BIFFI OLGA-H Installation, Operation And Maintenance Manual

Page 1

BIFFI OLGA-H HIGH PRESSURE DOUBLE ACTING HYDRAULIC ACTUATOR

INSTALLATION, OPERATION AND MAINTENANCE MANUAL

Before installation these instructions must be read fully and understood

1.1.1 Applicable regulation

EN ISO 12100-1: 2005: Safety of machinery – Basic notions, general design principles� Part 1-Basic terminology, method� EN ISO 12100-2: 2005: Safety of machinery – Basic notions, general design principles� Part 2-Technical principles and specification� 2006/42/EC: Machine directive� 97/23/EC: Directive for pressure PED equipment� 2006/95/EC: Directive for low voltage equipment� 2004/108/EC: Directive for the electromagnetic

TABLE OF CONTENTS

1 General warnings �� 1 2 Installation �� 3 3 Operation and use �� 9 4 Operational tests and inspections�� 23 5 Maintenance� �� 23 6 Troubleshooting �� 30 7 Layouts �� 30 8 Date report for maintenance operations �� 39

1 GENERAL WARNINGS

IMPORTANT

The manual is an integral part of the machine. It should be read carefully before carrying out any operation and should be kept for future reference.

1.1 Generalities

Biffi� actuators are conceived, manufactured and controlled according to a Quality Control System in compliance with EN ISO 9001 international regulation�

compatibility� 94/9/EC: Directive and safety instructions for use in hazardous area�

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� 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�

VCIOM-03744-EN 17/12

Page 2

BIFFI OLGA-H HIGH PRESSURE DOUBLE ACTING HYDRAULIC ACTUATOR

INSTALLATION, OPERATION AND MAINTENANCE MANUAL

FIGURE 1 Data plate

1.2 Identification plate

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 (figure 1)�

1.3 Introducing the actuator

The hydraulic actuator series OLGA-H is engineered and manufactured to provide maximum torque output with minimum supply pressure� OLGA-H actuators are suitable for the operation of any quarter turn operation such of ball, plug, butterfly valves or dampers, in both On-Off and Modulating heavy duty service�

The actuator (see figure 2) is made up of a weatherproof Scotch yoke mechanism transforming the linear movement of the pneumatic cylinder (on closing or opening) into the rotary movement, which is necessary for operation� The angular stroke of the yoke is adjustable between 82° and 98° by means of the external mechanical stops screwed into the left wall of the mechanism housing and into the end flange of the pneumatic cylinder� The cover of the Scotch yoke mechanism is arranged for the assembly of the required accessories (positioner, signalling limit switches, position transducer, etc�) by means of proper matching units� The above mentioned accessories are operated by the actuator drive sleeve� 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 the internal hole of which 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� The expected lifetime of actuator is approximately 30 years�

1.4 Data sheet

Supply fluid Hydraulic oil, special version for

fire-resistant fluids Operating temperature Supply pressure Standard ranging from 210 to

Maximum torque

Standard: from -30°C to +100°C

Optional: from -60° to +140°C

352 bar

Up to 40�000 Nm - higher value

with special versions

Manual hand pump - MHP

Optional: for OLGA-H-MHP models

or second pneumatic cylinder for

“double-cylinders” models

Scotch yoke mechanism

FIGURE 2 Identification of actuator parts

(optional)

Hydraulic cylinder

Valve position indicator

High pressure control valve enclosure (optional)

Page 3

BIFFI OLGA-H HIGH PRESSURE DOUBLE ACTING HYDRAULIC ACTUATOR

INSTALLATION, OPERATION AND MAINTENANCE MANUAL

2 INSTALLATION

2.1 Checks upon actuator receipt

• Check that the model, the serial number of the actuator and the technical data reported on the identification plate correspond with those of order confirmation (section 1�2)�

• Check that the actuator is equipped with the fittings as provided for by order confirmation�

• Check that the actuator was not damaged during transportation: if necessary renovate the painting according to the specification reported on the order confirmation�

• If the actuator is received already assembled with the valve, its settings have already been made at the factory�

If the actuator is delivered separately

from the valve, it is necessary to check, and, if required, to adjust, the settings of the mechanical stops (section 3�4) and of microswitches (if any) (section 3�5)�

2.2 Actuator handling

IMPORTANT

The lifting and handling should be made by qualified staff and in compliance with the laws and provisions in force.

FIGURE 3A, 3B, 3C, 3D Lifting points for OLGA-H / OLGA-H-MHP / OLGA-H-MSJ actuators

3A 3B

1, 2 = Lifting points (obligatory) 3 = Balancing point

3C 3D

WARNING

The fastening points are appropriate for the lifting of the actuator alone and not for the valve and actuator assembly. Avoid that during the handling, the actuator passes above the staff. The actuator should be handled with appropriate lifting means. The weight of the actuator is reported on the delivery bill.

1 = Point of support 2 = Supports for lateral positioning

WARNING

3 = Do not lay the actuator on tie rods of cylinder /s and do not lay the actuator on accessories (manualhand pump, manual jackscrew, pneumatic control group etc.)

Page 4

BIFFI OLGA-H HIGH PRESSURE DOUBLE ACTING HYDRAULIC ACTUATOR

INSTALLATION, OPERATION AND MAINTENANCE MANUAL

For the transport of OLGA-H actuators with hydraulic manual hand-pump, when it was necessary put in horizontal position the tank of MHP, 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); remove the blind plug and restore the dipstick before operate the actuator with MHP� Biffi hydraulic manual hand-pump must be maintained with tank in upper position to operate the actuator with MHP correctly�

OMFB manual hand-pump should be transported and used with MHP tank in horizontal position, but in position 3 of the following picture (extracted from OMFB technical documentation) it’s necessary to change the position of suction pipe and breather cap:

2.3 Storage

If the actuator needs storage, before installation follow these steps:

• Place it on a wood surface in order not to deteriorate the area of valve coupling�

• Make sure that plastic plugs are present on the hydraulic and electrical connections (if present)�

• Check that the cover of the control group and of the limit switch box (if any) are properly closed�

If the storage is long-term or outdoor:

• Keep the actuator protected from direct weather conditions�

• Replace plastic plugs of pneumatic and electrical connections (if any) with metal plugs that guarantee perfect tightness�

• Coat with oil, grease or protection disc, the valve coupling area�

• Periodically operate the actuator (section 3�3)�

2.4 Actuator assembly on the valve

2.4.1 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 centerline 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 can not 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 SCN6200and SCN6201 (see next pages)�

FIGURE 4 Fixing positions

POSITION 1

Standard application

POSITION 2

Standard application

Invert the position of the breather cap

POSITION 3

Change the position of suction pipe from AtoB

and the breather cap to top side

Page 5

BIFFI OLGA-H HIGH PRESSURE DOUBLE ACTING HYDRAULIC ACTUATOR

INSTALLATION, OPERATION AND MAINTENANCE MANUAL

FIGURE 5A Actuator models 0�3 to 6

H max

+0�5

h₁

W D10

N�8 holes flange

+0�2

Ø d₅

N�4 holes flange

Top view of the Scotch yoke mechanism

(actuator shown in closed position)

FIGURE 5B Actuator models 14 to 42

Drive sleeve

H max

+0�5

h₁

+0�1

Ø d₂

±0�2

Ø d₃

Ø d₁ max

+0�4

+0�1

Ø d₄

N� threaded holes PCD, number and size according to ISO 5211 (but the holes are on centerline instead of straddle the centerline)

h₂

Flow line

Ø d₅

Ø d₂

±0�2

Ø d₃

Ø d₁ max

N� threaded holes PCD, number and size

D10

'W'

