 actuator can be totally configured from the local interface by means of a series of menus that can be selected from the alphanumeric display. The operator is guided through the different displays by answering YES or NO to the appropriate prompt (change? OK?, view?, next?, etc.) in the right corner of the lower row of the...
  • Page 54 Section 6: Local Controls Installation, Operation and Maintenance Manual February 2025 FCIM-20206-EN Rev. 0 Nameplate This menu includes a series of data identifying the actuator characteristics, service and utilization mode. The data are entered by the manufacturer and can only be viewed (i.e., this menu is only available in View mode).
  • Page 55 Installation, Operation and Maintenance Manual Section 6: Local Controls FCIM-20206-EN Rev. 0 February 2025 Maintenance This menu includes all diagnostic and historic data which can help the operator in case of failure or during maintenance operations. The Maintenance menu also includes the “Set password”...

  • Page 56: Entering The View Mode

    Section 6: Local Controls Installation, Operation and Maintenance Manual February 2025 FCIM-20206-EN Rev. 0 Entering the View Mode The existing actuator configuration should be checked before commissioning. The parameters are configured in factory according to a standard setting or to customer requirements.

  • Page 57: Exit From View And Set-Up Mode

    February 2025 All settings are automatically saved to a non-volatile memory and retained also if the electrical power is removed from the actuator. All F01-3000 actuators are configured before shipping with a standard default setting unless alternatives were requested on order. In case of difficulty during commissioning, the default setting can be re-instated by the appropriate function in the routine ”miscellaneous”...
  • Page 58 Section 6: Local Controls Installation, Operation and Maintenance Manual February 2025 FCIM-20206-EN Rev. 0 Figure 36 shows the procedure to enter view and set-up mode. Figure 36. Enter View and Set-Up Mode Local Controls...

  • Page 59: Section 7: Set-Up Menu

    Installation, Operation and Maintenance Manual Section 7: Set-Up Menu FCIM-20206-EN Rev. 0 February 2025 Section 7: Set-Up Menu Figure 37. Set-up Menu Set-Up Menu...
  • Page 60 Section 7: Set-Up Menu Installation, Operation and Maintenance Manual FCIM-20206-EN Rev. 0 February 2025 The Figure 38 shows the procedure to move in the set-up routines. Figure 38. Access to Set-Up Routine Set-Up Menu...

  • Page 61: Section 8: View Menu

    Installation, Operation and Maintenance Manual Section 8: View Menu FCIM-20206-EN Rev. 0 February 2025 Section 8: View Menu Figure 39. View Menu View Menu...
  • Page 62 Section 8: View Menu Installation, Operation and Maintenance Manual February 2025 FCIM-20206-EN Rev. 0 The Figure 40 shows the procedure to move in the view routines. Figure 40. View Menu View Menu...

  • Page 63: Section 9: Set-Up Routines

    Installation, Operation and Maintenance Manual Section 9: Set-Up Routines FCIM-20206-EN Rev. 0 February 2025 Section 9: Set-Up Routines Actuator Set-Up 9.1.1 Set Stroke Limits This routine allows the actuator to be configured according to the type of valve it is mounted on.
  • Page 64 Section 9: Set-Up Routines Installation, Operation and Maintenance Manual FCIM-20206-EN Rev. 0 February 2025 Close limit by position • Move the local selector to LOCAL. The local controls can be used. • Move the valve to closed position (by CLOSE control or by handwheel). •...

  • Page 65: Torque Set-Up

    Installation, Operation and Maintenance Manual Section 9: Set-Up Routines FCIM-20206-EN Rev. 0 February 2025 9.1.2 Torque Set-Up The output torque limits to close or to open may be configured between 40% and 100% of the nominal torque stated on the actuator nameplate. Set-up procedure •...
  • Page 66 Section 9: Set-Up Routines Installation, Operation and Maintenance Manual FCIM-20206-EN Rev. 0 February 2025 Configuration procedure • Move the local selector to OFF and then simultaneously press OPEN and STOP. Select the language and then enter the password according to the instructions (see “Entering the set-up mode”).

