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BIFFI OLGAS-H Installation, Operation And Maintenance Manual

Spring-return high pressure hydraulic actuator
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Installation, Operation and Maintenance Manual  
MAN 609 Rev. 7
March 2025
Biffi OLGAS-H
Spring-Return High Pressure Hydraulic 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' 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 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’ A rda (PC) – Italy PH: +39 0523 944 411 – biffi_italia@biffi.it...
  • Page 2 Revision Details Installation, Operation and Maintenance Manual March 2025 MAN 609 Rev. 7 Revision Details Revision Date Description Prepared Checked Approved March 2025 General update Franco July 2021 General update (Migration to new template) April 2018 Updated Data plate Ermanni Orefici Vigliano April 2016...

  • Page 3: Table Of Contents

    Emergency Manual Operation ............23 3.3.2 Remote Control Operations ..............25 Calibration of the Angular Stroke ..............27 Calibration of Microswitches (Biffi Limit Switch Box Only) ......31 Calibration of the Operation Time (If Required) ..........34 Section 4: Operational Tests and Inspections Operational Tests and Inspections ................35...
  • Page 4 Table of Contents Installation, Operation and Maintenance Manual March 2025 MAN 609 Rev. 7 Section 5: Maintenance Periodic Maintenance ..................36 5.1.1 Check and Restore Oil Level in the Hydraulic Manual Hand Pump ............37 Extraordinary Maintenance ................39 5.2.1 Replacement of Cylinder Seal ............40 Lubrication of Mechanism .................44 Dismantling and Tear Down ................45 Section 6: Troubleshooting...

  • Page 5: Section 1: General Warnings

    Biffi pays the highest attention to collecting and verifying the documentation contained in this user manual. However Biffi is not liable for any mistakes contained in this manual, for damage or accidents due to the use of the latter. The information contained is of exclusive reserved ownership of Biffi and may be modified without prior notice.

  • Page 6: Terms And Conditions

    1.1.2 Terms and Conditions Biffi guarantees that all the items produced are free of defects in workmanship and manufacturing materials and meet relevant current specifications, provided they are installed, used and serviced according to the instructions contained in the present manual.

  • Page 7: Identification Plate

    March 2025 Identification Plate WARNING It is forbidden to modify the information and the marks without previous written authorization by Biffi. The plate fastened on the actuator contains the following information (Figures 2 and 3). Figure 2. Nameplate Base (Sample)

  • Page 8: Description Of The Actuator

    (by Biffi or at customer's care), according to the shape and dimensions of the valve stem. Biffi can supply different types of control system following customer's requirements.

