BIFFI ALGAS-MHW User manual

“ALGAS-MHW or MRHW"

Use and maintenance manual

Contents may change without notice

Use and maintenance manual

ALGAS-MHW or MRHW

(*DMHW or *DMRHW)

SPRING RETURN PNEUMATIC

ACTUATOR WITH HANDWHEEL MANUAL

OVERRIDE

(*D= declutch-able type)

MAN 604-1A

03/12/19

Added Declutch-able type

Ermanni

Orefici

Vigliano

21/03/18

Update Data-plate

Ermanni

Orefici

Vigliano

18/04/16

Updated applicable

regulation (chapter 1.1.1)

Ermanni

Orefici

Vigliano

11/06/12

Updated chapter G

and chapter H

Ermanni

Stoto

Vigliano

Rev.

Date

Description

Prepared

Checked

Approved

“ALGAS-MHW or MRHW"

Use and maintenance manual

Contents may change without notice

INDEX

1 General warnings _____________________ 4

1.1 Generalities ________________________________________4

1.1.1 Applicable regulation_______________________________4

1.1.2 Terms and conditions ______________________________4

1.2 Identification plate___________________________________5

1.3 Description of the actuator____________________________5

2 Installation____________________________ 7

2.1 Checks to be carried out on receiving the actuator ________7

2.2 Storage____________________________________________7

(for handling and lifting procedure, please refer to following

figures: 2.1- 2.2- 2.3) ____________________________________7

2.3 Assembling the actuator onto the valve _________________8

2.3.1 Types of assembly ________________________________8

2.3.2 Valve stem with vertical axis :_______________________12

2.3.3 Valve stem with horizontal axis :_____________________16

3 Operation and Use ___________________ 19

3.1 Setting of the angular stroke _________________________19

3.1.1 Travel stop screw screwed on the end of manual override 19

3.1.2 Travel stop screw screwed on the end of mechanical manual

override ____________________________________________20

3.1.3 Travel stop screw screwed on the end flange of spring

container ___________________________________________21

3.2 Calibration of limit switches__________________________23

3.3 Calibration of operating time in supply operation ________24

3.4 Preparation for start-up______________________________25

3.4.1 Pneumatic connections____________________________25

3.4.2 Electrical connections_____________________________25

3.5 Start-up___________________________________________26

4 Operational tests and inspections _____ 27

5 Maintenance _________________________ 28

5.1 Routine maintenance _______________________________28

5.2 Special maintenance________________________________29

5.2.1 Replacement of cylinder seals ______________________30

5.2.2 Replacement of the seals of manual override “MHW”: ____33

5.2.3 Replacement of the seals of reduced-manual override

“MRHW”____________________________________________34

5.3 Lubrication of mechanism ___________________________38

5.4 Dismantling and demolition __________________________42

6 Troubleshooting _____________________ 43

“ALGAS-MHW or MRHW"

Use and maintenance manual

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6.1 Failure or breakdown research _______________________43

7 Parts List ____________________________ 44

7.1 Spare parts order___________________________________44

7.2 Parts-list for maintenance and replacing procedure ______44

8 Date report for maintenance operations 50

NOTES:

BIFFI Italia has taken every care in collecting and verifying the

documentation contained in this instruction and operating manual.

Nevertheless Biffi Italia does not provide any guarantees for this

instruction manual. BIFFI Italia 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 and is subject to being modified without

notice.

“ALGAS-MHW or MRHW"

Use and maintenance manual

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1 General warnings

The manual is an integral part of the machine, it should

be carefully read before carrying out any operation and

it should be kept for future references.

1.1 Generalities

BIFFI Italia S.r.l actuators are conceived, manufactured and

controlled according to the Quality Control System in compliance with

EN-ISO 9001 international regulation.

1.1.1 Applicable regulation

EN ISO 12100:2010: Safety of machinery –General principles for

design –Risk assessment and risk reduction

2006/42/EC: Machine directive.

2014/68/EU: Directive for pressure PED equipment

2014/35/EU: Directive for low voltage equipment

2014/30/EU: Directive for the electromagnetic compatibility

2014/34/EU: Directive and safety instructions for use in

hazardous area

1.1.2 Terms and conditions

Biffi Italia srl 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. The warranty can last either one year from the date of

installation by the initial user of the product, or eighteen months from

the date of shipment to the initial user, depending on which event

occurs first. All detailed warranty conditions are specified in the

documentation forwarded together with the product. This warranty

does not cover special products or components not warranted by

subcontractors, or materials that were used or installed improperly or

were modified or repaired by unauthorized staff. In the event that a

fault condition be caused by improper installation, maintenance or

use, or by irregular working conditions, the repairs will be charged

according to applicable fees. The warranty and Biffi Italia srl

liability shall lapse in the event that any modification or

tampering whatsoever be performed on the actuator.

“ALGAS-MHW or MRHW"

Use and maintenance manual

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1.2 Identification plate

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 (Figure1).