  • Page 67: Remote Controls

    Installation, Operation and Maintenance Manual Section 9: Set-Up Routines FCIM-20206-EN Rev. 0 February 2025 9.1.4 Remote Controls The actuator may be remotely controlled by 4, 3 or 2 wires depending on the connection made on the terminal board of the actuator. The following options are available: •...

  • Page 68: Output Relays

    Section 9: Set-Up Routines Installation, Operation and Maintenance Manual FCIM-20206-EN Rev. 0 February 2025 Configuration procedure • Move the local selector to OFF and then simultaneously press OPEN and STOP. Select the language and then enter the password according to the instructions (see “Entering the set-up mode”).
  • Page 69 Installation, Operation and Maintenance Manual Section 9: Set-Up Routines FCIM-20206-EN Rev. 0 February 2025 The following situation can be configured individually to switch-over the monitor relay: • motor over-temperature • over-torque • jammed valve • LOCAL/OFF selected • manual operation •...
  • Page 70 Section 9: Set-Up Routines Installation, Operation and Maintenance Manual FCIM-20206-EN Rev. 0 February 2025 Alarm • motor over-temperature • over-torque • over-torque in OP • over-torque in CL • valve jammed • valve jammed in OP • valve jammed in CL •...
  • Page 71 Installation, Operation and Maintenance Manual Section 9: Set-Up Routines FCIM-20206-EN Rev. 0 February 2025 Default #1 Monitor relay • main voltage failure • lost phase • local/off selected • local stop pressed • manual operation • internal temperature alarm • K1 contactor failure •...
  • Page 72 Section 9: Set-Up Routines Installation, Operation and Maintenance Manual FCIM-20206-EN Rev. 0 February 2025 Default #2 Monitor relay • main voltage failure • lost phase • local/off selected • local stop pressed • manual operation • internal temperature alarm • K1 contactor failure •...

  • Page 73: Positioner

    The “position request R%” signal may either be received from the bus or the 4 to 20 mA analog input. If the F01-3000 is set to receive the position request R% from the bus, a fieldbus interface card must be present or a Hardware alarm will be generated.
  • Page 74 Section 9: Set-Up Routines Installation, Operation and Maintenance Manual FCIM-20206-EN Rev. 0 February 2025 Figure 41. Analog Input Setting INPUT 4 TO 20 mA INPUT 4 TO 20 mA POLARITY: 4 mA = CL POLARITY: 4 mA = OP INPUT REQUEST INPUT REQUEST 20 mA 20 mA...
  • Page 75 Installation, Operation and Maintenance Manual Section 9: Set-Up Routines FCIM-20206-EN Rev. 0 February 2025 Figure 42. Analog Input Setting EXAMPLE A EXAMPLE B POSITION REQUEST % POSITION REQUEST % 100% CONFIGURED VALUES: CONFIGURED VALUES: 100% % MINIMUM = 0% % MINIMUM = 25% % MAXIMUM = 100% % MAXIMUM = 75% POLARITY: 4 mA = CL...

  • Page 76: Fail-Safe

    This action only takes place if the local selector is in REMOTE and if the positioning function or the bus interface are active. When the 4 to 20 mA or bus signal is restored, the F01-3000 resumes its normal functioning. The Interlock and ESD controls override the fail-safe action according to Figure 43.

  • Page 77: Out 4 To 20 Ma

    This routine is only available if the Ain/Aout card is present. With this card the F01-3000 is provided with a 4 to 20 mA analog input and a 4 to 20 mA analog output. The 4 to 20 mA output can be configured to provide a current proportional to either “position”...