+0�2 +0�1

according to ISO 5211

+0,4

N�16 holes flange N�12 holes flange

Top view of the Scotch yoke mechanism

(actuator shown in closed position)

Drive sleeve

Ø d₄

h₂

Flow line

COUPLING DIMENSIONS MODELS 0.3 TO 0.6 (mm)

Actuator model Ø d₁ Ø d₂ Ø d₃ Ø d₄ N h₁ h₂ H max Ø d₅ W K

0�3 240 93 165 M20 4 5 17 127 70 12 75�6 0�9 310 112 254 M16 8 5 19 150 86 14 96�6 1�5 360 144 298 M20 8 6 19 190 112 18 119 3 430 195 356 M30 8 9 23 200 157 25 167�8 6 520 250 406 M36 8 14 29 260 200 28 212�8

COUPLING DIMENSIONS MODELS 14 TO 42 (mm)

Actuator model Ø d₁ Ø d₂ Ø d₃ Ø d₄ N h₁ h₂ H max Ø d₅ W K

14 580 250 483 M36 12 10 29 340 175 45 195�8 18 680 290 603 M36 16 12 32 350 200 45 220�8 32 780 290 603 M36 16 12 32 400 220 50 242�8 35 780 315 603 M36 16 11 32 400 240 50 242�8 42 840 310 603 M36 16 12 32 400 220 50 242�8

Page 6

BIFFI OLGA-H HIGH PRESSURE DOUBLE ACTING HYDRAULIC ACTUATOR

INSTALLATION, OPERATION AND MAINTENANCE MANUAL

FIGURE 5C Actuator models 50 and 60

H max

+0�5

h₁

'W'

+0�2

+0�1

Ø d₅

+0�1

Ø d₂

±0�2

Ø d₃

Ø d₁ max

D10

FIGURE 5D Insert bush + intermediate coupling flange

Drive sleeve

Ø d₄

N� threaded holes Flange sizing according to ISO 5211

h₂

Housing

Insert bush

N�8 holes flange

+0,4

Flow line

N�4 holes flange Insert bush

Drive sleeve

Adaptor flange

Standard position 1

Flow line

Drive sleeve

Top view of the Scotch yoke mechanism

(actuator shown in closed position)

Position 2 Position 3 Position 4

COUPLING DIMENSIONS MODELS 50 AND 60 (mm)

Actuator model Ø d₁ Ø d₂ Ø d₃ Ø d₄ N h₁ h₂ H max Ø d₅ W K

50 800 315 698 M36 24 10 32 430 240 56 264�8 60 840 315 698 M36 24 10 32 430 240 56 264�8

If required, for the standard models size 0�3 to 6, Biffi can supply an insert bush with un-machined bore in accordance with Biffi standard table SCN6202� On request the insert bush bore can be machined by Biffi to couple the valve stem� The particular execution of the flange and bushing allow the actuator to be

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� For biggest actuator models, the bore of the yoke can be machined according to the dimensions

of valve stem� rotated by 90° in 4 different positions according to figure 5D�

Rotate insert bush 180° around vertical-standard position (1)

Position 2 Position 3 Position 4

Rotate insert bush 180° around axis A-A, from position 2

Rotate insert bush 180° around axis A-A, from position 1

Insert bush turned upside down

Page 7

BIFFI OLGA-H HIGH PRESSURE DOUBLE ACTING HYDRAULIC ACTUATOR

INSTALLATION, OPERATION AND MAINTENANCE MANUAL

2.4.2 Assembly procedure

IMPORTANT

Failure to comply with the following procedures may impair product warranty.

WARNING

Installation, commissioning and maintenance and repair works should be carried out by qualified staff. A non-conforming assembly could be the source of serious accidents.

For actuator assembly on the valve:

IMPORTANT

Check that the assembly position, as shown on the documentation, complies with system’s geometry. Check the consistency of the parts of actuator-valve coupling.

• Operate the actuator so that it reaches the

position matching valve position (section 3�3)�

• Lubricate valve stem with oil or grease�

• Properly clean and remove grease from

coupling flange surfaces�

• Connect, if supplied separately, the

adjustment insert to valve stem and fasten it with the special fastening pins�

• Lift the actuator using the special lifting

points (section 2�2)�

• Install the actuator so that valve stem inserts

in the coupling area� This coupling should be made without forcing�

• Fasten the two parts with the threaded

connections (screws, tie rods, nuts)� If holes of coupling flanges are not aligned, adequately operate the actuator if necessary move the mechanical stops backwards (section 3�4)�

• Fasten threaded connections� Please refer to

table 1�

2.5 Pneumatic connections

IMPORTANT

Check that the values of pneumatic supply

available are compatible with those reported on

the identification plate of the actuator.

WARNING

The connections should be made by qualified

staff. Use pipes and connections appropriate as

for type, material and dimensions.

Connect the actuator to the hydraulic feed

line with fittings and pipes in accordance to

the plant specifications� They must be sized

correctly in order to guarantee the necessary

oil flow for the operation of the actuator, with

pressure drops not exceeding the maximum

allowable value� The shape of the connecting

piping must not cause excessive stress to

the inlets of the actuator� The piping must be

suitably fastened so as not to cause excessive

stress or loosening of threaded connections,

if the system undergoes strong vibrations�

Every precaution must be taken to ensure

that any solid or liquid contaminants, which

may be present in the hydraulic pipe-work to

the actuator, are removed to avoid possible

damages to the unit or loss of performance�

The inside of the pipes used for the connections

must be well-cleaned before use: wash them

with suitable substances and blow through

them with oil or nitrogen� The ends of the tubes

must be well debarred and cleaned� Once

the connections are completed, operate the

actuator and check that it functions correctly,

that the operation times meet the plant

requirements and that there are no leakages in

the hydraulic connections�

The screwing values in table 1 were calculated considering the materials ASTM A320 L7 for screws or tie rods and ASTM A194 gr�2H for the nuts�

TABLE 1 - NUTS TIGHTENING TORQUE

Threading Tightening torque (Nm)

M8 20 M10 40 M12 70 M14 110 M16 160 M20 320 M22 420 M24 550 M27 800 M30 1100 M33 1400 M36 1700

Page 8

BIFFI OLGA-H HIGH PRESSURE DOUBLE ACTING HYDRAULIC ACTUATOR

INSTALLATION, OPERATION AND MAINTENANCE MANUAL

2.6 Electrical connections (if any)

IMPORTANT

Use components appropriate as for type, material and dimensions. The connections should be made by qualified staff. Before carrying out any operation, cut line power off.

WARNING

Safety provisions: 2006/95/EC: Directive for low voltage equipment. 2004/108/EC: Directive for the electromagnetic compatibility. 94/9/CE: Directive and safety instructions for use in hazardous area

Remove plastic plugs from cables entries�

• Screw firmly the cable glands�

• Introduce connection cables�

• Make the connections in compliance

with applicable wiring diagrams on the documentation supplied�

• Screw the cable gland�

• Replace the plastic plugs of unused entries

with metal plugs�

2.7 Commissioning

WARNING

Check that values of electrical supply to the control group (if foreseen) are compatible with those on the plate on the junction box (figure 6). Installation, commissioning and maintenance and repair works should be made by qualified staff.

