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Biffi Pneumatic Actuators, Models Alga/Algas/Algas-QA

1. 1 2 Lifting points obligatory 3 Balancing point 1 Point of support 2 Supports for lateral positioning WARNING 3 Don t lay the actuator on tie rods of cylinder s and don t lay the actuator on accessories manual hand pump manual jackscrew pneumatic control group etc BIFFI ALGA DOUBLE ACTING PNEUMATIC ACTUATOR INSTALLATION OPERATION AND MAINTENANCE MANUAL FIGURE 4B ACTUATOR MODELS 14 TO 42 FIGURE 4A ACTUATOR MODELS 0 3 T0 6 Drive sleeve Drive sleeve H max H max d h2 0 i 0 de a a s d E y N readen holes of C On PCD number and size according to IS0 5211 N threaded holes a Di0 o D PCD number and size according to 150 5211 ES x but the holes are on centerline D instead of straddle the centerline Pe E Zz Gy Flow line Z O Flow line gt 45 E a E e y 2 Z 1 j Top view of the Scotch yoke mechanism Top view of the Scotch yoke mechanism actuator shown in closed position actuator shown in closed position COUPLING DIMENSIONS MODELS 0 3 TO 0 6 mm Actuator model d d d Od N h hz Hmax 0d 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 es 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 DIM
2. Viscosity at 40 C AI EST Viscosity at 40 C 14 1 cST Viscosity at 100 C Se TH Viscosity index ISO 2909 gt 200 Flash point 105 C Pour point lt 60 C Specific weight 0 87 kg dm3 or equivalent Low temperature conditions until 60 C Producer SYNTESIS Name SYNTRASS CS 500 Viscosity at 60 C 580 cal Viscosity at 30 C 3 cal Viscosity at 20 C 5 8 cST Viscosity at 50 C Zee Flash point 152 C Pour point 68 C Specific weight 0 897 kg dm3 or equivalent O ring Filter body Filter Retainer ring I I I l a F l Filter container Drain plug Screw Washer FIGURE 30 5 1 2 Gas supply dehydrating filter 1 Remove the nuts 16 and the washers 24 maintenance if foreseen from the tie rods 18 at the end flange 22 The gas supply filter is fitted with a mechanical side filter and a drain valve to discharge periodically 2 Slide off the end flange 22 and the the water generated by the condensation of the tube 19 humidity inside the gas supply 3 Remove the screw 2 and the cover 1 During the routine maintenance it is 4 Unscrew the piston rod 20 threaded recommended to check and clean the end from the adaptor bush 30 of guide mechanical filter and replace it in case of heavy block 14 dirty conditions 5 Slide off the piston rod 20 from the head To disassemble the filter proceed as follow flange 17 al close the stop valve at the inlet of pressure 6 Disassemble the
3. 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 paragraph 9 1 but with a frequency of once a year For standard applications please refer to paragraph 5 1 5 MAINTENANCE IMPORTANT Before executing any maintenance operation it Is necessary to close the pneumatic supply line and discharge pressure from the cylinder of the actuator and from the control unit if foreseen WARNING Installation commissioning and maintenance and repair works should be carried out by qualified staff 5 1 PERIODIC MAINTENANCE ALGA 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 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 e 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
4. A 9 l l gt i Of EM Bottom cam Lift up turn amp release FIGURE 27 20 BIFFI ALGA DOUBLE ACTING PNEUMATIC ACTUATOR INSTALLATION OPERATION AND MAINTENANCE MANUAL NOTES 1 The working ambient temperature of the enclosures Shall be as follows Resin enclosure 20 to 40 C Aluminium or stainless steel enclosure 40 to 60 C 2 The maximum upper ambient temperature ES of the equipment when installed with P amp F sensors is dependent on its certificate parameters with regards to T class and barrier type 6 The maximum upper ambient temperature shall not be considered to be higher than the following limits Resin enclosure 40 C Aluminium or stainless steel enclosure 60 C If the CS or RS transmitter is used in conjunction with any switches sensors or solenoids then the max surface temp for gas and dust shall be shown on the label The electrical rating of the internal components are as follows Switch type Electrical rating Cat no V3 mechanical SPDT gold plated simple apparatus Ui 30 V li 100 mA Pi 1 W Ci lt 10 nF Li 10 uH 1 Magnum XT90 proximity switch simple apparatus Ui 30 V li 100 mA Pi 1W Ci 10nF Li 10uH 1 CS transmitter Ui 28 V li 100 mA Pi 0 75 W Ci 68 3 nF Li 0 uH 1 RS transmitter Bourns type 3852C UE SV i 100 mA PEN SW 1 IFM NS5002 BVS 04 ATEX E153 Ex ia IIB only Ui 15 V li 50 mA Pi 120 mW Ci BU nF Li 110 UH 1 Tu
5. gas supply filtering degree dehydration are as prescribed 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 par 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 BIFFI ALGA DOUBLE ACTING PNEUMATIC ACTUATOR INSTALLATION OPERATION AND MAINTENANCE MANUAL 3 OPERATION AND USE 3 1 OPERATION DESCRIPTION In the normal operating situation the ALGA 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
6. k en tr Ld Mr k i p Ei ae e a ri ES 1 i E F ET ke VA Li i i r DE S H F Item Q ty Description Material 1 4 Screw Alloy steel Ea 1 Gasket Fiber 3 1 Side plate Carbon steel figs 2 Gasket Fiber 5 1 Washer Carbon steel 6 2 Adaptor bush Alloy steel 7 4 Washer Copper 8 4 Screw Alloy steel 9 1 Washer Carbon steel Recommended spare parts 34 BIFFI ALGA DOUBLE ACTING PNEUMATIC ACTUATOR INSTALLATION OPERATION AND MAINTENANCE MANUAL FIGURE 37 HYDRAULIC CONTROL UNIT MHP uo en Pa pr mm CN un 20 e pr TF Ex Ae 09 HK N MM Me le i H BN Bh H H H NN H H i Mile Mi Mi Ve S to SA E 3 S p F SU T EN st O dTa w D 3 LI 4 Ke S SEE gt HHH if EN NR 9 HET JE Fa C m tee U i YS y A E N A N L CP 35 BIFFI ALGA DOUBLE ACTING PNEUMATIC ACTUATOR INSTALLATION OPERATION AND MAINTENANCE MANUAL Item Q ty Description 1 1 Dipstick 2 2 Cap nut y 2 Washer 4 1 Hydraulic tank 3 1 Hand pump Cn 2 O ring 7 2 Ball 8 2 Spring E 1 Washer 10 1 Screw 11 1 Plate 12 1 Flange 13 4 Screw 14 1 Lever 15 1 Distributor lev 1 O ring Vi 1 O ring 18 1 Nozzle 19 2 Screw AS O ring I 2 O ring 27 1 Tank cover 23 2 Tie rod 24 1 Screw 25 1 Flange 26 2 Check valve body 27 2 Plug 28 2 Flow control valve setting screw 29 2 Spring pin 30 2 Nut S 2 Flange S O rin
