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Biffi F02

Pentair Biffi F02 Installation And Maintenance Instructions Manual

BIFFI F02 QUARTER-TURN ELECTRIC ACTUATOR
InstallatIon and MaIntenance InstructIons
INDEX
1 General safety instructions ......................... 1
2 Machine description .................................... 4
3 Storage end pre-installation ....................... 6
4 Installation .................................................... 7
5 Lubrication ................................................. 14
6 Actuator setting and configuration ........... 14
7 Maintenance and trouble-shooting .......... 20
8 Decommissioning ...................................... 21
9 Parts list and drawings.............................. 21
1 GENERAL SAFETY INSTRUCTIONS
1.1 INTENDED USE
WARNING
Any repair work, other than the operations outlined in this manual, is strictly reserved to qualified Biffi personnel or to personnel directly authorized by the company itself.
F02 electric actuators are designed in accordance with the applicable international rules and specifications, but the following regulations must be observed in any case:
• The general and safety regulations
• The plant specific regulations and requirements
• The proper use of personal and protective devices (glasses, clothing, gloves, etc.)
• The proper use of tools, lifting and transport equipment
• Electrical installation, use and maintenance on F02 has to be carried out in accordance with the National Legislation and statutory requirement related to the safe use of F02 actuators, applicable to the site of installation
• Should further information and guidance related to the safe use of F02 actuators is requested, please contact Biffi
WARNING
The electronic parts of the F02 and all the optional modules can be damaged by a discharge of static electricity. Before you start, touch a grounded metal surface to discharge any static electricity.
WARNING
It is assumed that the installation, configuration, commissioning, maintenance and repair works are carried out by qualified personnel and checked by responsible specialists.
www.pentair.com/valves © 2015 Pentair plc. All rights reserved. VCIOM-03859-EN 15/09
BIFFI F02 QUARTER-TURN ELECTRIC ACTUATOR
InstallatIon and MaIntenance InstructIons
1.2 TERMS AND CONDITIONS
Biffi guarantees each single product to be free from defects and to conform to current goods specifications. The warranty period is one year from the date of installation by the first user, or eighteen months from the date of shipment to the first user, whichever occurs first. No warranty is given for products which have been subject to improper storage, improper installation, misuse, or corrosion, or which have been modified or repaired by unauthorized personnel. Repair work due to improper use will be charged at standard rates.
1.3 MANUFACTURER’S LIABILITY
Biffi declines all liability in the event of:
• Use of the actuator in contravention of local safety at work legislation
• Incorrect installation, disregard or incorrect application of the instructions provided on the actuator nameplate and in this manual
• Modifications without Biffi’s authorisation
• Work done on the unit by unqualified or unsuitable persons
1.4 IDENTIFICATION
1.4.1 Water-, dust-proof version
F02 actuators are designed and manufactured according to EN 60529 standards. Specific types of protection are printed on the label, as follows:
• IP66/68
• NEMA 4/4X/6 according to NEMA ICS6/ NEMA 250
1.4.2 Explosionproof version
The version of F02 suitable for installation in hazardous areas is designed and manufactured according to EN 50014, 50018, 50019, EN 50281-1-1 standards. Different types of protection are available, depending on the requirements of the installation site. The driven valve or associated gear reducer will form part of a separate risk analysis according to Directive ATEX 94/9/EC and following the EN 13463-1 and 13463-5 norms. Specific types of protection are printed on the label, as follows:
• ATEX Ex de IIB T5 with enclosures in ‘explosionproof’ version and terminal board enclosure in ‘increased safety’ version
• FM rated as flameproof for Class I, Zone 1, Group IIB, T5; Class II, III, Div. 1, Groups E, F and G, T4
• NEMA 7 and NEMA 9
The above versions of F02 prevent the risk of explosion in the presence of gas or ignitable dusts. F02 actuators have IP 66/68M protection degree in accordance with EN 60529.
WARNING
Whenever F02 actuators must be installed in a HAZARDOUS AREA as defined by the applicable rules, it is mandatory to check whether the actuator nameplates indicate their suitability to a hazardous area, and the appropriate protection degree. Maintenance and repair works must be carried out by qualified personnel and checked by responsible specialists.