Upon actuator commissioning please carry out

the following checks:

• Check that paint is not be damaged during transport, if necessary repair the damages to paint coat�

• Check that the values of hydraulic supply available in the system are compatible with those reported on the identification plate of the actuator (figure 1) and on the documentation supplied�

• Check that the feed voltage values of the electric components (solenoid valve coils, microswitches, pressure switches, etc�) are compatible with those reported on the identification plate of the actuator (figure 1)�

• Check that the setting of the components of the actuator control unit (pressure regulator, pressure switches, flow control valves, etc�) meet the plant requirements�

• Carry out all kinds of operations and check their proper execution (section 3�3)�

• Check the absence of leakages in the pneumatic connections� If necessary tighten the nuts of the pipe-fittings�

• Check proper operation of all the due signalling (valve position, gas supply pressure etc�)�

• Make a complete functional test in order to verify all the operations are executed according to operating schematic diagram supplied�

FIGURE 6 Junction box on control group (if foreseen)

Ground

Page 9

BIFFI OLGA-H HIGH PRESSURE DOUBLE ACTING HYDRAULIC ACTUATOR

INSTALLATION, OPERATION AND MAINTENANCE MANUAL

3 OPERATION AND USE

3.1 Operation description

In the normal operating situation, the double acting actuator is fed by pressurized gas which flows into the relevant cylinder chamber (for example opening)� The cylinder piston stroke causes the actuator operation and the consequent valve movement to the operational position requested (in this case to the “open” position)� Upon a demand, the closing chamber the cylinder is fed by pressurized gas and at the same time the gas is discharged from the open chamber into the return line: the actuator performs the closing operation driven by the piston movement, and the valve moves from the open position to the close (safety-related) position�

For local or remote operations, please refer to section 3�3�1, 3�3�2, 3�3�3 and 3�3�4 and prior to technical documentation furnished with actuators� Typical schematics for various applications are following for information only� The power and control system are suppied on specific customer demand�

For all the relevant information please refer to the specific technical documentation supplied with actuators.

3.2 Residual risks

WARNING

The actuator has parts under pressure. Use the due caution. Use individual protections provided for by the laws and provisions in force.

FIGURE 7

PARTS LIST

Item Name

1 Housing 2 Yoke 3 Yoke bushing 4 Cover 5 Guide block pin 6 Sliding block 7 Guide block 8 Guide bar 9 Guide block bushing 10 Travel stop screw 11 Cylinder head flange 12 Piston rod bushing 13 Piston rod O-ring 14 Piston rod seal ring 15 Piston rod 16 Piston 17 Piston O-ring 18 Piston guide sliding ring 19 Piston seal ring 20 Cylinder tube 21 End flange 22 Sealing washer 23 Travel stop screw 24 Tie rod

Page 10

BIFFI OLGA-H HIGH PRESSURE DOUBLE ACTING HYDRAULIC ACTUATOR

INSTALLATION, OPERATION AND MAINTENANCE MANUAL

FIGURE 8 OLGA-H with hydraulic manual handpump

1 Scotch yoke mechanism 2 Hydraulic cylinder 3 Hydraulic manual override D Directional control valve P Hand pump R Relief valve O Oil tank

Hydraulic connections tothe hydraulic control panel (toclose) (toopen)

1 Scotch yoke mechanism 2 Hydraulic cylinder 3 Hydraulic manual override 4 Hydraulic manual selector D Directional control valve P Hand pump R Relief valve O Oil tank

3.3 Operations

(refer to specific document: operating diagram furnished)

3.3.1 Local manual operation

The OLGA-H actuators can only have the hydraulic manual override for local operation�

The compact hydraulic control unit mounted on the actuator consist of:

- hand pump

- directional control valve to select “toopen” or “toclose” actuator operation

- relief valve to prevent the oil pressure delivered by the hand pump from exceeding the maximum allowable value

- oil tank

Accessory are available on request, for instance:

- dual pilot operated check valve

- bladder-type or piston-type accumulator delivered by the hand pump from exceeding

the maximum allowable value� On request the emergency manual override can be included in the power pack�

3.3.3 Emergency manual operation by MSJ - MHW

The MSJ jackscrew manual override can be supplied for OLGA-H actuators from model 0�3 to model 3� The override is mounted on the left side of the actuator, the jackscrew end is screwed into the guide block� A bronze split screw nut is mounted inside the body� By rotating the engagement lever, the screw nut is engaged with the jackscrew� When the screw nut is engaged with the jackscrew manual operation follows by rotating the body

3.3.2 Emergency manual operation by MHP

The OLGA-H actuators can have an emergency manual override in addition to the local and/

of the screw container by a lever� The manual jackscrew, on request, could be furnished with

fixed hand-wheel welded on it� or remote control panel which controls the oil supplied by a power pack for the “normal” actuator operation� The emergency manual override, mounted on the actuator, consists of a hydraulic manual override and a

hydraulic manual selector to choose actuator “Normaloperation” with oil supply from

a power pack, or the “Emergency manual operation”� Thecompact hydraulic override

consist of:

- hand pump

- directional control valve to select the

“toopen” or “toclose” operation by handpump

- relief valve to prevent the oil pressure

delivered by the hand pump from exceeding

the maximum allowable value On request the emergency manual override can be included in the power pack�

Page 11

BIFFI OLGA-H HIGH PRESSURE DOUBLE ACTING HYDRAULIC ACTUATOR

INSTALLATION, OPERATION AND MAINTENANCE MANUAL

FIGURE 9A, 9B Mechanical stops

3.4 Calibration of the angular stroke

The angular stroke of the yoke can be adjusted between 82°÷98° (±4° with respect to the nominal positions of complete opening and closing) by means the mechanical stops screwed into the left side of the housing (open valve) and into the end flange of the hydraulic cylinder (closing) (figures 9A, 9B)�

For the adjustment of the mechanical stop on the end flange of cylinder, follow these steps (Figure 10):

• Remove with the specific wrench (c2) the plug of cylinder end-flange�

• Insert a wrench for Allen keys (c1) in the through hole until reaching the adjustment pin�

• Turn counter-clockwise to increase the angular stroke, turn clockwise to decrease it�

• When the adjustment is over tighten the plug with the wrench c2�

FIGURE 10 Mechanical stop of the cylinder

Hydraulic cylinder diameter

16 - 28 8 19 28 - 40 8 22 45 - 60 12 27 70 - 175 14 36 200 - 235 22 36 235 - 300 22 36

Wrench c1

(mm)

Wrench c2

(mm)

Page 12

BIFFI OLGA-H HIGH PRESSURE DOUBLE ACTING HYDRAULIC ACTUATOR

INSTALLATION, OPERATION AND MAINTENANCE MANUAL

For the adjustment of the mechanical stop srewed into the left side of housing, follow these steps (figures 11A and 11B):

• Loosen the locknut (d) with the specific wrench (c2)�

• Adjust the pin (g)/screw (v) with the adequate wrench (c1)�

• Turn counter-clockwise to increase the angular stroke, turn clockwise to decrease it�

• When the adjustment is over tighten the locknut (d)�

FIGURE 11A, 11B Mechanical stop on the housing

Wrench c1

Actuator model

0,1 30 30 0,3 30 30 0,9 30 30 1,5 41 41 3 41 41 6 46 46

(mm)

Wrench c2

(mm)

Wrench c1

Actuator model

14 17 60 18 17 60 32 17 60 50 17 60

(mm)

Wrench c2

(mm)

For the adjustment of the mechanical stop screwed on the end flange of manual override (see section 7�2 figure 33: sectional drawing for manual jackscrew MSJ)�

FIGURE 12A, 12B Mechanical stop on the end flange of manual override

Wrench c1

(mm)

0,1 34 34 0,3 34 34 0,9 34 34

Wrench c2

(mm)

Actuator size

1,5 24 65 3 24 65

Wrench c1

(mm)

Wrench c2

(mm)Actuator size

Page 13

BIFFI OLGA-H HIGH PRESSURE DOUBLE ACTING HYDRAULIC ACTUATOR

INSTALLATION, OPERATION AND MAINTENANCE MANUAL

3.5 Calibration of microswitches (with safety instructions for limit switch box)

If the actuator is delivered separately from the valve, it is necessary to check, and, if required, to adjust, the settings of the position signalling microswitches�

IMPORTANT

Operate only the microswitch corresponding to the direction of operation being carried out, as clearly reported on the microswitch.