7. 13 1 O ring 14 1 Thrust nut operating cam 13 1 Screw 16 1 Nut 17 1 Flange 18 1 Body 17 1 Spring pin 20 2 Screw 21 1 Ball 1 4 27 1 Screw 23 1 Screw nut 24 1 Pin 25 1 Spring 26 1 Bush 27 2 Thrust shoulder washer 28 1 Operating instruction plate Recommended spare parts Material Carbon steel Carbon steel Stainless steel Fluorosilicon rubber Fiber Carbon steel Alloy steel Carbon steel Stainless steel Carbon steel Alloy steel Fluorosilicon rubber Alloy steel Carbon steel Carbon steel Carbon steel Carbon steel Spring steel Carbon steel Stainless steel Carbon steel Bronze Carbon steel Spring steel Bronze Bronze Aluminium 38 BIFFI ALGA DOUBLE ACTING PNEUMATIC ACTUATOR INSTALLATION OPERATION AND MAINTENANCE MANUAL 8 DATE REPORT FOR MAINTENANCE OPERATIONS Last maintenance operation date in factory on delivery oooocoonionicncccccciccccconocacinoso A A ls Next maintenance operation date Start up date lin factory on delivery c oocococicicociciconicioniccccccnncnoso plant 0 sc 39 gt PENTAIR PENTAIR VALVES amp CONTROLS www pentair com valves All Pentair trademarks and logos are owned by Pentair plc All other brand or product names are trademarks or registered marks of their respective owners Because we are continuously improving our products and services Pentair reserves the right to change product designs and specifications without notice
8. 2 and clean the internal surfaces of the tank If necessary substitute the gaskets 21 of the tank e Replace the plug 27 and the washer 9 into the plate 11 and tighten e Pour the new oil into the tank through the dipstick hole 1 on the cover 22 e Replace the dipstick 1 e Add oil refer to table 2 if in the tank the oil level is BELOW THE MINIMUM figure 29 minimum level is in correspondence to the end of dipstick until to reach the optimal MAXIMUM oil level e Operate the distributor lever to Remote position FERMETURE MANUELLE CHIUSURA MANUALE REMOTE AUTOMATE IMPORTANT For refill use oil of the same brand as previous refer to related technical documentation 23 BIFFI ALGA DOUBLE ACTING PNEUMATIC ACTUATOR INSTALLATION OPERATION AND MAINTENANCE MANUAL TABLE 2 FEATURES OF HYDROLIC OIL Standard temperature conditions 30 C 85 Producer AGIP Name ARNICA 22 Viscosity at 40 C 20 9 mm s Viscosity at 100 C 4 73 mm s Viscosity index ASTM 153 Flash point 192 C Pour point 42 C Specific weight at 15 C 0 857 kg l suggested by Biffi Italia S r l for refilling in different working condition Equivalent oils SHELL TELLUS PLUS 22 CHEVRON HYDRAULIC OIL AW ISO 22 MOBIL DTE22 EXXON UNIVIS N22 EQUIVIS 4522 BP ENERGOL HLP HM22 CASTROL DYSPIN AWS22 Low temperature conditions until 46 C Producer SHELL Name AEROS SI FEUD Viscosity at 54 C 2300 CST
9. Customer Service Restore par 3 3 Restore par 3 4 Position the handle on the indication of the operation to make handle positioned on remote control Call Biffi Italia S r l Customer Service 30 BIFFI ALGA DOUBLE ACTING PNEUMATIC ACTUATOR INSTALLATION OPERATION AND MAINTENANCE MANUAL 7 2 PARTS LIST FOR MAINTENANCE AND REPLACING PROCEDURE FIGURE 33 SCOTCH YOKE MECHANISM 13 POPES PIE ERD a SS ee Item Q ty Description Material IS 4 O ring NBR 2 2 Yoke bushing Bronze 3 2 Retainer ring Stainless steel 4 1 Housing Carbon steel 1 Guide bar Alloy steel 6 1 Yoke Carbon steel qe 1 Cover gasket Fiber 8 1 Guide block Carbon steel 9 1 Bushing Steel bronze PTFE 10 2 Sliding block Bronze 117 1 Vent valve Stainless steel 12 12 Screw Carbon steel 13 1 Cover Carbon steel 14 1 Guide block pin Alloy steel Recommended spare parts BIFFI ALGA DOUBLE ACTING PNEUMATIC ACTUATOR INSTALLATION OPERATION AND MAINTENANCE MANUAL FIGURE 34 PNEUMATIC CYLINDER Item Q ty Description 1 1 Piston rod bushing DE 1 O ring a 2 O ring 4 1 Head flange 5 12 Nut 6 6 Tie rod 7 1 Cylinder tube 8 1 Piston rod 9 1 Piston 10 1 End flange 11 1 Liftting eyelet 12 2 Spring washer 13 1 Washer 14 1 Sealing washer 15 1 Nut 16 1 Stop setting screw 17 1 Guide sliding ring for piston 18 1 O ring Recommended spare parts EZ Material Steel bronze PTFE NBR NBR Carbon s
10. KEM 06 0036X Cylindrical inductive sensors P F types NC and NJ PTB 00ATEX2048X Cuboidal inductive sensors HET types NJ and NC PTB 00ATEX2032X SN sensors Pepperl Fuchs types NJ PTB 00ATEX2049X Magnum XT90 proximity switch V3 microswitches CS transmitter RS transmitter Bourns type 3852C The certification applies to equipment WITHOUT cable glands When mounting the enclosure in the hazardous area only suitably rated 1P66 67 or 68 ATEX certified glands MUST BE USED All unused cable entries MUST be plugged with a suitably rated 1P66 67 or 68 ATEX certified blanking devices The first two digits of the Westlock nomenclature signifies the series with the third digit defining whether the product has a visual beacon or not The fourth digit identifies the switch sensor type The fifth digit details the enclosure material R Resin A Aluminium S Stainless steel The table below details the applicable ambient ranges Tamb Ta range ATEX T6 20 C to 55 C 1G T5 20 C to 60 C IEC 20 C to 60 C 25 C to 60 C AG fo TO See Fe 0080 40 C to C See certificate lt 460 C ORG O Seercertiicate lt 00 C T1 T6 40 C to 60 C T1 T6 40 C to 60 C T1 T6 40 C to 60 C T1 T4 40 C to 60 C T1 T4 40 C to 60 C Resin enclosure Metal enclosure FIGURE 26 Top cam Push down turn amp release
11. Pentair is an equal opportunity employer 2015 Pentair plc All rights reserved 40