  • Page 78: Interlock

    Section 9: Set-Up Routines Installation, Operation and Maintenance Manual FCIM-20206-EN Rev. 0 February 2025 9.1.10 Interlock The interlock inputs can be used to inhibit the actuator movement in open or close direction. The controls are momentary, the inhibit action continues until the relevant signal is present.
  • Page 79 Installation, Operation and Maintenance Manual Section 9: Set-Up Routines FCIM-20206-EN Rev. 0 February 2025 Closing direction • Press YES if the status is OK or NO to change. Press YES to confirm (status = On, enables 2-speed timer operation in closing direction status = Off, disables timer operation in closing direction).

  • Page 80: Bus (Or Fdi Control)

    (node address, termination, etc.) necessary to connect the actuator to a fieldbus. If the F01-3000 was set to work with fieldbus, but the fieldbus card is not present, a Hardware alarm will be generated. Different interfaces are available to connect the F01-3000 to different types of fieldbus.
  • Page 81 Installation, Operation and Maintenance Manual Section 9: Set-Up Routines FCIM-20206-EN Rev. 0 February 2025 9.1.13.2 Torque Limits Torque limits are used as a reference for torque alarm and end of travel. With the option “standard”, the torque limits are constant along the full stroke. The limits can be configured in the “stroke limits”...
  • Page 82 Section 9: Set-Up Routines Installation, Operation and Maintenance Manual FCIM-20206-EN Rev. 0 February 2025 9.1.13.3 Lithium Battery In the standard version, the actuator is provided with a lithium battery to keep visible the local position display, to back-up the RTC (real-time-clock) for diagnostic functions, to test the battery charge and to update the remote outputs (output relays status when set as “open limit”...

  • Page 83: Valve Data

    Installation, Operation and Maintenance Manual Section 9: Set-Up Routines FCIM-20206-EN Rev. 0 February 2025 9.1.13.5 Valve Jammed (Time) The valve jammed time is used to monitor the following situations: The time passed after receiving an open or close control is greater than the “valve jammed time”, but the valve position variation is smaller than 0.5%.

  • Page 84: Sample Configuration Procedure

    Section 9: Set-Up Routines Installation, Operation and Maintenance Manual FCIM-20206-EN Rev. 0 February 2025 9.2.1 Sample Configuration Procedure Tag name • Move the local selector to OFF and then simultaneously press OPEN and STOP. Select the language and enter the password according to the instructions (see “Entering the set-up mode”).

  • Page 85: Set Password

    9.3.1 Set Password The actuator is supplied by Biffi with a default password (“0 0 0 0”). By the above routine, the end user can enter a different password consisting of 4 alphanumeric characters. After entering the new password, the old one ceases to be valid.

  • Page 86: Set Curve Reference

    The “set curve reference” routine allows to select 1 off 100 opening and closing torque curves in the memory of the F01-3000 and to transfer them to the torque curve reference registers. The old reference data are lost and the new ones will be the new torque curves reference (see View Routines, Maintenance, Torque Curve, Section 10.4.3).

  • Page 87: Configuration (Backup/Restore)

    Installation, Operation and Maintenance Manual Section 9: Set-Up Routines FCIM-20206-EN Rev. 0 February 2025 9.3.6 Configuration (Backup/Restore) This routine allows the user to save or restore a copy of the current actuator configuration. After completing the configuration operations and verifying that they are working properly, the Backup sub-routine creates a copy of the configuration in the actuator’s permanent memory.

  • Page 88: Set Pst Reference

    Section 9: Set-Up Routines Installation, Operation and Maintenance Manual FCIM-20206-EN Rev. 0 February 2025 9.3.7 Set PST Reference This routine allows the user to select as reference a PST curve among the curves already stored. Configuration procedure • Move the local selector to OFF and then simultaneously press OPEN and STOP.

  • Page 89: Set Maintenance Date

    Installation, Operation and Maintenance Manual Section 9: Set-Up Routines FCIM-20206-EN Rev. 0 February 2025 9.3.9 Set Maintenance Date The maintenance date routine allows the following operations: • to set the last maintenance date • to set the next maintenance date •...