WARNING

If microswitches assembly or limit switch box is supplied, please refer to the specific technical documentation.

IMPORTANT

End of stroke microswitches should be operated before the stop of the stroke of the actuator due to mechanical stops. Adjust the relative cams properly.

WARNING

Do not open when energized or when an explosive atmosphere is present.

WARNING

Electrostatic hazard, clean only with damp cloth.

Page 14

BIFFI OLGA-H HIGH PRESSURE DOUBLE ACTING HYDRAULIC ACTUATOR

INSTALLATION, OPERATION AND MAINTENANCE MANUAL

FIGURE 22 Example of operating time adjustment (if foreseen), by flow-regulator valve (pleaserefertospecific operating diagram, item 526/530 and to specific flow-regulator valve)

TECHNICAL FEATURES

Max� adjusted flow (l/min�) 10 Max� working pressure (bar) 250 Fluid viscosity range (cSt) 5 – 750 Fluid temperature range (˚C) -45 – +60 Mass (kg) 0�70 Hydraulic fluid: mineral oils Recommended filtration: 19/15 ISO 4466 (25 µ abs�) Seals in MFQ (fluoro-silicone)

Torque 30 Nm

OUT

PARTS LIST

Item Qty Name Material Type or drawing

1 1 Body AISI 316 49�144�031 2 1 Cartridge AISI 316 FT 2267/2-14-hFQSV 3 * 1 O-ring MFQ-70Sh OR 2-116 4 1 Screw A4-70 M5x5 UNI 5923 5 2 O-ring MFQ-70Sh OR 5-612 6 4 Screw A4-70 VCTEI M5x45 UNI 5931 7 1 Handwheel 11S (2011) 29�102�378 8 * 1 OR+2BK MFQ-6Sh+PTFE OR2-013 + 2BK * included in cartridge item 2

3.6 Calibration of the operating time

(optional- if foreseen)

The calibration of the operation time is made 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 two flow regulation valves (optional) placed on inlets of hydraulic cylinder (see figure 22 and the applicable operating diagram)�

To carry out the adjustment, operate the hand-wheel (turn clockwise the hand-wheel to increase the operating time or turn the hand-wheel counter-clockwise to decrease the operation time)�

For OLGA-H actuator models with manual hand pump (MHP), the operating time is adjustable through two regulation valves placed on manual hand pump body (see section 7�2 figure 32: sectional drawing for hydraulic control unit MHP)� To carry out the adjustment, use a suitable Allen wrench and follow these steps (figure 23):

Torque 5 Nm

• Remove the cap nut�

• Loosen the locknut�

• Screw with a screwdriver the setting screw to increase the operating time�

• Unscrew with a screwdriver the setting screw to decrease the operating time�

• After the adjustment is over screw the locknut and put back in place the cap nut�

FIGURE 23 Flow regulators placed on manual hand pump MHP (optional – if foreseen)�

Lock nut

Acorn nut

Adjustment screw

Page 15

BIFFI OLGA-H HIGH PRESSURE DOUBLE ACTING HYDRAULIC ACTUATOR

INSTALLATION, OPERATION AND MAINTENANCE MANUAL

4 OPERATIONAL TESTS AND INSPECTIONS

IMPORTANT

To ensure the guaranteed SIL Level, according to IEC 61508, the functionality of actuator must be checked with regular intervals of time, as described following.

For safety related applications, the following test operation has to be performed: 1� Full stroke of actuator once a year� 2� Partial stroking test at least every six

months (if applicable, please refer to operating diagram and operate accordingly)�

3� Visual inspection-checks , according to

section 5�1, but with a frequency of once a year�

4� Before start up and afterwards every

6months check accumulator pre-charging pressure (if present: please refer to technical data-sheet)�

For standard applications please refer to section 5�1�

5 MAINTENANCE

IMPORTANT

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.

WARNING

Installation, commissioning and maintenance and repair works should be carried out by qualified staff.

5.1 Periodic maintenance

OLGA-H actuators are designed to operate long-term in heavy-duty operating conditions, without maintenance needs�

IMPORTANT

Periodicity and regularity of inspections is particularly influenced by specific environmental and working conditions.

WARNING

They can be initially determined experimentally and then be improved according to actual maintenance conditions and needs.

Anyway every 2 years of operation the following is recommended:

• Check that the actuator operates the valve correctly and with the required operating times� If the actuator operation is very infrequent, carry out a few opening and closing operations with all the existing controls (remote control, local control, emergency controls, etc�), if this is allowed by the conditions of the plant�

FIGURE 24 Level measuring stick

MAXIMUM LEVEL

MINIMUM LEVEL

• Check there are no hydraulic leakages� If necessary tighten the nuts of the pipe-fittings�

• Check oil level (figure 24) into the hydraulic control unit (see section 5�1�1)

• Check the actuators did not undergo accidental damage with oil leakages found on site (section 4�1�1)�

• Check that improper closing of control-group cover did not produce the presence of condensation on it�

• Check the integrity of worn out parts (gaskets, pads etc�)�

• If there is an oil filter on the actuator, bleed the condense water accumulated in the cup by opening the drain cock� Disassemble the cup periodically and wash it with soap and water; disassemble the filter: if this is made up of a sintered cartridge, wash it with nitrate solvent and blow through with oil� If the filter is made of cellulose, it must be replaced when clogged�

5.1.1 Check and restore oil level in the hydraulic

manual override

(refer to section 7�2 figure 26)

- Operate the distributor lever to “closing manual operation”�

- Move the actuator into his “fail to close” position�

- Unscrew the dipstick (1)�

- Check that the oil level into the tank (4) is in correspondence of the “MAX LEVEL” notch of the dipstick�

- Screw and tighten the dipstick�

- If necessary substitute or add the oil, proceeding as follows:

• Remove the dipstick (1) from the tank cover (22)�

• Unscrew the plug (27) and the washer (9) to drain all the oil�

• If some dirt or/and sludge is found in the oil drained from the tank, before filling with new oil in the tank, disassemble the oil tank tube, by unscrewing the two cap nuts (2), and clean the internal surfaces of the tank� If necessary substitute the gaskets (21) of the tank�

• Replace the plug (27) and the washer (9) into the plate (11) and tighten�

• Pour the new oil into the tank through the dipstick hole (1) on the cover (22)�

• Replace the dipstick (1)�

• Add oil (refer to table 2) if in the tank the oil level is BELOW THE MINIMUM (figure 24: minimum level is in correspondence to the end of dipstick) until to reach the optimal (MAXIMUM) oil level�

• Operate the distributor lever to “Remote” position�

IMPORTANT

For refill use oil of the same brand as previous, refer to related technical documentation

Page 16

BIFFI OLGA-H HIGH PRESSURE DOUBLE ACTING HYDRAULIC ACTUATOR

INSTALLATION, OPERATION AND MAINTENANCE MANUAL

TABLE 2 Features of hydraulic oil suggested for refilling in different working conditions

Standard temperature conditions (-30°C/+85°C)

Producer AGIP Name ARNICA 22 Viscosity at 40°C 20�9 mm²/s Viscosity at 100°C 4�73 mm²/s Viscosity index ASTM 153 Flash point 192°C Pour point -42°C Specific weight (at 15°C) 0,857 kg/l Equivalent oils SHELL TELLUS PLUS 22

CHEVRON HYDRAULIC OIL AW ISO 22 MOBIL DTE22 EXXON UNIVIS N22 EQUIVIS ZS22 BP ENERGOL HLP-HM22 CASTROL DYSPIN AWS22

Low temperature conditions (down to -46°C)

Manufacturer SHELL Name AEROSHELL FLUID 41 Viscosity at -54°C 2300 cST Viscosity at -40°C 491 cST Viscosity at 40°C 14�1 cST Viscosity at 100°C 5�3 cST Viscosity index (ISO 2909) >200 Flash point 105°C Pour point <-60°C Specific weight 0�87 kg/dm (Or equivalent)

Low temperature conditions (down to -60°C)

Manufacturer SYNTESIS Name SYNTRASS-CS 500 Viscosity at -60°C 580 cST Viscosity at -30°C 39cST Viscosity at 20°C 5�8 cST Viscosity at 50°C 2�1 cST Flash point 152°C Pour point -68°C Specific weight 0�897 kg/dm (Or equivalent)

FIGURE 25 Replacement of cylinder seals

Stop setting screw cover

A – B

5.2 Extraordinary maintenance

If there are leaks in the hydraulic cylinder, pneumatic 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�

5.2.1 Replacement of high pressure cylinder seals

(refer to figure 27)

IMPORTANT

Before executing any maintenance operation, it is necessary to intercept the supply line and discharge pressure from the cylinder of the actuator.

Replacement of cylinder seals

1� Unscrew the plug (27) from the cylinder end

flange�

2� Measure the distance of the stop screw

(23) 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�

3� Unscrew the stop screw (23) by turning it

anticlockwise with an Allen wrench until the screw is completely with drawn inside the end flange threaded hole�

4� Unscrew the nuts (28) from the tie rods (19):

they must be gradually unscrewed all at the same time�

5� Slide off the end flange (26) and the tube

(22)�

6� If the actuator control unit requires the

cylinder chamber head flange side to be also filled with oil, and the piston rod seal ring (44) to be replaced, remove the screw (2) and the cover (1)� Unscrew the piston rod (18) threaded end from the adaptor bush (32) of the guide block (14)� Slide off the piston rod (18) from the head flange (33)�

7� Disassemble the head flange (33) from the

mechanism housing (8) by removing the screw (17) only if the gasket (39) and (41) have to be replaced because damaged�

Stop setting screw

Plug

Page 17

BIFFI OLGA-H HIGH PRESSURE DOUBLE ACTING HYDRAULIC ACTUATOR

INSTALLATION, OPERATION AND MAINTENANCE MANUAL

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 grease� If the O-ring must be replaced, remove the existing one from its groove, clean the groove carefully and lubricate it with protective oil or grease film� Assemble the new O-ring into its groove and lubricate it with a protective oil or grease film� 1� Replace the O-rings (43) of the head flange

(33)�

2� Replace the O-ring (42) of the end flange

(26)� To replace the piston rod seal rings (44) proceed as follows: 1� Remove the existing PTFE seal ring (44) with

its O-ring from their groove� 2� Clean the groove carefully and lubricate it

with a protective oil or grease film� 3� Assemble the new O-ring into its groove and

lubricate it with a protective oil or grease

film� 4� Assemble the new PTFE seal ring (44) into

the flange groove, inside its rubber O-ring,

by bending it: take care that the bending

radius is as large as possible to avoid

damaged the seal� Then enlarge the seal

ring with your fingers so as to restore its

round shape: pay attention not to utilize any

tools, which can damage the seal ring� To replace the piston seal ring (46) proceed as follows: 1� Remove the existing PTFE seal ring (46) with

its O-ring from their groove� 2� Clean the groove carefully and lubricate it

with a protective oil or grease film� 3� Assemble the new O-ring into its groove and

lubricate it with a protective oil or grease

film� 4� Assemble the new PTFE seal ring (46) on

its rubber O-ring by introducing one side of

it into the groove, then enlarge it with your

fingers so as to fit it into the groove: take

care to enlarge it uniformly without any

tools which could possibly damage it� The

elastic memory of the kind of PTFE the seal

ring is made of allows the ring to shrink

back to its previous dimension after a short

time�

the threaded end of the piston rod (18) and the threaded hole of the adaptor bush (32) of guide block (14)� Spread some sealant LOCTITE 452, or equivalent, on the rod threaded end and tighten�

4� Carefully clean the inside of the tube

(22) and check that the entire surface, particularly that of the bevels, is not damaged� Lubricate with a protective oil film the tube internal surface and the bevels at the ends� Slide the tube onto the piston taking care not to damaged the PTFE seal ring (46): the tube bevel has to smoothly compress the seal ring; take care also not to damage the head flange O-ring (43)�

5� Assemble the end flange by centring it on

the inside diameter of the tube, taking care not to damage the O-ring (43)�

6� Assemble the nuts (28) onto the tie rods

(19)� Tighten the nuts to the recommended torque, alternating between opposite corners�

7� Restore a generous coating of grease on

the contact surfaces of the yoke (11) and the bushing (35), on the yoke grooves, on the sliding blocks (5), on guide bar (9)�

8� Assemble the new gasket (10) after cleaning

the surfaces of the housing (8) and cover (1)

9� Lubricate with protective oil or grease the

O-ring (34)�

10� Assemble the cover (1) and the screws (2)�

Tighten the screws to the recommended torque�

11� Screw the stop screw (21) by turning it

clockwise with an Allen wrench until it reaches its original position (the same distance with reference to the end flange surface)�

12� Screw the plug (27) into the cylinder end

flange�

IMPORTANT

AFTER MAINTENANCE OPERATIONS CARRY OUT A FEW ACTUATOR OPERATIONS TO CHECK THAT ITS MOVEMENT IS REGULAR AND THAT THERE IS NO AIR LEAKAGE THROUGH THE SEALS.