1.4.1.1 Label for application in water-, dust­proof areas
Marking description (see Figure 1A).
FIGURE 1A
A Manufacturer logo B Product model C Nominal output torque value D Product code E Serial number F Stroking time range G Power supply data
BIFFI
H Max current absorption in ampere I Environmental data L Actuator duties M Weatherproof protection degree (EU and US) N Weatherproof certificate reference (EU and US) O Manufacturer details P Year of construction
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BIFFI F02 QUARTER-TURN ELECTRIC ACTUATOR
InstallatIon and MaIntenance InstructIons
1.4.2.1 ATEX label for application in hazardous areas
FIGURE 1B
B
F
R
L
M
S
A Manufacturer logo B Product model C Nominal output torque value D Product code E Serial number F Stroking time range G Power supply data H Max current absorption in ampere I Environmental data
1.5 APPLICABLE STANDARDS AND REGULATIONS
EN ISO 12100-1 Safety of machinery - Basic concepts, general principles for design Part 1 - Basic terminology, methodology EN ISO 12100-2 Safety of machinery - Basic concepts, general principles for design Part 2 - Technical principles and specification EN 60204-1 Electrical equipment of industrial machines Part 1 - General requirements 98/37/EC Machinery Directive 2006/95/EC Low Voltage Directive 2004/108/EC EMC Directive 94/9/EC ATEX Directive
CD
G
I
N
P
L Actuator duties M Explosionproof protection degree N Weatherproof protection degree (IP66/NEMA types 4, 4X and 6 when labelled FM) O ATEX certificate reference P Manufacturer details Q Year of construction R Notified body for ATEX quality assurance (Ineris) S ATEX marking
E
A
H
O
BIFFI
Q
1.6 EXTRACT FROM THE STANDARD
Type of hazard zone Zone Categories according to 94/9/EC Directive
Gas, mist or vapors 0 1G Gas, mists or vapors 1 2G Gas, mists or vapors 2 3G Dust 20 1D Dust 21 2D Dust 22 3D
1.7 MANUFACTURER
Manufacturer with respect to Machinery Directive 98/37 is Biffi Italia, as specified on the actuator label.
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BIFFI F02 QUARTER-TURN ELECTRIC ACTUATOR
InstallatIon and MaIntenance InstructIons
2 MACHINE DESCRIPTION
2.1 GENERAL
The F02 is an electric quarter-turn actuator suitable to operate a valve in a 90° manoeuver.
2.2 PRINCIPLE OF OPERATION
The electric motor drives the input to an epicyclical gear train via a spur reduction. The input member of the epicyclical gear train carries two compound planet gears which meshes with one internally toothed gears: the fixed annulus. The fixed annulus gear has external helical teeth meshing with a transversely fixed worm gear. Since the annulus cannot drive the worm gear this provides a fixing point for the annulus, and since the worm gear can drive the annulus, a means of manual operation is provided which needs no declutch. An end-of-travel-position detection device is operated via a position sensor directly linked to the output shaft. The valve position is continuously monitored in electric mode by means of a position sensor directly connected to the F02 output drive.
2.3 ELECTRICAL OPERATION
- Control command ‘open’: counter-clockwise or clockwise rotation (selectable on the logic board) moves the valve to a completely or partially open position.
- Control command ‘closed’: clockwise or counter-clockwise rotation (selectable on the logic board) moves the valve to a completely or partially closed position.
Control system details are shown in the specific wiring diagram.
IMPORTANT
Handwheel rotation In standard applications clockwise rotation of the handwheel moves the valve to close position and counter-clockwise rotation moves the valve to open position. Different operation are clearly indicated on the handwheel.