12. biggest actuator models the bore of the yoke the valve stem provided its dimensions match can be machined according to the dimensions the maximum stem acceptance of the bush of valve stem according to Biffi doc TN1005 The particular execution of the flange and bushing allow the Position 2 Position 3 actuator to be rotated by 90 in 4 different Rotate insert bush 180 around Rotate insert bush 180 around positions according to figure 4D vertical standard position 1 axis A A from position 2 G X Flow line Ho Drive sleeve Position 4 Position 4 Rotate insert bush 180 around axis A A from position 1 Insert bush turned upside down BIFFI ALGA DOUBLE ACTING PNEUMATIC 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 e Operate the actuator so that it reaches the position matching valve position par 3 3 e Lubricate valve stem with oil or grease e Properly clean and remove grease from coupling fl
13. connections if present e 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 e Keep the actuator protected from direct weather conditions e Replace plastic plugs of pneumatic and electrical connections if any with metal plugs that guarantee perfect tightness e Coat with oil grease or protection disc the valve coupling area e Periodically operate the actuator par 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 SCN6200 and SCN6201 see next pages FIGURE 3A 3B Lifting points for ALGA ALGA MHP ALGA MSJ actuators
14. do so 3 With the actuator in the correct position attach the Accutrak bracket to the actuator using the hardware provided in the mounting kit 4 To release the cover loosen the cover retaining screws Twist the cover approx 45 and lift up See figure 26 below 5 To set the switches lift the bottom cam and turn until the switch has activated and then release The spring will push the cam back onto the splined shaft BIFFI ALGA DOUBLE ACTING PNEUMATIC ACTUATOR INSTALLATION OPERATION AND MAINTENANCE MANUAL 3 4 3 3 Field wiring and installation 3 WARNING The 3000 series should always be handled with care when the cover is removed 4 NOTE Before electrical installation please read and follow the wiring diagram located inside the cover The electrical ratings can be found on the d product I D label 1 Field wiring must be carried out in accordance with site local and national electrical codes requirements This includes special attention to earth bond to the aluminium or stainless steel enclosure using the internal and external earth points provided Installation of this product shall be carried out by competent personnel in accordance with the applicable code of practice such as EN 60079 14 2 Equipment Inductive proximity sensor IFM type NS5002 PTB O1ATEX2191 IECEx BYS 06 0003 Inductive proximity sensor Turck sensors type group KEMA 02 ATEX 1090X IECEx
15. gt PENTAIR BIFFI ALGA DOUBLE ACTING PNEUMATIC ACTUATOR INSTALLATION OPERATION AND MAINTENANCE MANUAL Bis d e 2 y TABLE OF CONTENTS 1 Genera IWS Sue metida cnsiics ost 1 MENN 3 3 Operation and USE Lunner 7 4 Operational tests and inspections 23 SJ ER 23 E NN 30 EE 30 8 Date report for maintenance operations 39 NOTE Biffi Italia S r l pays the highest attention to collecting and verifying the documentation contained in this user manual However Biffi Italia S r l is not liable for any mistakes contained in this manual for damage or accidents due to the use of the latter The information contained is of exclusive reserved ownership of Biffi Italia S r l and may be modified without prior notice www pentair com valves 1 GENERAL WARNINGS IMPORTANT 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 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 Machin
16. head flange 17 from the supply line mechanism housing 8 by removing the b discharge the pressure from the drain valve screw 15 only if the gasket 36 has to be c Remove the lover enclosure screws replaced because damaged d remove the mechanical filter el clean or replace the filter Reinstall all parts carefully paying attention to avoid any damage to the O ring 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 cylinder seals refer to figure 31 IMPORTANT Before executing any maintenance operation itis necessary to intercept the supply line and discharge pressure from the cylinder of the actuator If the actuator can be operated it is essential to take it to fail safe position otherwise the actuator should be disassembled from the valve and follow these steps 24 BIFFI ALGA DOUBLE ACTING PNEUMATIC 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 oil SHELL OMALA S4 W
17. is allowed by the conditions of the plant refer to specific operating diagram in technical documentation furnished with actuators MAXIMUM LEVEL MINIMUM LEVEL FIGURE 29 Level measuring stick e Check there are no hydraulic or pneumatic leakages e Check oil level figure 29 into the hydraulic control unit see par 5 1 1 e Check the actuators did not undergo accidental damage with oil leakages found on site par 4 1 1 e Check that improper closing of control group cover did not produce the presence of condensation on it e Check the integrity of worn out parts gaskets pads etc e Replace if any the mechanical filter of the supply gas refer to par 5 1 2 5 1 1 Check and restore oil level in the hydraulic manual override refer to par 7 2 figure 37 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 follow e Remove the dipstick 1 from the tank cover 22 e Unscrew the plug 27 and the washer 9 to drain all the oil e 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