  • Page 90: Set Data Logger

    Section 9: Set-Up Routines Installation, Operation and Maintenance Manual FCIM-20206-EN Rev. 0 February 2025 9.3.10 Set Data Logger The “data logger” routine allows to set the data logger parameters (see View Routines, Maintenance, Data Logger, Section 10.4.6). To start the data logger, the following data should be set: Logger mode recorder, event, off...

  • Page 91: Example Of Set-Up Routine

    Installation, Operation and Maintenance Manual Section 9: Set-Up Routines FCIM-20206-EN Rev. 0 February 2025 Example of Set-Up Routine 9.4.1 Torque Set-Up Figure 47. Torque Set-Up Menu REMOTE LOCAL ACTUATOR SETUP ACTUATOR SETUP ACTUATOR SETUP SETUP MODE TORQUE SETUP STROKE LIMIT CHANGE? CHANGE? CHANGE?

  • Page 92: Section 10: View Routines

    Installation, Operation and Maintenance Manual Section 10: View Routines February 2025 FCIM-20206-EN Rev. 0 Section 10: View Routines 10.1 Actuator Set-Up The above menu allows to view the present actuator configuration. No change can be made to the present data. The following data can be viewed (see Table 11). Table 11.

  • Page 93: Nameplate

    Icc, maximum 999.9 A — Duty (S2/15 min, etc.) — Poles (2, 4, etc.) — Biffi name, maximum 28 characters — Gear ratio, maximum 1000 • Test date: date of the in-house functional test of actuator. • Wiring diagram (WD): wiring diagram number, maximum 28 characters.

  • Page 94: Valve Data

    Installation, Operation and Maintenance Manual Section 10: View Routines February 2025 FCIM-20206-EN Rev. 0 10.3 Valve Data To identify the valve and its function in the process, the following data can be viewed: • Tag name (maximum 28 characters) • Serial number (maximum 28 characters) •...

  • Page 95: Torque Profile

    % of the nominal torque. At the end of a full stroke in opening or closing, the F01-3000 stores the 3 maximum torque values in position intervals 0 to 10%, 10 to 90%, 90 to 100% in opening and the 3 maximum torque values in position intervals 100 to 90%, 90 to 10%, 10 to 0% in closing.

  • Page 96: Torque Curve

    During a full valve stroke in opening or closing, the F01-3000 measures the torque values relevant to every 1% of position variation. At the end of the stroke, the...

  • Page 97: Operation Log

    Installation, Operation and Maintenance Manual Section 10: View Routines FCIM-20206-EN Rev. 0 February 2025 The amount of data to be viewed is large and the local display can only visualize one datum at a time. To use this function, we suggest to utilize the features available with PDA’s and PC through Bluetooth wireless connection.
  • Page 98 Installation, Operation and Maintenance Manual Section 10: View Routines February 2025 FCIM-20206-EN Rev. 0 Figure 48. Torque Log Table 13 shows list of data collected by the general and recent data log. Table 13. Operation Log List Routine Parameters Opening time Closing time Contactor cycles Contactor cycles...
  • Page 99 Installation, Operation and Maintenance Manual Section 10: View Routines FCIM-20206-EN Rev. 0 February 2025 View procedure • Move the local selector to OFF and then simultaneously press OPEN and STOP. Select the language according to the instructions (see “Entering the view mode”).

  • Page 100: Maintenance Date

    Next date This is the date of the next scheduled actuator maintenance. When the date is reached, the F01-3000 generates a maintenance request warning. The date should be updated by the user after all maintenance operations (see Section 9.3). Start-up date This is the date of actuator start-up.
  • Page 101 Section 10: View Routines FCIM-20206-EN Rev. 0 February 2025 Data logger modes: • OFF: the data logger is not active. • RECORDER mode: the F01-3000 measures and memorizes the following 3 data: — Main voltage supply (V) — Motor temperature (°C) —...
  • Page 102 • EVENT mode: the F01-3000 detects the type of received command (OPEN or CLOSE), the source of the command (local controls, remote controls, bus, etc.) and date and time of command. Up to 128 EVENTS can be memorized.