Reassemble

1� Assemble the new gasket (39-41) after

cleaning the surfaces of housing (8), the

flange (40) and head flange (33), which are in

contact� 2� Assemble the head flange (33), replace the

washers if damaged, tighten the screws (17)

to the recommended torque� 3� Lubricate the piston rod (18) surface, with a

protective oil or grease film and introduce

it into the head flange hole, taking care not

to damage the O-ring (43)� Carefully clean

Page 18

BIFFI OLGA-H HIGH PRESSURE DOUBLE ACTING HYDRAULIC ACTUATOR

INSTALLATION, OPERATION AND MAINTENANCE MANUAL

FIGURE 26 OLGA-H double acting hydraulic actuator with manual override

1917

1 3 5 7 9 11 13 15 17 19 21 23 25 27

5 931 11

2 4 6 8 10 12 14 16 18 20 22 24 26 28

16 201084

142

34 34

35 36

PARTS LIST

Item Description

1 Cover 2 Screw 3 Guide block pin 4 Vent valve 5 Sliding block 6 Travel stop screw 7 Screw 8 Housing 9 Guide bar 10 Cover gasket 11 Yoke 12 Plug 13 Bushing 14 Guide block 15 Washer 16 Piston rod bushing

464442

FED GBA

4440

33 Head flange 34 O-ring 35 Yoke bushing 36 Retainer ring 37 Flange 38 Gasket 39 Gasket 40 Flange 41 Gasket 42 Back-up ring 43 O-ring 44 Piston rod seal ring 45 Guiding sliding ring for piston 46 Piston seal ring

37 394041 43 45

B C D E F G

Item Description Item Description

17 Screw 18 Piston rod 19 Tie rod 20 Piston 21 Stop setting screw 22 Cylinder tube 23 Friction bar 24 Washer 25 Plug 26 End flange 27 Plug 28 Nut 29 Nut 30 Nut 31 Stopper bush 32 Adaptor bush

3934 37

Page 19

BIFFI OLGA-H HIGH PRESSURE DOUBLE ACTING HYDRAULIC ACTUATOR

INSTALLATION, OPERATION AND MAINTENANCE MANUAL

Replacement of seals for actuators with Biffi manual hand-pump (see figure 27)

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 sectional drawing and adopting the following procedures: 1� Remove the nuts (item 16) and the washers

(item 15) from the tie rods (item 10) at the

end flange (item 13) side� 2� Slide off the end flange and the tube

(item12)� 3� Remove the screws (item 2-fig� 26) and the

cover (item 1-fig� 26)� 4� Unscrew the piston rod (item 6) threaded

end from the adaptor bush (item 32-fig� 26)

of guide block (item 14-fig� 26)� 5� Slide off the piston rod from the head flange

(item 2)� 6� Disassemble the head flange from the

mechanism housing (item 8-fig� 26) by

removing the screws (item 7- fig� 26) only

if the gasket (item 39-fig� 26) has to be

replaced because damaged�

Seals replacement

(2)� 2� Replace the O-ring (3) of the end flange (13)� For replacement of piston rod seal ring (4) and of the O-ring (5) proceed as follows: 1� Remove the existing PTFE seal ring (4) and

the O-ring (5) from their groove� 2� Clean the groove carefully and lubricate it

with a protective oil or grease film� 3� Assemble the new O-ring into its groove and

lubricate it with a protective oil or grease

film� 4� Assemble the new PTFE seal ring (4) into

the flange groove, on the rubber O-ring (5),

by bending it: take care that the bending

radius is as large as possible to avoid

damaged the seal� Then enlarge the seal

ring with your fingers so as to restore its

round shape: pay attention not to utilize any

tools, which can damage the seal ring� To replace the piston dual-seal ring (9) proceed as follows : 1� Remove the existing dual-seal ring (9) from

its groove� 2� Clean the groove carefully and lubricate it

with a protective oil or grease film�

3� Assemble the new dual-seal ring (9) by

introducing one side of it into the groove and then enlarge it with your fingers so as to introduce it into the groove: take care to enlarge it uniformly without any tools which could possibly damage it� The elastic memory of the kind of PTFE type the seal ring is made of allows the ring to shrink back to its previous dimension after a short time�

4� If the O-ring (17) has to be replaced,

measure the protrusion of the stop screw (11) with reference to the end flange (13) surface, so as to be able to easily restore the setting of the actuator mechanical stop in the open valve position, once the maintenance procedures have been completed�

5� Loosen the protection cover (14) and

unscrew the stop screw (11) until it is removed�

6� Replace the O-ring (17) from the stop screw

cover (14)�

7� Screw the stop screw into the threaded hole

of the end flange until it reaches its original position (the same protrusion with reference to the flange surface)�

8� Tighten the protection cover (14)�

Reassemble

1� Assemble the new gasket (item 39-fig�26)

after cleaning the surfaces of housing (item8-fig� 26) and head flange (item 2) which are in contact�

2� Assemble the head flange and tighten the

screws (item 7- fig� 26) to the recommended torque�

3� Clean and lubricate the piston rod (item 6)

surface, particularly that of the bevel, with a protective oil or grease film and introduce it into the head flange hole, taking care not to damage the PTFE seal ring (item 4): the piston rod bevel has to enlarge smoothly the seal ring�

4� Carefully clean the threaded end of the

piston rod and the threaded hole of the adaptor bush (item 32-fig� 26) of guide block (item 14-fig� 26)� Spread some sealant LOCTITE 452, or equivalent, on the rod threaded end and screw into the adaptor bush threaded hole and tighten�

5� Carefully clean the inside of the tube

(item12) and check that the entire surface, particularly that of the bevels, is not damaged� Lubricate with protective oil or a grease film the tube inside surface and the bevels at the ends� Slide the tube onto the piston taking cares not to damaged the dual-seal ring (item 9): the tube bevel has to smoothly compress the seal ring�

6� Take care also not to damage the head

flange O-ring (item 3)�

7� Assemble the end flange (item 13) by

centring it on the inside diameter of the

tube, taking cares not to damage the O-ring (item 3)�

8� Assemble the washers (item 15) and the

nuts (item 16) onto the tie rods (item 10)� Tighten the nuts to the recommended torque, alternating between opposite corners�

9� Restore a generous coating of grease on

the contact surfaces of the yoke (item 11fig� 26) and the bushings (item 13-fig� 26), on the yoke grooves, on the sliding blocks (item5-fig� 26), on guide bar (item 9-fig� 26)�

10� Assemble the new gasket (item 39-fig� 26)

after cleaning the surfaces of the housing (item 8-fig� 26) and cover (item 1-fig� 26)

11� Lubricate with protective oil or grease the

O-ring (item 34-fig� 26)�

12� Assemble the cover (item 1-fig� 26) and the

screws (item 2-fig� 26)� Tighten the screws to the recommended torque�

IMPORTANT

AFTER MAINTENANCE OPERATIONS CARRY OUT A FEW ACTUATOR OPERATIONS TO CHECK THAT ITS MOVEMENT IS REGULAR AND THAT THERE IS NO AIR LEAKAGE THROUGH THE SEALS.