18. supply Blocked valve Wrong position of the distributor of the manual hydraulic group Failure of the control group Low supply pressure Actuator too slow Low supply pressure Wrong calibration of flow regulator valves Wear of the valve Actuator too fast High supply pressure Wrong calibration of flow regulator valves Leakages on hydraulic or pneumatic circuits Deterioration and or damage to gaskets Incorrect position of the valve Wrong adjustment of mechanical stops Wrong warning of microswitches Hydraulic manual pump does not work Leakages on the check valve of the hydraulic control group 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 par 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 Tel 0523 944523 Fax 0523 941885 E mail spareservice biffi it Please specify Actuator model Biffi acknowledgement Spare parts code Quantity Transport condition Involved people Os EN fv E a Remedy Restore it Open line interception valve Repair or replace Restore correct position Call Biffi Italia S r l Customer Service Restore par 1 4 Restore par 1 4 Restore par 3 5 Replace Restore par 1 4 Restore par 3 5 Call Biffi Italia S r l
19. the serial number of the actuator and the technical data reported on the identification plate correspond with those of order confirmation par 1 2 e Check that the actuator is equipped with the fittings as provided for by order confirmation e Check that the actuator was not damaged during transportation if necessary renovate the painting according to the specification reported on the order confirmation e f 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 par 3 3 and of microswitches if any par 3 4 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 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 2 3 STORAGE If the actuator needs storage before installation follow these steps e Place it on a wood surface in order not to deteriorate the area of valve coupling e Make sure that plastic plugs are present on the pneumatic and electrical
20. to do so and that all hands are kept away from the moving shaft 6 Stroke the actuator to the opposite end of travel Set the top cam by pushing down and turning the cam until the switch is activated WARNING Before stroking the actuator please ensure that ae are the process IS safe to do 50 and that all hands are amp release kept away from the moving shaft GREG 7 Stroke the actuator from one end of stroke to the other several times to check the switch operation If the switches require adjustment repeat steps 5 to 7 3 4 1 3 Field wiring and installation The 2200 series should always be handled with N i 78 pm care when the cover Is removed and wired to PA electrical power source BEAGON NOTE Before electrical installation please read and follow the wiring diagram located inside the cover The electrical ratings can be found on the product I D label Conduit B 1 Field wiring must be carried out in double coil optional accordance with site local and national electrical codes requirements This includes special attention to earth bond to Conduit Condado Conduird the aluminium enclosure using the internal single coil and external earth points provided FIGURE 21 BIFFI ALGA DOUBLE ACTING PNEUMATIC ACTUATOR INSTALLATION OPERATION AND MAINTENANCE MANUAL 4 The certification applies to equipment without cable glands When mounting the flamepr
21. 1 Attach the mounting bracket and adaptor out by competent personnel in accordance if required to the Quantum housing and with the applicable code of practice such as a shaft with the fasteners provided with the EN 60079 14 L mounting kit 3 The 2200 control monitor housing can offer To ensure that the 2200 series Quantum up to three of the following conduit entries is mounted correctly it may necessary M20 x 1 5p M25 x 1 5p 2 14 NPT or pl i to stroke the actuator to the fully closed 14 NPT These entries are detailed on a o P position the product I D label found on the product cover Please see figure 21 for conduit WARNING positions Before stroking the actuator to the fully closed position please ensure that the process IS safe VP 9 to do so C e e EI 2 CLOSED PA 3 With the actuator in the correct position FIGURE 19 attach the 2200 series Quantum bracket to the actuator using the hardware provided in the mounting kit Top cam To release the cover loosen the cover Push down turn retaining screws Twist the cover approx 45 amp release and lift up See figure 19 To set the switches lift the bottom cam and turn until the switch has activated and then release The spring will push the cam back onto the splined shaft 4 D WARNING Before stroking the actuator please ensure that the process IS safe
22. 5 05 BIFFI ALGA DOUBLE ACTING PNEUMATIC ACTUATOR INSTALLATION OPERATION AND MAINTENANCE MANUAL sel G CONSTA YEAR gt SUPPLY PRESSURE RANGE VALVE TAG Relerence 1P47M 11200125 C T jens p s NEMA 4088 FIGURE 1 Data plate 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 figure 1 1 3 INTRODUCING THE ACTUATOR The ALGA actuator is engineered and manufactured to provide maximum torque output with minimum supply pressure ALGA 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 ab
23. C2 FIGURE 13A C1 3 1 gas 1 2 d I ee aan T lt l P FIGURE 13B Wrench c1 Wrench c2 Actuator model mm mm 14 17 60 18 17 60 32 17 60 50 IIE 60 e y L 3 e m FIGURE 14B Mechanical stop on the housing BIFFI ALGA DOUBLE ACTING PNEUMATIC ACTUATOR INSTALLATION OPERATION AND MAINTENANCE MANUAL Wrench c1 Wrench c2 3 1 GIG actuator size mm mm E z 0 3 34 34 BLY 34 34 FIGURE 15 Optional if foreseen For the adjustment of the mechanical stop screwed on the end flange of manual override see par 7 2 figure 33 sectional drawing for manual jackscrew MSJ MHW 3 1 Wrench c1 Wrench c2 4 GIG actuator size mm mm 1 5 24 65 3 24 65 FIGURE 17 Mechanical stop on the end flange of manual override FIGURE 16 Optional if foreseen For the adjustment of the mechanical stop on Hydraulic the end flange of hydraulic cylinder of MHP cylinder Wrenchc1 Wrenchc2 Wrench c3 follow these steps figure 18 size mm mm mm e Remove with the specific wrench c1 the 075 22 10 36 plug t 100 22 10 36 e Insert a wrench for Allen keys c2 in the 135 22 10 36 through hole until reaching the adjustment 175 22 14 46 pin g 200 27 14 46 e Keep the protection cover blocked with the 205 27 17 65 special wrench c3 280 27 17 65 e Turn counter clockwise to increase the 300 36 IS 110 angular stroke turn clockwise to decrease It e When the adjustment is over