2.4 MANUAL OPERATION
To be used in case of power supply failure or during actuator setting. The manual operating device is completely independent of the motor drive and can be operated at any time, whether or not the motor is running, without danger to the operator. The handwheel does not rotate during power operation. To close the valve turn the handwheel clockwise. To open the valve, turn the handwheel counter­clockwise. If the handwheel is turned during electric operator, an error will occur and the actuator will stop. After few seconds the actuator will restart its operation and move the valve to the requested position
FIGURE 2
Local position indicator
Control unit
Manual override
Terminals enclosure
Mechanical gearing
Cable entries
Base flange
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BIFFI F02 QUARTER-TURN ELECTRIC ACTUATOR
InstallatIon and MaIntenance InstructIons
2.5 DESCRIPTION OF THE MAIN PARTS
The F02 actuator consists of five main parts:
• Base flange: for coupling the actuator to the valve
• Terminals enclosure: for power and signal cable connection through four available cable entries
• Mechanical gearing: internal epicyclical gear reduction, which increases the torque of the electric motor
• Control unit: integral control unit inclusive of electric motor with the relevant driver, power and logic electronic card. By way of the mechanical gearing, the electric motor operates the valve in normal working conditions
• Manual override: for actuator manual operation in case of power supply failure or during actuator setting
2.6 OPTIONAL MODULES
F02 actuators can be provided with several optional modules, as listed in the table below. Please refer to this table for possible combinations of available modules.
OPTIONAL MODULES SELECTION TABLE
Order code
P1 PA P6 P7 P3 5P 6P 5D 6D PG
NOTES
1. Each optional module (OMx) will be provided with its own Installation and Maintenance Instructions. All modules except OM13 are available for both 1-phase and 3-phase voltage versions.
2. Bluetooth component is integrated in the OM1, OM9 and OM11 card: not available for integration by local organizations, as a stand alone unit.
3. OM13 is not available with 3-phase supply. Not available for LV version (1-phase voltage from 24 to 48 V DC/V AC).
OM1 I/O
additionalmodule
✓
✓ ✓ ✓
✓ ✓
✓ ✓
OM3 local
interface
Bluetooth
component
✓
✓ ✓
✓ ✓ ✓
✓ ✓
✓ ✓ ✓
OM9
PDP V0/V1
OM11
DeviceNet
OM13
3 wiresmodule
✓
2.7 OPTIONS LABEL
A label is always provided with base actuators where optional modules will have to be checked out once they are installed after delivery at local organisations’ care.
Options Label
S/N:
Please make sure the label is stuck where shown in the picture below.
OM1OM3 OM9
OM11 OM13
FIGURE 3 FIGURE 4
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BIFFI F02 QUARTER-TURN ELECTRIC ACTUATOR
InstallatIon and MaIntenance InstructIons
3 STORAGE AND PRE-INSTALLATION
3.1 CHECKS TO BE CARRIED OUT WHEN THE ACTUATOR IS RECEIVED
IMPORTANT
Not performing the following procedures will invalidate the product guarantee.
First of all check if the data on the nameplate (model, serial number, nominal torque, nominal voltage range, protection degree, operating speed range, protection class, etc.) correspond to the expected product data. If the actuator is received already assembled onto the valve, the setting of the mechanical stops and of the electric end-of-travel should have been already done during actuator assembly onto the valve. An additional check is anyway recommended to verify that all the requested settings have been completed as indicated in the present Instruction and Operating Manual. If the actuator is received separately from the valve, the setting of the mechanical stops and of the electric end-of-travel must be checked and, if necessary, carried out while assembling the actuator onto the valve. In any case, all the setting operations described in this Instruction and Operating Manual must be carried out. Check that the actuator was not damaged during transport: in particular, inspect the local position indicator area glass. If necessary, repair all damages to the paint-coat, etc. Check that the fitted accessories comply with those listed in the order acknowledgement and the delivery note.
3.2 STORAGE PROCEDURE
3.2.1 General
The actuators leave the factory in perfect working conditions and with an excellent finish, in order to maintain these characteristics until the actuator is installed on site, it is necessary to observe a few rules and take appropriate measures during the storage period. The basic version of F02 actuators is weatherproof to IP66/68. This condition can only be maintained if the units are correctly installed and connected on site, and if they were previously correctly stored. The standard plastic plugs used to close the cable entries are not weatherproof, they just prevent the entry of undesired objects during transport. Biffi cannot accept responsibility for deterioration caused on site when the covers are removed.
IMPORTANT
The actuator handwheel is removed for transport. If the actuator must be shipped fully assembled, please make sure the handwheel is packed securely to avoid all possible damage.