  • Page 103: Example Of View Routine

    Installation, Operation and Maintenance Manual Section 10: View Routines FCIM-20206-EN Rev. 0 February 2025 View procedure • Move the local selector to OFF and then simultaneously press OPEN and STOP. Select the language according to the instructions (see “Entering the view mode”).

  • Page 104: Section 11: Maintenance

    11.1 Standard Maintenance Approximately every 2 years: Under normal operating conditions, the F01-3000 is maintenance-free: no actuator maintenance is formally required, even though visual inspection for oil leakage or external visible damages is recommended every two years. When conditions are severe (frequent operation or high temperatures), inspect the oil level and oil quality more often.
  • Page 105 Installation, Operation and Maintenance Manual Section 11: Maintenance FCIM-20206-EN Rev. 0 February 2025 The following checks will assure optimum performance and can be considered as good practice in preventive and/or predictive maintenance: • External visual inspection and general health check. •...

  • Page 106: Special Maintenance

    11.2 Special Maintenance In case of actuator failure, please refer to Section 12, Troubleshooting for possible causes. Spare parts can be required to Biffi: please refer to the individual item number shown in Section 13, Parts List and Drawings. NOTICE Special maintenance is also recommended when, during operations, the actuator generates an excessive noise.
  • Page 107 Installation, Operation and Maintenance Manual Section 11: Maintenance FCIM-20206-EN Rev. 0 February 2025 Figure 55. Open the Battery Enclosure Figure 56. Remove the Battery Cover Figure 57. Loosen the Lock Nut Maintenance...
  • Page 108 Installation, Operation and Maintenance Manual Section 11: Maintenance February 2025 FCIM-20206-EN Rev. 0 Figure 58. Detach Sealing Bushing Figure 59. Detach Battery Board — Replace the battery. Figure 60. Access to the Battery Maintenance...
  • Page 109 Installation, Operation and Maintenance Manual Section 11: Maintenance FCIM-20206-EN Rev. 0 February 2025 Figure 61. Remove the Battery Figure 62. Replace with New Battery WARNING If the actuator is located in a hazardous area, a “hot work” permit must be obtained unless the actuator can be moved to a non-hazardous area.

  • Page 110: Section 12: Troubleshooting

    Installation, Operation and Maintenance Manual FCIM-20206-EN Rev. 0 February 2025 Section 12: Troubleshooting The F01-3000 actuator has passed the functional test performed by Biffi Quality Assurance personnel. WARNING The actuator is non-intrusive. The control compartment was sealed in dry and clean conditions and contains no site serviceable components.

  • Page 111: Dc Output Voltage Not Available At The Terminals

    Installation, Operation and Maintenance Manual Section 12: Troubleshooting FCIM-20206-EN Rev. 0 February 2025 12.2 DC Output Voltage Not Available at the Terminals • Switch the main power supply off and disconnect all wires from terminals B1 to B2 and C1. •...

  • Page 112: The Motor Is Very Hot And Does Not Start

    Section 12: Troubleshooting Installation, Operation and Maintenance Manual FCIM-20206-EN Rev. 0 February 2025 12.4 The Motor is Very Hot and Does Not Start • Check that no alarm other than motor overheating is present. • Wait until the motor cools down and the normally closed contact of the thermal switch automatically resets before trying to operate the actuator again.