  • Page 9: Section 2: Installation

    For coupling to the valve, the housing is provided with a flange with threaded holes according to Biffi standard tables (SCN6200 SCN6201). The number, dimensions and diameter of the holes are made in accordance with ISO 5211, but for actuator models 0.3 to 6 the holes are drilled on the centerline in order to allow an easier assembly of...
  • Page 10 Section 2: Installation Installation, Operation and Maintenance Manual March 2025 MAN 609 Rev. 7 Figure 5. Coupling Dimensions - Actuator Models 0.3 to 6 (SCN6200 - Rev. 15/10/19) DRIVE SLEEVE Ød +0.1 Ød Ød ±0.2 Ød N. THREADED HOLES PCD, NUMBER AND SIZE ACCORDING TO ISO 5211 (BUT THE HOLES ARE ON CENTERLINE INSTEAD OF...
  • Page 11 Installation, Operation and Maintenance Manual Section 2: Installation MAN 609 Rev. 7 March 2025 Figure 6. Coupling Dimensions - Actuator Model 14 (SCN6201 - Rev. 16/06/20) DRIVE SLEEVE Ød Ød +0.1 Ød ±0.2 Ød N. THREADED HOLES PCD, HOLES, NUMBER AND SIZE ACCORDING TO ISO 5211 FLOW LINE Ø...
  • Page 12 Section 2: Installation Installation, Operation and Maintenance Manual March 2025 MAN 609 Rev. 7 Figure 7. Coupling Dimensions - Actuator Models 18 and 32 (SCN6201 - Rev. 16/06/20) DRIVE SLEEVE Ød Ød +0.1 Ød ±0.2 Ød N. THREADED HOLES P.C.D. AND HOLES SIZE ACCORDING TO ISO (NUMBER AND THREAD DEPTH IS NOT ACCORDING TO ISO 5211) W D10...
  • Page 13 Installation, Operation and Maintenance Manual Section 2: Installation MAN 609 Rev. 7 March 2025 Figure 8. Coupling Dimensions - Actuator Model 50 (SCN6201-1 - Rev. 15/10/19) DRIVE SLEEVE Ød Ød +0.1 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 14 Section 2: Installation Installation, Operation and Maintenance Manual March 2025 MAN 609 Rev. 7 Figure 9. Coupling Dimensions - Actuator Models 65 and 80 (SCN6201-3 - Rev. 19/06/20) DRIVE SLEEVE Ød Ød +0.1 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)
  • Page 15 Installation, Operation and Maintenance Manual Section 2: Installation MAN 609 Rev. 7 March 2025 Figure 10. Coupling Dimensions - Actuator Model 100 (SCN6201-5 - Rev. 22/07/22) DRIVE SLEEVE Ød Ød +0.1 Ød ±0.2 Ød N. THREADED HOLES P.C.D. NUMBER AND HOLES SIZE ACCORDING TO ISO (BUT THE HOLES ARE ON CENTERLINE AND THREAD DEPTH IS NOT...
  • Page 16 A-A, from position 1 Insert bush turned upside down The Biffi insert bush with 2 external keys at 45° allows to position the keyway for the valve every 90°. Consequently, actuator can be mounted in 4 positions at 90° on top of the valve.

  • Page 17: Actuator Handling (Valve Stem With Vertical Axis)

    Installation, Operation and Maintenance Manual Section 2: Installation MAN 609 Rev. 7 March 2025 2.3.2 Actuator Handling (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 18 Section 2: Installation Installation, Operation and Maintenance Manual March 2025 MAN 609 Rev. 7 Figure 13. Lifting Points for OLGAS-H Actuators LIFTING POINTS (OBLIGATORY) BALANCING POINT LIFTING POINTS (OBLIGATORY) DO NOT LAY THE ACTUATOR ON TIE-RODS OF CYLINDER/S AND DON’T LAY THE ACTUATOR ON...
  • Page 19 Installation, Operation and Maintenance Manual Section 2: Installation MAN 609 Rev. 7 March 2025 • When lifting unbalanced loads, use ropes of different lengths or chains with adjustable length. • Always check the condition of all lifting equipment used and discard it if not in perfect working order.
  • Page 20 March 2025 MAN 609 Rev. 7 When the transporting OLGAS-H with a hydraulic manual hand pump (Figure 14), it is necessary to place the tank of MHP in a horizontal position, to avoid leakage on oil level stick, substitute these with a blind-plug during the transport (a specific warning label for transport in horizontal position is attached on the MHP body);...
  • Page 21 Installation, Operation and Maintenance Manual Section 2: Installation MAN 609 Rev. 7 March 2025 For actuator assembly on the valve: NOTICE Check that the assembly position, as shown on the documentation, complies with system’s geometry. Check the consistency of the parts of the actuator-valve coupling. •...

  • Page 22: Valve Stem With Horizontal Axis

    Section 2: Installation Installation, Operation and Maintenance Manual March 2025 MAN 609 Rev. 7 2.3.3 Valve Stem with Horizontal Axis The actuator can also be lifted to assemble directly onto the valve with stem with horizontal axis. To make a correct lifting procedure, proceed as follow: Connect properly the actuator lifting points 1 with chains, and connect by suitable slings the support brackets 2 and 3.
  • Page 23 Installation, Operation and Maintenance Manual Section 2: Installation MAN 609 Rev. 7 March 2025 Balance the weight and lift the actuator until it can rotate in its final mounting position, with the cylinder on top or the spring container placed on top, as shown in Figure 17.