3.2.2 Storage for a brief period (less than
one year)
3.2.2.1 Indoor storage
• Make sure the actuators are kept in a dry
place, laid on a wooden pallet (not directly on the floor surface) and protected from dust
• In very humid environments, a moisture
absorbent desiccant packet should be introduced in the motor enclosure. (Desiccant is not included in the actuator package)
3.2.2.2 Outdoor storage
• Make sure the actuators are protected from
the direct action of weather agents (protection by a canvas tarp or similar). Environment temperature: -20°C to +65°C
• Place the actuators on a wooden pallet, or
some raised platform, so that they are not in direct contact with the ground, and protected from dust
• In very humid environments, a moisture
absorbent desiccant packet should be introduced in the motor enclosure. (Desiccant is not included in the actuator package)
• If the actuators are supplied with standard
plastic plugs, remove them from the cable entries and replace them with weatherproof plugs
3.2.3 Long period storage (more than
one year)
3.2.3.1 Indoor storage
In addition to the instructions at point 3.2.2.1:
• If the actuators are supplied with standard
plastic plugs, replace them with weatherproof plugs
• The coupling parts (i.e. flange, etc.) must
be coated with a protective oil or grease; (if possible, blank off the flange by a protection disk)
3.2.3.2 Outdoor storage
In addition to point 3.2.2.2:
• If the actuators are supplied with standard
plastic plugs, replace them with weatherproof (metal) plugs
• The coupling parts (i.e. flange, etc.) must
be coated with a protective oil or grease; (if possible, blank off the flange by a protection disk)
• Check the actuator general conditions, paying
particular attention to the terminal board
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BIFFI F02 QUARTER-TURN ELECTRIC ACTUATOR
InstallatIon and MaIntenance InstructIons
4 INSTALLATION
4.1 CHECKS TO BE PERFORMED BEFORE INSTALLATION
To assemble the actuator onto the valve proceed as follows:
• Check that the coupling dimensions of the valve flange and stem, or of the relevant extension, meet the actuator coupling dimensions
• The electrical supply cables must be suitable for the power rating
• Gather the necessary tools for the assembly and configuration of the actuator controls
• Lubricate the valve stem with oil or grease to make the assembly easier: pay attention not to contaminate with lubricant the flange surfaces which transmit the actuator torque
• Clean the valve flange and remove anything that might prevent a perfect adherence to the actuator flange and especially all traces of grease
• Install the actuator onto the valve so that the shaft output drive enters the groove of the stem extension. This coupling must take place without forcing and only with the weight of the actuator. When the actuator output shaft and the valve stem are connected, check the holes of the valve flange. If they do not meet with the holes of the spool piece flange or the stud bolts screwed into them, the actuator shaft output drive must be rotated. Actuate the manual override until coupling is made possible. Tighten the nuts of the connecting stud bolts evenly
• If possible, operate the actuator to verify it moves the valve smoothly
4.2 WORKING CONDITION
Standard F02 actuators are suitable for the following environment temperatures:
• -25°C to +70°C (-13°F to +158°F)
Special versions are available for extreme environment temperatures:
• -40°C to +70°C (-40°F to +158°F)
4.3 COUPLING BLOCK
The electric actuator is delivered with drive details and flange in accordance with the technical characteristics required by the customer, ready to be installed onto the valve. Only one insert is included in the actuator package delivered to end users.
IMPORTANT
Check the ‘ambient temperature range’ printed on the nameplate, for the correct utilisation with respect to the ambient temperature. Installation in ambient with temperature range outside the specified values will invalidate the warranty.
WARNING
During normal operation the temperature of the actuator surface can reach 30°C above the ambient temperature.
IMPORTANT
In case the screws of the cover, of the terminal compartment and of the OM3 must be replaced, SS Class A4 grade 80 screw must be used with minimum yield strength 600 N/mm Every time the main cover, the terminal compartment cover and the OM3 are reassembled, make sure to tight all the screws with 5 Nm torque.
2
.