  • Page 113: The Actuator Does Not Stop In Fully Open Or Fully Closed Position

    Installation, Operation and Maintenance Manual Section 12: Troubleshooting FCIM-20206-EN Rev. 0 February 2025 12.8 The Actuator Does Not Stop in Fully Open or Fully Closed Position • Check that the actual open and close positions of the valve respectively correspond to 100% and 0% on the actuator display. •...
  • Page 114 Section 12: Troubleshooting Installation, Operation and Maintenance Manual FCIM-20206-EN Rev. 0 February 2025 Figure 64. Diagnostic Menu LOCAL REMOTE WARNINGS ALARMS VIEW? VIEW? 3-POSITION SELECTOR DISPLAY XXXXXX XXXXXX WARNING ALARM XXXXXX NEXT? NEXT? NEXT? VIEW VARIABLES WARNING ALARM NEXT? NEXT? RESET RESET Troubleshooting...
  • Page 115 Installation, Operation and Maintenance Manual Section 12: Troubleshooting FCIM-20206-EN Rev. 0 February 2025 Table 16. Alarm Table Available Controls Display Alarm Condition for Alarm Action Message Reset Local Remote High torque Measured torque Operate the Only Only open Configuration Close control in closing greater than the relevant actuator in...
  • Page 116 Section 12: Troubleshooting Installation, Operation and Maintenance Manual FCIM-20206-EN Rev. 0 February 2025 Table 16. Alarm Table (continued) Available Controls Display Alarm Condition for Alarm Action Message Reset Local Remote Configuration The checksum of the Reconfigure all Not available Memory OK error EEPROM memory parameters...

  • Page 117: Section 13: Parts List And Drawings

    Section 13: Parts List and Drawings 13.1 Introduction This chapter includes the drawings and parts list of each component and subassembly of F01-3000 actuators. CAUTION Using a fastener other than the approved type may result in damage to the actuator or valve.
  • Page 118 Section 13: Parts List and Drawings Installation, Operation and Maintenance Manual FCIM-20206-EN Rev. 0 February 2025 Table 18. Parts List Item Quantity Description Item Quantity Description Item Quantity Description Screw Worm wheel Column Terminal board Planicentric Torque plate cover assembly * O-ring Guide bush Screw...
  • Page 119 Installation, Operation and Maintenance Manual Section 13: Parts List and Drawings FCIM-20206-EN Rev. 0 February 2025 Figure 66. F01-3000 - Planicentric Assembly 30.1 30.2 30.3 30.4 30.5 30.4 30.2 30.3 30.2 30.6 30.7 30.8 Table 19. Parts List Item Quantity Description 30.1...
  • Page 120 Section 13: Parts List and Drawings Installation, Operation and Maintenance Manual FCIM-20206-EN Rev. 0 February 2025 Figure 67. F01-3000 - Worm Gear Assembly 49.7 49.6 49.5 49.4 49.3 49.2 49.1 Table 20. Parts List Item Quantity Description 49.1 Stop ring 49.2...
  • Page 121 Installation, Operation and Maintenance Manual Section 13: Parts List and Drawings FCIM-20206-EN Rev. 0 February 2025 Figure 68. F01-3000 - Torque/Position Assembly 61.1 61.3 61.5 61.7 61.9 61.11 61.13 61.2 61.4 61.6 61.8 61.10 61.12 Table 21. Parts List Item...
  • Page 122 Section 13: Parts List and Drawings Installation, Operation and Maintenance Manual FCIM-20206-EN Rev. 0 February 2025 Figure 69. F01-3000 - Local Interface Assembly 72.6 72.5 72.4 72.3 72.2 72.1 Table 22. Parts List Item Quantity Description 72.1 Plug 72.2 * Screw 72.3...
  • Page 123 Installation, Operation and Maintenance Manual Notes FCIM-20206-EN Rev. 0 February 2025 This page is intentionally left blank...
  • Page 124 FCIM-20206-EN © 2025 Biffi. All rights reserved. Biffi Italia s.r.l. Strada Biffi 165 The contents of this publication are presented for information purposes 29017 Fiorenzuola d’Arda (PC) only, and while every effort has been made to ensure their accuracy, they...

This manual is also suitable for:

F01-3000/150F01-3000/300F01-3000/600

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