  • Page 24: Hydraulic Connections

    Section 2: Installation Installation, Operation and Maintenance Manual March 2025 MAN 609 Rev. 7 Hydraulic Connections WARNING Check that the values of hydraulic supply available are compatible with those reported on the identification plate of the actuator. NOTICE The connections should be made by qualified staff. Use pipes, fittings and connections appropriate as for type, material and dimensions.

  • Page 25: Electrical Connections (If Present Or Applicable)

    Installation, commissioning and maintenance and repair works should be made by qualified staff. Any calibration relative to functional aspects of the actuator are preset at the factory. Before any modifications, please contact Biffi. Upon actuator commissioning, please carry out the following checks: •...

  • Page 26: Section 3: Operation And Use

    (if the optional double hydraulic chamber is present). For local or remote operations, please refer to technical documentation supplied with actuators. WARNING For all the relevant information, please refer to the specific documentation supplied. Figure 18. OLGAS-H General Sectional Cutoff Operation and Use...

  • Page 27: Residual Risks

    Refer to specific document: operating diagram furnished. 3.3.1 Emergency Manual Operation The OLGAS-H actuators can have an emergency manual override in addition to the local and/or remote control panel which controls the oil supplied by a power pack for the “normal” actuator operation.
  • Page 28 Section 3: Operation and Use Installation, Operation and Maintenance Manual March 2025 MAN 609 Rev. 7 Figure 20. OLGAS-H with Hydraulic Power Pack Figure 21. OLGAS-H with MHP General Arrangement HYDRAULIC CONNECTION TO THE HYDRAULIC CONTROL PANEL SCOTCH YOKE MECHANISM...

  • Page 29: Remote Control Operations

    March 2025 3.3.2 Remote Control Operations Biffi has the ability to apply advanced engineering technology to the design and manufacture of hydraulic controls and accessories. The experience and the knowledge acquired in the actuator industry allows Biffi to meet with the highest requirements for control modes and operating conditions by the correct selection of schematics, components, materials and protection treatment.
  • Page 30 March 2025 MAN 609 Rev. 7 Biffi has the ability to apply advanced engineering technology to the design and manufacture of hydraulic power packs, in order to meet with the highest requirements for operating modes and working conditions by a correct selection of schematics, components, materials and protection treatment.

  • Page 31: Calibration Of The Angular Stroke

    Installation, Operation and Maintenance Manual Section 3: Operation and Use MAN 609 Rev. 7 March 2025 Calibration of the Angular Stroke The angular stroke of the yoke can be adjusted between 82° and 98° (±4° with respect to the nominal positions of complete opening and closing) by means the mechanical stops screwed at the end of spring cartridge, and into the end flange of the pneumatic cylinder (Figure 24).
  • Page 32 Section 3: Operation and Use Installation, Operation and Maintenance Manual March 2025 MAN 609 Rev. 7 Figure 25. Mechanical Stop of the Cylinder Table 9. Travel Stop Adjustment Tools Size Hydraulic Cylinder Diameter Allen Key C1 (mm) Wrench C2 (mm) From 16 to 28 From 28 to 40 From 45 to 60...
  • Page 33 Installation, Operation and Maintenance Manual Section 3: Operation and Use MAN 609 Rev. 7 March 2025 For the adjustment of the travel stop screw, proceed as follows: Figure 26. Spring Cartridge Models from 006 to 150 Figure 27. Spring Cartridge Models from 200 to 15600 Loosen the lock nut “d”.
  • Page 34 Section 3: Operation and Use Installation, Operation and Maintenance Manual March 2025 MAN 609 Rev. 7 To operate the adjustments, refer to following tables: Table 10. Travel Stop Adjustment Tools Size Spring Container Size Allen Key C1 (mm) Wrench C2 (mm) 0100 0150 Table 11.