Figure 1 –Data plate

1.3 Description of the actuator

ALGAS low pressure pneumatic spring return, are suitable for the

operation of quarter turn valves (ball valves, butterfly valves, plug

valves) in both ON-OFF and modulating heavy-duty service.

The actuator is made up of a weatherproof scotch yoke mechanism

transforming the linear movement of the pneumatic cylinder (or

mechanical manual override, if foreseen) and of the spring into the

rotary movement, which is necessary for operation.

The spring return pack incorporates up to four springs, fully

encapsulated in a factory welded cartridge: this ensures safety to

personnel and simplifies assembly. The spring action can be easily

changed in the field from to close in to open or from to open in to

close (modular design).

The angular stroke of the yoke is adjustable between 82° and 98° by

means of the external mechanical stops screwed into the end flange

of the pneumatic cylinder and into the end flange of the spring return

pack . The cover of the scotch yoke mechanism is arranged for the

assembly of the required accessories (position-transmitter, signaling-

limit switches, positioner , etc.) by means of proper matching units.

The above mentioned accessories are operated by the actuator drive

sleeve.

“ALGAS-MHW or MRHW"

Use and maintenance manual

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The housing of the scotch yoke mechanism has a flange with

threaded holes to fix the actuator to the valve either directly or, if

required, with the interposition of an adaptor flange or a mounting

bracket.

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's care), according to the shape and

dimensions of the valve stem.

BIFFI can supply different types of control system following

Customer's requirements.

K - - -

Manual Override

Blank = No Manual Override

MHP = Manual Pump

MHW = Manual Handwheel

MRHW = Manual Reduced Handwheel

Service

Blank = Standard

QA = Quick Acting

Spring Action

CL = Closing

OP = Opening

Cylinder Size

Internal diametre in mm

Spring Cartridge Size

Yoke Shape

C = Canted

S = Symmetric

Scotch-yoke mechanism size

Actuator Series

ALGAS

Single Acting Low Pressure

Pneumatic Actuators

- Coding System -

! @ç $ flow control

ALGAS

XXX

YYYYY

ZZZZ

The expected lifetime of actuator is approximately 25 years .

“ALGAS-MHW or MRHW"

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2 Installation

2.1 Checks to be carried out on receiving the actuator

1) If the actuator arrives already assembled onto the valve, the

settings of the mechanical stops and of the micro switches (if

existing) has already been made by the person who assembled the

actuator onto the valve. If the actuator arrives separately from the

valve, the settings of the mechanical stops and of the micro

switches (if existing) must be checked and, if necessary, carried out

while assembling the actuator onto the valve.

2) Check that the actuator has not been damaged during transport. If

necessary, repair all damages to the paint-coat, etc.

3) Check that the model, the serial number of the actuator and the

performance data written on the data-plate are in accordance with

those described on the order acknowledgement, test certificate and

delivery note.

4) Check that the fitted accessories comply with those listed in the

order acknowledgement and the delivery note.

2.2 Storage

(for handling and lifting procedure, please refer to

following figures: 2.1- 2.2- 2.3)

The actuators leave the factory in excellent working conditions and

with an excellent finish (these conditions are guaranteed by an

individual inspection certificate); in order to maintain these

characteristics until the actuator is installed on the plant, it is

necessary to observe a few rules and take appropriate measures

during the storage period.

1) Make sure that plugs are fitted in the air connections and in the

cable entries. The plastic plugs, which close the inlets, do not have

a weatherproof function, but are only a means of protection against

the entry of foreign matter during transport. If long-term storage is

necessary and especially if the storage is outdoors, metal plugs

must replace the plastic protection plugs, which guarantee a

complete weatherproof protection.

2) If the actuators are supplied separately from the valves, they must

be placed onto a wooden pallet so as not to damage the coupling

flange to the valve. In case of long-term storage, the coupling parts

(flange, drive sleeve, insert bush) must be coated with protective oil

or grease. If possible, blank off the flange by a protection disk.

“ALGAS-MHW or MRHW"

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3) In case of long-term storage, it is advisable to keep the actuators in

a dry place or to provide at least some means of weather

protection. If possible, it is also advisable, to periodically operate

the actuator with filtered, dehydrated and lubricated air; after such

operations all the threaded connections of the actuator and the

valves of the control panel (if existing) should be carefully plugged.

2.3 Assembling the actuator onto the valve

2.3.1 Types of assembly

For coupling to the valve, the housing is provided with a flange with

threaded holes according to Biffi standard tables (SCN6200;

SCN6200-1; SCN6201; SCN6201-1). 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 centreline in order

to allow an easier assembly of an intermediate flange, when required.

This intermediate flange ( or spool-piece ) can be supplied when the

valve flange cannot directly match the actuator flange in its “standard”

configuration. For the biggest actuator models, the actuator flange can

be machined in accordance with the valve flange dimensions.

The yoke has bored with keyways for coupling to the valve stem, the

dimensions of which are according to Biffi standard tables SCN6200*

and SCN6201*.

“ALGAS-MHW or MRHW"

Use and maintenance manual

Contents may change without notice

“ALGAS-MHW or MRHW"

Use and maintenance manual

Contents may change without notice

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