24. E or equivalent If the O ring must be replaced remove the existing one from its groove clean the groove carefully and lubricate it with protective oil film Assemble the new O ring into its groove and lubricate it with a protective oil film 1 Replace the O rings 39 40 of the head flange 17 2 Replace the O ring 42 and the guide sliding ring 41 of the piston 21 Replace the O ring 40 of the end flange 22 If the sealing washer 43 has to be replaced measure the protrusion of the stop screw 26 with reference to the end flange 22 surface so as to be able to easily restore the setting of the actuator mechanical stop in the closed valve position once the maintenance procedures have been completed 1 Loosen the lock nut 25 and unscrew the stop screw 26 until it is removed together with the nut 25 the washer 44 and the sealing washer 43 Remove the sealing washer 43 from the stop screw 26 Carefully clean and lubricate the stop screw thread and the surface of the end flange area on which the sealing washer works Screw the new sealing onto the stop screw until it touches the nut 25 Assemble the washer 44 onto the sealing washer 43 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 Check that the sealing washer 43 and the washer 44 are in contact with the fl
25. ENSIONS MODELS 14 TO 42 mm Actuator model d d d Od N h hz Hmax 0d 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 BIFFI ALGA DOUBLE ACTING PNEUMATIC ACTUATOR INSTALLATION OPERATION AND MAINTENANCE MANUAL FIGURE 4C FIGURE 4D ACTUATOR MODELS 50 AND 60 INSERT BUSH INTERMEDIATE COUPLING FLANGE Drive sleeve Housing 0 1 dzo dq l Pei d d max N threaded holes oO a sizing according to ISQ 5211 So Flow line xX m D Pa y Top view of the Scotch yoke mechanism actuator shown in closed position Position 2 COUPLING DIMENSIONS MODELS 50 AND 60 mm Actuator model 0d dz d Od N h hz Hmax Od W K 50 800 315 698 M36 24 10 32 430 240 56 264 8 60 840 sil 698 M36 24 10 32 430 240 56 264 8 If required for the standard models size The Biffi insert bush with 2 external keys at 45 0 3 to 6 Biffi can supply an insert bush with allows to position the keyway for the valve every un machined bore in accordance with Biffi 90 Consequently actuator can be mounted standard table SCN6202 On request the insert in 4 positions at 90 on top of the valve For bush bore can be machined by Biffi to couple
26. Plug 19 O ring 20 Plug BIFFI ALGA DOUBLE ACTING PNEUMATIC 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 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 par 2 2 If the a
27. UBLE ACTING PNEUMATIC ACTUATOR INSTALLATION OPERATION AND MAINTENANCE MANUAL FIGURE 37A HAND PUMP Item Q ty Description 1 2 Ball 2 1 Delivery valve bush 3 1 Suction valve bush 4 2 Spring 5 1 Suction valve ring 6 1 Spring retainer ring 7 1 Fork 8 2 Pin 9 4 Retainer ring 10 1 Rod 11 1 Body 12 1 Lever ha 1 Split pin with rope 14 1 Scraper ring 15 1 Threaded bush 16 2 Rod seal ring 17 2 O ring TIE 1 O ring 19 1 Nut 20 1 Screw 21 1 Fork 20 1 Piston rod bushing Recommended spare parts Material Stainless steel Carbon steel Carbon steel Stainless steel Carbon steel Carbon steel Carbon steel Stainless steel Carbon steel Alloy steel Carbon steel Carbon steel Nylon carbon steel PTFE fluorosilicon rubber Aluminium PTFE graphite Fluorosilicon rubber Fluorosilicon rubber Carbon steel Carbon steel Carbon steel Steel bronze PTFE S BIFFI ALGA DOUBLE ACT NG PNEUMATIC ACTUATOR INSTALLATION OPERATION AND MAINTENANCE MANUAL FIGURE 38 JACKSCREW MANUAL OVERRIDE MSJ OR MHW gg R C Eee 1 3 4 5 6 7 8 9 10 11 12 13 14 i 4 Ta E R F m ANE Ve So es er Pad Ass gt ree 7 mum 15 16 17 18 19 20 21 22 23 24 25 26 27 28 Item Q ty Description 1 1 Protection pipe 2 3 1 Jackscrew 4 1 Engagement lever pin 9 1 O ring o 1 Cover gasket 7 1 Cover 8 3 Cam 9 1 Fork 10 3 Spring pin 11 3 Screw 12 1 Screw nut operating cam
28. ange surface Tighten the lock nut 25 2 3 4 7 6 Z Reassemble 1 Assemble the new gasket 36 after cleaning the surfaces of housing 8 and head flange 17 which are in contact Assemble the head flange 17 replace the washers 37 if damaged tighten the screws 15 to the recommended torque Lubricate the piston rod 20 surface with a protective oil film and introduce it into the head flange hole taking care not to damage the O ring 39 Carefully clean the threaded end of the piston rod 20 and the threaded hole of the adaptor bush 30 of guide block 14 Spreads some sealant LOCTITE 452 or equivalent on the rod threaded end and screw into the adaptor bush 30 threaded hole and tighten 2 E 4 Carefully clean the inside of the tube 19 and check that the entire surface particularly that of the bevels is not damaged Lubricate the inside surface of the tube and the bevels at the ends Slide the tube onto the piston taking care not to damage the piston O ring 42 and the head flange O ring 40 5 Assemble the end flange by centring it on the inside diameter of the tube taking care not to damage the O ring 40 6 Assemble the washers 24 and the nuts 16 onto the tie rods 18 Tighten the nuts to the recommended torque alternating between opposite corners 7 Restore a generous coating of grease on the contact surfaces of th
29. ange surfaces e Connect if supplied separately the adjustment insert to valve stem and fasten It with the special fastening pins e Lift the actuator using the special lifting points par 2 2 e Install the actuator so that valve stem Inserts in the coupling area This coupling should be made without forcing e 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 par 3 3 e Fasten threaded connections Please refer to table 1 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 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 e Properly de burr the ends of rigid pipes e Properly clean the interior of pipes sending through them plenty of the supply fluid used in the system e Mould and fasten the connection pipes so that no irregular strains at entries