  • Page 35: Calibration Of Microswitches (Biffi Limit Switch Box Only)

    Section 3: Operation and Use MAN 609 Rev. 7 March 2025 Calibration of Microswitches (Biffi Limit Switch Box Only) NOTICE Operate only the microswitch corresponding to the direction of operation being carried out, as clearly reported on the microswitch. WARNING If different microswitches assembly or limit switch box is supplied, please refer to the specific documentation.
  • Page 36 Section 3: Operation and Use Installation, Operation and Maintenance Manual March 2025 MAN 609 Rev. 7 Figure 28. Microswitches Box Figure 29. Cam Adjustment Operation and Use...
  • Page 37 Installation, Operation and Maintenance Manual Section 3: Operation and Use MAN 609 Rev. 7 March 2025 If the index (Figure 30), 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 38: Calibration Of The Operation Time (If Required)

    Calibration of the Operation Time (If Required) 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’s possible to modify or reset the operating time through the two flow regulation valves (optional) placed on inlets of the hydraulic cylinder (see Figure 31 and the applicable operating diagram).

  • Page 39: Section 4: Operational Tests And Inspections

    Installation, Operation and Maintenance Manual Section 4: Operational Tests and Inspections MAN 609 Rev. 7 March 2025 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 40: Section 5: Maintenance

    Section 5: Maintenance Installation, Operation and Maintenance Manual March 2025 MAN 609 Rev. 7 Section 5: Maintenance NOTICE Before carrying out any maintenance operation, it is necessary to close the hydraulic feed line and exhaust the pressure from the actuator cylinder and from the control unit, to ensure safety of maintenance staff.

  • Page 41: Check And Restore Oil Level In The Hydraulic Manual Hand Pump

    Installation, Operation and Maintenance Manual Section 5: Maintenance MAN 609 Rev. 7 March 2025 Figure 32. Level Measuring Stick Maximum level Minimum level 5.1.1 Check and Restore Oil Level in the Hydraulic Manual Hand Pump Operate the distributor lever to “manual operation” to operate valve and to compress completely the actuator spring.
  • Page 42 The cleanliness level for actuator without control-system is NAS 8 minimum. For actuators with control system, the cleanliness level is that required by singles components, in any case, Biffi respects the customer's requirements to scope of supply, for applicable cleanliness level, refer to document: technical data sheet for actuators.

  • Page 43: Extraordinary Maintenance

    Installation, Operation and Maintenance Manual Section 5: Maintenance MAN 609 Rev. 7 March 2025 Extraordinary Maintenance If there are leaks in the hydraulic cylinder, or a malfunction in the mechanical components, or in case of scheduled preventive maintenance, the actuator must be disassembled and seals must be replaced with reference to the following general sectional drawing and adopting the following procedures: WARNING...

  • Page 44: Replacement Of Cylinder Seal

    Section 5: Maintenance Installation, Operation and Maintenance Manual March 2025 MAN 609 Rev. 7 5.2.1 Replacement of Cylinder Seal Unscrew the plug (27) from the cylinder end flange. Measure the distance of the stop screw (21) with reference to the end flange (26) surface, so as to be able to easily restore the setting of the actuator mechanical stop, once the maintenance procedures have been completed.
  • Page 45 Installation, Operation and Maintenance Manual Section 5: Maintenance MAN 609 Rev. 7 March 2025 5.2.1.1 Seals Replacement Prior to reassemble check that the actuator components are in good conditions and clean. Lubricate all the surfaces of the parts, which move in contact with other components, by recommended oil (ARNICA 22 or the oil used in the hydraulic cylinder).
  • Page 46 Section 5: Maintenance Installation, Operation and Maintenance Manual March 2025 MAN 609 Rev. 7 5.2.1.2 Reassemble Assemble the new gasket (46-48) after cleaning the surfaces of housing (8), the flange (47) and head flange (34) which are in contact. Assemble the head flange (34), replace the washers if damaged, tighten the screws (17) to the recommended torque.
  • Page 47 Installation, Operation and Maintenance Manual Section 5: Maintenance MAN 609 Rev. 7 March 2025 Figure 35. OLGAS-H Spring-Return Hydraulic Actuator Table 13. Parts List Item Description Item Description Stop setting screw Spring container Guide rod Spring Spring thrust flange Rod bushing...