Page 20

BIFFI OLGA-H HIGH PRESSURE DOUBLE ACTING HYDRAULIC ACTUATOR

INSTALLATION, OPERATION AND MAINTENANCE MANUAL

FIGURE 27 Hydraulic cylinder for Biffi manual hand pump

1917

18 15

8 19

125 931

136

142

1610

PARTS LIST

Item Q.ty Description Material

1 1 Piston rod bushing Steel + bronze + PTFE 2 1 Head flange Carbon steel 3* 2 O-ring NBR 4* 1 Piston rod seal ring PTFE + graphite 5* 1 O-ring NBR 6 1 Piston rod Alloy steel 7 1 Piston Nickel plated carbon steel 8* 2 Guide sliding ring for piston PTFE + graphite 9* 1 Piston seal ring PTFE + NBR 10 4 Tie rod Alloy steel - ASTM A320 gr� L7 11 1 Stop setting screw Alloy steel 12 1 Cylinder tube Nickel plated carbon steel 13 1 End flange Carbon steel 14 1 Stop setting screw cover Carbon steel 15 4 Spring washer Carbon steel 16 4 Nut Carbon steel - ASTM A194 gr� 7 17* 1 O-ring NBR 18 6 Plug Carbon steel 19 1 Plug Carbon steel * Recommended spare parts

Page 21

BIFFI OLGA-H HIGH PRESSURE DOUBLE ACTING HYDRAULIC ACTUATOR

INSTALLATION, OPERATION AND MAINTENANCE MANUAL

5.3 Lubrication of mechanism

For normal duty the scotch yoke mechanism of the actuator is lubricated “for life”� In case of high load and high frequency of operation it may be necessary to periodically restore lubrication: it is advisable to apply a generous coating of grease on the contact surfaces of the yoke and bushings, on the yoke link grooves, on the sliding blocks, on the guide bar� For this operation it is necessary to disassemble the mechanism cover� In larger actuators the lubrication can be performed through the inspection holes of the cover after removing the plugs� The following grease is used by Biffi for standard working temperature and suggested for re-lubrication, see table�

5.4 Dismantling and demolition

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 work-site�

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 from the accumulator tank, if present.

AGIP MU/EP/2 AEROSHELL GREASE 7 or equivalent

To be used in standard temperature conditions (-30°C/+85°C)

NLGI consistency: 2 Worked penetration: 280 dmm ASTM dropping point: 185°C Base oil viscosity at 40°C: 160 mm²/s ISO classification: L-X-BCHB 2 DIN 51 825: KP2K – 20

Equivalent to: ESSO BEACON EP2 BP GREASE LTX2 SHELL ALVANIA GREASE R2 ARAL ARALUB HL2 CHEVRON DURALITH GREASE EP2 CHEVRON SPHEEROL AP2 TEXACO MULTIFAK EP2 MOBILPLEX 47 PETROMIN GREASE EP2

To be used in low temperature conditions (-60°C/+65°C)

Color: Buff Physical state: Semi-solid at ambient temperature Odor: Slight Density: 966 kg/m³ at 15°C Flash point: >215°C (COC)(based on synthetic oil) Dropping point: 260°C (ASTM D-566) Product code: 001A0065 Infosafe no�: ACISO GB/eng/C

If actuator is still mounted onto the valve, loosen the threaded connections between valve and actuator (screws, tie rods, nuts)� Lift the actuator using the proper lifting points (see section 2�2)� If the actuator needs storage, before demolition, see section 2�3�

IMPORTANT

The demolition of the actuator both concerning any electrical and mechanical parts should be made by specialized staff.

Separate the parts composing the actuator according to their nature (ex� metallic, and plastic materials, fluids etc�) and send them to differentiated waste collection sites, as provided for by the laws and provisions in force�

Page 22

BIFFI OLGA-H HIGH PRESSURE DOUBLE ACTING HYDRAULIC ACTUATOR

INSTALLATION, OPERATION AND MAINTENANCE MANUAL

6 TROUBLESHOOTING

6.1 Failure or breakdown research

Event Possible cause Remedy

Actuator does not work 1� Lack of power supply 1� Restore it

2� Lack of pneumatic supply 2� Open line interception valve 3� Blocked valve 3� Repair or replace 4� Wrong position of the distributor of the manual hydraulic group 4� Restore correct position 5� Failure of the control group 5� Call Biffi Customer Service 6� Low supply pressure 6� Restore (section 1�4)

Actuator too slow 1� Low supply pressure 1� Restore (section 1�4)

2� Wrong calibration of flow regulator valves 2� Restore (section 3�6) 3� Wear of the valve 3� Replace

Actuator too fast 1� High supply pressure 1� Restore (section 1�4)

2� Wrong calibration of flow regulator valves 2� Restore (section 3�6) Leakages on hydraulic or pneumatic circuits Incorrect position of the valve 1� Wrong adjustment of mechanical stops 1� Restore (section 3�4)

Hydraulic manual pump does not work

1� Deterioration and/or damage to gaskets 1� Call Biffi Customer Service

2� Wrong warning of microswitches 2� Restore (section 3�5)

1� Handle positioned on remote control 1� Re-position the operation indication handle to manual

2� Leakages on the check valve of the hydraulic control group 2� Call Biffi Customer Service

7 LAYOUTS

7.1 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�

Please send every spare-parts request to: Biffi Italia S�r�l� Servizio Assistenza Tecnica Clienti E-mail: spareservice@biffi�it

Please specify: 1� Actuator model 2� Biffi acknowledgement 3� Spare parts code 4� Quantity 5� Transport condition 6� Involved people

Page 23

BIFFI OLGA-H HIGH PRESSURE DOUBLE ACTING HYDRAULIC ACTUATOR

INSTALLATION, OPERATION AND MAINTENANCE MANUAL

7.2 Parts list for maintenance and replacing procedure

FIGURE 28 Scotch yoke mechanism

5 6 7

9 10 11

PARTS LIST

Item Q.ty Description Material

1* 4 O-ring NBR 2 2 Yoke bushing Bronze 3 2 Retainer ring Stainless steel 4 1 Housing Carbon steel 5 1 Guide bar Alloy steel 6 1 Yoke Carbon steel 7* 1 Cover gasket Fiber 8 1 Guide block Carbon steel 9 1 Bushing Steel + bronze + PTFE 10 2 Sliding block Bronze 11* 1 Vent valve Stainless steel 12 12 Screw Carbon steel 13 1 Cover Carbon steel 14 1 Guide block pin Alloy steel 15 1 Washer Copper 16 1 Inspection plug Carbon steel * Recommended spare parts

Page 24

BIFFI OLGA-H HIGH PRESSURE DOUBLE ACTING HYDRAULIC ACTUATOR

INSTALLATION, OPERATION AND MAINTENANCE MANUAL

FIGURE 29 Hydraulic cylinder

5931

136

1718

PARTS LIST

Item Q.ty Description Material

1 1 Piston rod bushing Steel + bronze + PTFE 2 1 Head flange Nickel plated carbon steel 3* 2 O-ring NBR 4* 1 Piston rod seal ring PTFE + graphite + NBR 5* 1 Back-up ring NBR 6 1 Piston rod Chomium plated alloy steel 7 1 Piston Carbon steel 8* 2 Guide sliding ring for piston PTFE + graphite 9* 1 Piston seal ring PTFE + graphite + NBR 10 4 Tie rod Carbon steel - ASTM A320 gr� L7 11 1 Stop setting screw Carbon steel 12 1 Cylinder tube Nickel plated carbon steel 13 1 End flange Nickel plated carbon steel 14 1 Plug Carbon steel 15 4 Nut Carbon steel - ASTM A194 gr� 7 16* 4 Washer 17 1 Plug Stainless steel 18 6 Friction bar Nylon 19 1 Plug Stainless steel * Recommended spare parts

Page 25

BIFFI OLGA-H HIGH PRESSURE DOUBLE ACTING HYDRAULIC ACTUATOR

INSTALLATION, OPERATION AND MAINTENANCE MANUAL

FIGURE 30 Hydraulic cylinder for manual hand pump (optional)