30. ans of a resistive signal RS or current signal CS The RS transmitter electrical ratings are I k ohms standard or 5 k ohms optional See 1 0 M TECH 084 The CS transmitter electrical ratings are current loop 4 20 mA at 18 to 24 V DC See 1 0 M TECHUK 301 9 The 2200 series valve control monitor has the ability to connect to bus networks via Netpak modules With the Netpak options It may be possible to assemble other switches within the enclosure depending on enclosure cover variation 9 1 Netpak electrical parameters Netpak option Electrical parameters 1 0 M AS I Actuator Sensor Interface 24 V DC 140 mA MAX TECH 316 Device Net 24 V DC 105 mA MAX TE H 30 Modbus 24 V DC 85 mA MAX TECH 214 Profibus DP 24V DC 120 mA MAX TECH 326 Foundation Fieldbus 9 32 V DC 34 mA MAX TECH 485 10 Digit 10 of the Westlock nomenclature signifies the coil voltage with the following voltage and type available 24 48 110 and 240 V AC or VDC 11 Before replace the enclosure cover ensure that both of the housing and cover flange surfaces are clean and undamaged Tighten the cover screws hand tight using a standard 6 mm A F Allen key ensuring there are no gaps 3 4 1 4 Product repair and service 1 2 3 4 Inspection of this product shall be carried out by suitably trained personnel in accordance with the applicable code of practice such as EN 60079 17 In the event of any repairs that may be required such tasks must be ca
31. by suitably trained personnel in accordance with the applicable code of practice such as EN 60079 17 2 In the event of any repairs that may be required such tasks must be carried out by suitably trained competent personnel in accordance with the applicable code of practice such as EN 60079 19 3 The certification of this product has been approved based on the material of construction as per the drawings listed in the schedule within this certificate Any replacement parts that are not made in accordance to the listed drawing will invalidate the approval certification 4 Replacement parts must be purchased through Westlock Controls UK Ltd or via an approved Westlock Controls distributor FE EE EM MS BIFFI ALGA DOUBLE ACTING PNEUMATIC ACTUATOR INSTALLATION OPERATION AND MAINTENANCE MANUAL 3 5 CALIBRATION OF THE OPERATING TIME OPTIONAL IF FORESEEN The calibration of the operating time Is made by Biffi Italia S r l 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 placed between the control valves enclosure and the pneumatic cylinder figure 28 To carry out the adjustment use an adequate Allen wrench and follow these steps figure 28 e Loosen the locknut e Screw with a screwdriver the setting screw to increase the operating time e Unscrew wi
32. cable entries dependant on enclosure material for connection to an external power source via appropriate ATEX certified cable glands M20 x 1 5p M25 x 1 5p 2 T4NPT 14 NPT PG13 5 or any other suitable thread that can maintain IP6X ingress rating Note Before installation of this product please ensure that the product and its certification IS suitable for the intended application If the equipment is likely to come into contact with aggressive substances then it is the responsibility of the user to take suitable precautions that prevent it from being adversely affected thus ensuring that the type of protection provided by the equipment IS not compromised Installation of any cable entry devices conduit entry devices or blanking devices shall not compromise the degree of ingress protection level IP6X for use in the presence of combustible dusts The unit has an ingress protection of 1P66 67 and therefore any conduit device fitted must maintain this WARNING Electrostatic hazard clean only with damp cloth 3 4 3 2 Mounting instructions 1 Attach the mounting bracket and adaptor if required to the AccuTrak housing and shaft with the fasteners provided with the mounting kit 2 To ensure that the AccuTrak is mounted correctly It may be necessary to stroke the actuator to the fully closed position WARNING Before stroking the actuator to the fully closed position please ensure that the process IS safe to
33. cal stops screwed into the left side of the housing open valve and into the end flange of the pneumatic cylinder closing figures 11A and 11B In case of an actuator with two cylinders figure 12 both mechanical stops are screwed on the end flanges of the cylinders Pneumatic connection to open Pneumatic connection to close Ra Relief valve for automatic operation Rm Relief valve for manual operation P Hand pump D Hand operated directional control valve FIGURE 10B MANUAL OPERATION The diagram is drawn with actuator under manual operation towards open The operation to be performed is selected by the directional control valve D Pneumatic connection 3 to open IH TR 0 E i 4 i Pneumatic rr PI op connection to close Fa Unidirectional flow regulator opening operation Fc Unidirectional flow regulator closing operation Fr Bidirectional flow regulator Cv Check valve Ot Oiltank Ls Level stick with relief valve FIGURE 11A 11B Mechanical stops FIGURE 12 Actuator with two cylinders BIFFI ALGA DOUBLE ACTING PNEUMATIC ACTUATOR INSTALLATION OPERATION AND MAINTENANCE MANUAL For the adjustment of the travel stop screws proceed as follows see figures 13A 13B 1 Loosen the lock nut 2 with a proper wrench c2 If the actuator angular stroke is stopped before reaching the end position fully open or closed unscrew the stop screw 1 by