  • Page 48: 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 49: Dismantling And Tear Down

    Installation, Operation and Maintenance Manual Section 5: Maintenance MAN 609 Rev. 7 March 2025 Dismantling and Tear Down Before starting the disassembly, a large area should be created around the actuator so to allow any kind of movement without problems of further risks created by worksite.

  • Page 50: Section 6: Troubleshooting

    Lack of power supply Restore it Lack of hydraulic supply Open line interception valve Failure of the spring Call Biffi Customer Service Actuator does not work Blocked valve Repair or replace Wrong position of the distributor of the Restore correct position...

  • Page 51: Section 7: Spare Parts

    Section 7: Spare Parts Spare Parts Order For spare parts order to the relevant Biffi office, please make reference to Biffi order confirmation concerning all the supply, and serial number of the actuator (Section 1.2) for any specific spare part for a specific actuator model.

  • Page 52: Parts List For Maintenance And Replacing Procedure

    Section 7: Spare Parts Installation, Operation and Maintenance Manual March 2025 MAN 609 Rev. 7 Parts List for Maintenance and Replacing Procedure Figure 36. Scotch Yoke Mechanism Table 15. Parts List Item Quantity Description Material O-ring Nitrile Butadiene Rubber (NBR) * Yoke bushing Bronze Retainer ring...
  • Page 53 Section 7: Spare Parts Installation, Operation and Maintenance Manual MAN 609 Rev. 7 March 2025 Figure 37. Hydraulic Cylinder Table 16. Parts List Item Quantity Description Material Piston rod bushing Steel + Bronze + PTFE Head flange Nickel plate carbon steel O-ring NBR * Piston rod seal ring...
  • Page 54 Section 7: Spare Parts Installation, Operation and Maintenance Manual March 2025 MAN 609 Rev. 7 Figure 38. Spring Cartridge Table 17. Parts List Item Quantity Description Material Carbon steel Washer Carbon steel Sealing washer Polyvinyl Chloride (PVC) * Stop setting screw Carbon steel Spring container Carbon steel...
  • Page 55 Section 7: Spare Parts Installation, Operation and Maintenance Manual MAN 609 Rev. 7 March 2025 Figure 39. Assembly Kit Table 18. Parts List Item Quantity Description Material Screw PTFE coated alloy steel Gasket Fiber * Plug Carbon steel Washer Carbon steel Screw Alloy steel Gasket...
  • Page 56 Section 7: Spare Parts Installation, Operation and Maintenance Manual March 2025 MAN 609 Rev. 7 Figure 40. Hydraulic Control Unit MHP Spare Parts...
  • Page 57 Section 7: Spare Parts Installation, Operation and Maintenance Manual MAN 609 Rev. 7 March 2025 Table 19. Parts List Item Quantity Description Material Plate Carbon Steel Stuffing box Aluminum Seal ring PTFE + Graphite Stem Stainless steel Plug Stainless steel Oil tank Carbon steel Oil tank cover...
  • Page 58 Section 7: Spare Parts Installation, Operation and Maintenance Manual March 2025 MAN 609 Rev. 7 Figure 41. Hydraulic Control Unit - Hand Pump Table 20. Parts List Item Quantity Description Material Ball Stainless steel Delivery valve bush Carbon steel Suction valve bush Carbon steel Spring Stainless steel...

  • Page 59: Date Report For Maintenance Operations

    Installation, Operation and Maintenance Manual Section 8: Maintenance Operations MAN 609 Rev. 7 March 2025 Section 8: Date Report for Maintenance Operations Last maintenance operation date: (in factory, on delivery): ……… exec. by: ………… ……… exec. by: ………… ……… exec. by: ………… Next maintenance operation date: ………...
  • Page 60 Biffi Italia s.r.l. VCIOM-03746-EN © 1999, 2025 Biffi. All rights reserved. Strada Biffi 165 29017 Fiorenzuola d’Arda (PC) The contents of this publication are presented for informational purposes Italy only, and while every effort has been made to ensure their accuracy,...

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