1917

18 15

8 19

125 931

136

142

1610

PARTS LIST

Item Q.ty Description Material

Page 26

BIFFI OLGA-H HIGH PRESSURE DOUBLE ACTING HYDRAULIC ACTUATOR

INSTALLATION, OPERATION AND MAINTENANCE MANUAL

FIGURE 31 Assembly kit

6 12

5 931

1084

PARTS LIST

Item Q.ty Description Material

1 1 Screw Alloy steel 2 1 Nut Carbon steel 3 1 Nut Carbon steel 4 4 Screw Alloy steel 5 2 Flange Carbon steel 6* 2 Gasket Fiber 7 1 Stopper bush Alloy steel 8 1 Plug Alloy steel 9 1 Adaptor bush Alloy steel 10 4 Screw Alloy steel 11* 1 Gasket Fiber 12 1 Washer Alloy steel * Recommended spare parts

Page 27

BIFFI OLGA-H HIGH PRESSURE DOUBLE ACTING HYDRAULIC ACTUATOR

INSTALLATION, OPERATION AND MAINTENANCE MANUAL

FIGURE 32 Hydraulic control unit MHP

Flow

regulator

4243 3650 38

44 4548 47 21

Oil tank

relief valve

operation

Relief valve

for automatic

Relief valve for

manual operation

16 20

Page 28

BIFFI OLGA-H HIGH PRESSURE DOUBLE ACTING HYDRAULIC ACTUATOR

INSTALLATION, OPERATION AND MAINTENANCE MANUAL

PARTS LIST - HYDRAULIC CONTROL UNIT MHP

Item Q.ty Description Material

1 1 Dipstick 2 2 Cap nut Carbon steel 3 2 Washer Carbon steel + rubber 4 1 Hydraulic tank Carbon steel 5 1 Hand pump See attached table 6* 2 O-ring Fluorosilicon rubber 7 2 Ball Stainless steel 8 2 Spring Spring steel 9 1 Washer Carbon steel + rubber 10 1 Screw Carbon steel 11 1 Plate Carbon steel 12 1 Flange Aluminium 13 4 Screw Carbon steel 14 1 Lever Carbon steel 15 1 Distributor Stainless steel 16* 1 O-ring Fluorosilicon rubber 17* 1 O-ring Fluorosilicon rubber 18 1 Nozzle Carbon steel 19 2 Screw Carbon steel 20* 3 O-ring Fluorosilicon rubber 21* 2 O-ring Fluorosilicon rubber 22 1 Tank cover Carbon steel 23 2 Tie rod Carbon steel 24 1 Screw Carbon steel 25 1 Flange Aluminium 26 2 Check valve body Aluminium 27 2 Plug Carbon steel 28 2 Flow control valve setting screw Stainless steel 29 2 Spring pin Stainless steel 30 2 Nut Carbon steel 31 2 Flange Carbon steel 32* 2 O-ring Fluorosilicon rubber 33 2 Spring Spring steel 34 2 Plug Stainless steel 35 2 Retainer ring Spring steel 36 2 Spring pin Carbon steel 37 4 Screw Carbon steel 38 1 Operation instruction plate Stainless steel 39 4 Screw Carbon steel 40 1 Spring Stainless steel 41 1 Ball Stainless steel 42 4 Ball Stainless steel 43 2 Spring Spring steel 44 1 Relief valve setting screw Stainless steel 45 2 Spring pin Carbon steel 46 1 Screw Alloy steel 47 1 Spring Stainless steel 48 1 Nut Carbon steel 49 1 Washer Carbon steel + rubber 50 2 Washer Carbon steel + rubber 51 1 Dipstick Stainless steel 52* 1 Plug + O-ring 53 1 Spring Stainless steel 54 1 Screw Alloy steel 55 1 Nut Carbon steel 56 1 Silencer Brass 57* 2 O-ring Fluorosilicon rubber 58 2 Retainer ring Spring steel 59 1 Dipstick body Aluminium 60 2 Nut Carbon steel 61 1 Relief valve body Aluminium * Recommended spare parts

Page 29

BIFFI OLGA-H HIGH PRESSURE DOUBLE ACTING HYDRAULIC ACTUATOR

INSTALLATION, OPERATION AND MAINTENANCE MANUAL

FIGURE 32A Hand pump

7 13

5 931 11

6 12

142

PARTS LIST

Item Q.ty Description Material

1 2 Ball Stainless steel 2 1 Delivery valve bush Carbon steel 3 1 Suction valve bush Carbon steel 4 2 Spring Stainless steel 5 1 Suction valve ring Carbon steel 6 1 Spring retainer ring Carbon steel 7 1 Fork Carbon steel 8 2 Pin Stainless steel 9 4 Retainer ring Carbon steel 10 1 Rod Alloy steel 11 1 Body Carbon steel 12 1 Lever Carbon steel 13 1 Split pin with rope Nylon + carbon steel 14 1 Scraper ring PTFE + fluorosilicon rubber 15* 1 Threaded bush Aluminium 16 2 Rod seal ring PTFE + graphite 17* 2 O-ring Fluorosilicon rubber 18* 1 O-ring Fluorosilicon rubber 19* 1 Nut Carbon steel 20 1 Screw Carbon steel 21 1 Fork Carbon steel 22 1 Piston rod bushing Steel + bronze + PTFE * Recommended spare parts

17 1815

161084

Page 30

BIFFI OLGA-H HIGH PRESSURE DOUBLE ACTING HYDRAULIC ACTUATOR

INSTALLATION, OPERATION AND MAINTENANCE MANUAL

FIGURE 33 Jackscrew manual override MSJ

4 5 6

17 18 19

7 8 9 10 11 12 13 14

20 21 22 23 24 25 26 27 28

ENGAGED

TO OPEN

TO CLOSE

DISENGAGED

PARTS LIST

Item Q.ty Description Material

1 1 Protection pipe Carbon steel 2 3 1 Jackscrew Carbon steel 4 1 Engagement lever pin Stainless steel 5* 1 O-ring Fluorosilicon rubber 6* 1 Cover gasket Fiber 7 1 Cover Carbon steel 8 3 Cam Alloy steel 9 1 Fork Carbon steel 10 3 Spring pin Stainless steel 11 3 Screw Carbon steel 12 1 Screw nut operating cam Alloy steel 13* 1 O-ring Fluorosilicon rubber 14 1 Thrust nut operating cam Alloy steel 15 1 Screw Carbon steel 16 1 Nut Carbon steel 17 1 Flange Carbon steel 18 1 Body Carbon steel 19 1 Spring pin Spring steel 20 2 Screw Carbon steel 21 1 Ball ¼" Stainless steel 22 1 Screw Carbon steel 23 1 Screw nut Bronze 24 1 Pin Carbon steel 25 1 Spring Spring steel 26 1 Bush Bronze 27 2 Thrust shoulder washer Bronze 28 1 Operating instruction plate Aluminium * Recommended spare parts

Page 31

BIFFI OLGA-H HIGH PRESSURE DOUBLE ACTING HYDRAULIC ACTUATOR

INSTALLATION, OPERATION AND MAINTENANCE MANUAL

8 DATE REPORT FOR MAINTENANCE OPERATIONS

Last maintenance operation date:

(in factory, on delivery): …��

��…��… exec� by: …��……

Next maintenance operation date:

��…��… exec� by: …��……

Start-up date:

(in factory, on delivery): �……………………��

(on plant): …��

Biffi reserves the the right to change product designs and specifications without notice�

Biffi Italia S.r.L.

Località Caselle San Pietro, 420, 29017 Fiorenzuola d’Arda (PC) ITALY Ph: +39 (0)523 944 411 E-mail: biffi_italia@biffi�it www.biffi.it