34. control valve can have many types of actuating devices solenoid manual control pneumatic pilot spring etc The spring return control valves allow fail safe operation The system allows fail safe operation when the pressure in the gas supply line drops below a set value The diagram shows the actuator in the fail safe condition When the gas supply pressure drops below the pressure switch 5 set point the pneumatic supply to the solenoid valve 6 pilot is exhausted and the actuator moves to the fail safe position by using the gas stored in the tank 4 The tank is connected to the gas supply through the check valve 3 When modulating control is required as a function of a pneumatic or electric control signal a positioned 5 is used which controls the supply to the actuator cylinder to keep the valve in the required angular position The positioner has a mechanical linkage to the actuator for a feedback of the valve position FIGURE 8A ON OFF SERVICE FOUR WAY CONTROL VALVE mk Manual control Xp Pneumatic pilot control ral BRA Dual solenoid control Solenoid E Pressurized air control mn Atmospheric pressure air FIGURE 8B ON OFF SERVICE AIR FAIL SAFE SYSTEM Gay Pressurized air EJ Pressurized air low pressure E Atmospheric pressure air FIGURE 8C MODULATING SERVICE Electropneumatic positioner Pneumatic positioner Electric control signal Pneumatic con
35. ctuator needs storage before demolition see par 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 lex metallic and plastic materials fluids etc and send them to differentiated waste collection sites as provided for by the laws and provisions in force AGIP MU EP 2 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 mm s ISO Classification L X BCHB 2 DIN 51 825 KP2K 20 Equivalent to ESSO BEACON EP2 dd da aa Vedl DO SHELL ALVANIA GREASE R2 ARAL ARALUB HL2 CHEVRON DURALITH GREASE EP2 CHEVRON SPHEEROL AP2 TEXACO MULTIFAK EP2 MOBILPLEX 47 PETROMIN GREASE EP2 AEROSHELL GREASE 7 or equivalent To be used in low temperature conditions 60 C 65 C Color Buin Physical state Semi solid at ambient temperature Odour Slight Density 966 kg m 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 29 BIFFI ALGA DOUBLE ACTING PNEUMATIC ACTUATOR INSTALLATION OPERATION AND MAINTENANCE MANUAL 6 TROUBLESHOOTING 6 1 FAILURE OR BREAKDOWN RESEARCH Event Possible cause Actuator does not work Lack of power supply Lack of pneumatic
36. e directive 97 23 EC Directive for pressure PED equipment 2006 95 EC Directive for low voltage equipment 2004 108 EC Directive for the electromagnetic compatibility 94 9 EC Directive and safety instructions for use In hazardous area 1 1 2 Terms and conditions Biffi Italia S r l 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 2012 Pentair plc All Rights Reserved installation maintenance or use or by irregular working conditions the repairs will be charged according to applicable fees The warranty and Biffi Italia S r l liability shall lapse in the event that any modification or tampering whatsoever be performed on the actuator VCIOM 03129 EN 1
37. e yoke 11 and the bushing 33 on the yoke grooves on the sliding block 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 the O ring 32 10 Assemble the cover 1 and the screw 2 Tighten the screws to the recommended torque 11 Carry out a few actuator operations to check that its movement is regular and that there is no air leakage through the seals 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 25 BIFFI ALGA DOUBLE ACTING PNEUMATIC ACTUATOR INSTALLATION OPERATION AND MAINTENANCE MANUAL FIGURE 31 ALGA DOUBLE ACTING PNEUMATIC ACTUATOR 1 3 G i I ES 65 X A G At RA eg Q G D Z SS L Z K Ss E c 2 RR K py UG ZAZ MLL MZ ZZ MU Item Description Item Description Item Descr
38. ed flameproof glands must be used 7 All unused cable entries must be plugged with a suitably rated IP66 67 ATEX certified blanking devices 6 protection 7 Thread adaptors shall satisfy the requirements of the specific type of The first two digits of the Westlock nomenclature signifies the series with the third digit defining whether the product has a visual beacon or not The table below details the applicable ambient ranges Series code Cover type 264 Beacon 264 Beacon 264 Beacon 266 No beacon 266 No beacon 266 No beacon T class Ambient range T6 80 C 60 C to 65 C 1519520 60 C to 80 C T4 130 C 60 C to 110 C T 80 C 60 C to 65 C 15 95 C 60 C to 80 C rene 60 C to 110 C 8 The forth digit designates the switch sensor type The following table details the most common switch sensor types together with their electrical ratings Series code Switch designation 26 5 26 6 26 7 2O79 Mechanical SPDT Mechanical DPDT Inductive proximity sensors Magnum ratings Electrical rating 15 A 125 or 250 V AC 0 5 A 125 V DC 0 25 A 250 V DC 10A 125 or 250 Y AC 10A 2V DC 0 2 A 125 V DC 3 A 120 V AC 1 5 A 240 VAC or 2 A 24V DC NOTE The series code signifies the maximum electrical rating of the product suitable overloading protection must be provided to prevent these values being exceeded 7 The 2600 s
39. eplace the piston seal ring 9 and the O ring 19 proceed as follows 1 Remove the existing PTFE seal ring 9 and the O ring 19 from their groove 2 Clean the groove carefully and lubricate it with a protective oil film 3 Assemble the new O ring into its groove and lubricate it with a protective oil film 4 Assemble the new PTFE seal ring 9 on its rubber O ring 19 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 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 stop setting screw cover 14 and unscrew the stop screw 11 6 Remove the O ring 17 from the stop screw 11 Carefully clean and lubricate the stop screw thread and the surface of the end flange area on which the O ring works 7 Screw the new O ring onto the stop screw until it touches the cover 14 8 Screw the stop screw into the threaded hole of the end flange until it reaches its original positio