If a long storage period has occurred, before reinstalling the actuator, please:
• Check the status of the O-ring seals
• Check the installation of the plugs or cable glands on the cable entries
• Check whether the enclosure covers or the actuator body are cracked or broken
FIGURE 5 - Overview of one type of insert and drive details of the F02.
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BIFFI F02 QUARTER-TURN ELECTRIC ACTUATOR
InstallatIon and MaIntenance InstructIons
WARNING
Never lift the valve/actuator assembly without securing slings to both the valve and the actuator.
Never use the handwheel to lift the actuator.
4.4 INSTALLATION OF THE F02 UNIT ONTO
A VALVE
Move the valve to the completely open position. Manually bring the F02 to the completely open position (verify the local mechanical indicator) and check the rotation direction of actuator and valve. The actuator should be mounted for counter-clockwise rotation to open and clockwise to close.
The F02 unit can be installed onto the valve in two different ways:
Direct mounting:
Insert the valve shaft into the actuator bottom flange, taking care to correctly connect the insert. Fix the screws on the valve flange to the actuator coupling block.
FIGURE 6 - Manual operation.
Bracket mounting:
Install the bracket and the adapter onto the valve; then insert the valve shaft into the actuator bottom flange, taking care to correctly connect the insert. Fix the screws between the bracket and the valve flange and the actuator coupling block.
4.5 MANUAL OPERATION
F02 electric actuators are supplied with a handwheel for manual override as standard, to operate the actuator in case of power supply failure or during setting. The handwheel is always engaged. For safe operation, the handwheel does not rotate during electric operation. Turn the handwheel clockwise to close and counter-clockwise to open. During manual operation, check the actuator manoeuver on the local mechanical indicator.
WARNING
Do not manually operate the actuator with devices other than the handwheel. Using cheater bars, wheel wrenches, pipe wrenches, or other such devices on the actuator handwheel may cause serious personal injury and/or damage to the actuator or valve.
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BIFFI F02 QUARTER-TURN ELECTRIC ACTUATOR
InstallatIon and MaIntenance InstructIons
4.6 SETTING OF THE ANGULAR STROKE:
MECHANICAL STOPS
It is important for the mechanical stops to end the angular stroke at both extreme valve positions (fully open and fully closed). The setting of the angular stroke is performed by adjusting the travel stop screw mounted on the actuator housing. For the adjustment of the stop screw proceed as follows:
• Loosen the lock nut
• Screw 1: open
To set the mechanical stop in opening,
manually bring the actuator to the completely open position, then turn screw 1 clockwise to find the correct position, then block it by means of the nut
• Screw 2: close
To set the mechanical stop in closing,
manually bring the actuator to the completely close position, then tighten screw 2
If the actuator angular stroke is stopped before reaching the end position (fully open or closed), proceed as follows:
• Unscrew the stop screw by turning it anticlockwise until the valve reaches the correct position
• When unscrewing the stop screw, keep the lock nut still with a wrench so that the sealing washer does not withdraw together with the screw
• Tighten the lock nut
If the actuator angular stroke is stopped beyond the end position (fully open or closed), proceed as follows:
• Screw the stop screw by turning it clockwise until the valve reaches the correct position
• Tighten the lock nut
4.7 ELECTRICAL CONNECTIONS
Before powering the actuator, check that the supply voltage details on the nameplate are correct for the plant. Access to terminals for electrical connections is through the terminal cover.
WARNING
After electrical on-field installation, please make sure all removal of the cover assembly is done in total observance of the applicable safety rules.
All the accessories (cable glands in particular) must be certified according to the requirements of the installation area and the relevant applicable regulations.
Setting must be done while the actuator is powered on. As a consequence, all setting operations must be carried out by specifically qualified personnel for operations on powered electronic cards.
4.8 PLANT REQUIREMENTS
Protection devices (over-current breakers, magneto-thermal switches or fuses) must be provided by the customer to protect the main lines in case of motor over-current or loss of insulation between phases and earth.
IMPORTANT
The following circuit breakers were identified on the basis of the actuator technical features:
- Reference: IEC EN 60947-2
- Characteristic: K
It is the plant engineer’s or installer’s responsibility to select the most appropriate electric protection.
Screw 1
FIGURE 7 - Setting of the mechanical stop.
Screw 2
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