40. eries valve position monitor has the option for position feedback by the means of a resistive signal RS or current signal CS The RS transmitter electrical ratings are I k ohms standard or 5 k ohms optional See 1 0 M TECH 084 The CS transmitter electrical ratings are current loop 4 20 mA at 18 to 24 V DC See 1 0 M TECHUK 301 10 Before replacing the enclosure cover ensure that both of the housing and cover threads are clean and undamaged Screw the cover onto the housing ensuring that it is not cross threaded and turns freely Continue tightening the cover until metal to metal condition is achieved between the bottom edge of the cover and the housing surface Lock the cover as follows Using a 3mm A F Allen key wrench rotate the Jack screw in an anti clockwise direction until sufficient pressure has been applied to the bottom edge of the cover to prevent the cover from being removed by hand 3 4 2 4 Product repair and service 1 2 3 4 Inspection of this product shall be carried out by suitably trained personnel in accordance with the applicable code of practice such as EN 60079 17 In the event of any repairs that may be required such tasks must be carried out by suitably trained competent personnel in accordance with the applicable code of practice such as EN 60079 19 The certification of this product has been approved based on the material of construction as per the drawings listed in the schedule
41. 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 FIGURE 7 FIGURE 6 Pneumatic connection For local or remote operations please refer for information only to par 3 3 and prior to technical documentation furnished with actuators Typical schematics for various applications are follow attached for information only the function described are furnished only on specific customer demand For all the relevant information please refer to the specific technical documentation supplied with actuators PARTS LIST Item Name Housing Yoke Yoke bushing Cover Guide block pin Sliding block Guide block Guide bar Guide block bushing Travel stop screw 0 JJ e 01 FE won gt ZA 0 ZOO Cylinder head flange 12 Piston rod bushing 13 Piston rod seal 14 Piston rod 15 Piston 16 Piston guide sliding ring 17 Piston seal ring 18 Cylinder tube 19 End flange 20 Travel stop screw 21 Sealing washer 22 Tie rod BIFFI ALGA DOUBLE ACTING PNEUMATIC ACTUATOR INSTALLATION OPERATION AND MAINTENANCE MANUAL The diagram shows the simplest On Off control The gas supply pressure is applied to one side of the cylinder and exhausted from the opposite side When the control valve 2 is actuated the connection of supply and exhaust to the cylinder chambers are reversed The
42. g 33 2 Spring 34 2 Plug 35 2 Retainer ring 36 2 Spring pin 37 4 Screw 38 1 Operation instruction plate 39 4 Screw 40 1 Spring 41 1 Ball 42 4 Ball 43 2 Spring 44 1 Relief valve setting screw 45 2 Spring pin 46 1 Screw 47 1 Spring 48 1 Nut 49 1 Washer 50 2 Washer 51 1 Dipstick Bj r 1 Plug O ring 53 1 Spring 94 1 Screw 55 1 Nut 56 1 Silencer SIR 2 O ring 58 2 Retainer ring 59 1 Dipstick body 60 2 Nut 61 1 Relief valve body Recommended spare parts Material Carbon steel Carbon steel rubber Carbon steel See attached table Fluorosilicon rubber Stainless steel Spring steel Carbon steel rubber Carbon steel Carbon steel Aluminium Carbon steel Carbon steel Stainless steel Fluorosilicon rubber Fluorosilicon rubber Carbon steel Carbon steel Fluorosilicon rubber Fluorosilicon rubber Carbon steel Carbon steel Carbon steel Aluminium Aluminium Carbon steel Stainless steel Stainless steel Carbon steel Carbon steel Fluorosilicon rubber Spring steel Stainless steel Spring steel Carbon steel Carbon steel Stainless steel Carbon steel Stainless steel Stainless steel Stainless steel Spring steel Stainless steel Carbon steel Alloy steel Stainless steel Carbon steel Carbon steel rubber Carbon steel rubber Stainless steel Stainless steel Alloy steel Carbon steel Brass Fluorosilicon rubber Spring steel Aluminium Carbon steel Aluminium 36 BIFFI ALGA DO
43. ge item 13 by centring It on the inside diameter of the tube taking care 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 11 Fig 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 36 Fig 26 after cleaning the surfaces of the housing item 8 Fig 26 and cover item 1 Fig 26 11 Lubricate with protective oil the O ring litem 32 Fig 26 12 Assemble the cover item 1 Fig 26 and the screws item 2 Fig 26 Tighten the screws to the recommended torque AFTER MAINTENANCE OPERATIONS CARRY OUT A FEW ACTUATOR OPERATIONS TO CHECK THAT ITS MOVEMENT IS REGULAR AND THAT THERE IS NO OIL LEAKAGE THROUGH THE SEALS 27 BIFFI ALGA DOUBLE ACTING PNEUMATIC ACTUATOR INSTALLATION OPERATION AND MAINTENANCE MANUAL FIGURE 32 HYDRAULIC CYLINDER 1 B 10 C 12 17 20 16 Item Description 1 Piston rod bushing 2 Head flange 3 O ring 4 Piston rod seal ring 5 O ring 6 Piston rod 7 Piston 8 Guide sliding ring for piston 9 Piston seal ring 10 Tie rod 11 Stop setting screw 12 Cylinder tube 13 End flange 14 Stop setting screw cover 15 Spring washer 1 6 Nut 17 O ring 18
44. he bottom cam and turn until the switch has activated and then release The spring will push the cam back onto the splined shaft Fig 24 WARNING Before stroking the actuator please ensure that the process IS safe to do so and that all hands are kept away from the moving shaft 6 Stroke the actuator to the opposite end of travel Set the top cam by pushing down and turning the cam until the switch is activated WARNING Before stroking the actuator please ensure that the process is safe to do so and that all hands are kept away from the moving shaft 7 Stroke the actuator from one end of stroke to the other several times to check the switch operation If the switches require adjustment repeat steps 5 to 7 8 Beacon setting if fitted Loosen the beacon fixing screw see figures 22 and 23 rotate beacon window outer beacon to indicate appropriate open or closed text as corresponding to actuator position 9 Tighten beacon fixing screw sufficiently to prevent movement of window ALGA DOUBLE ACTING PNEUMATIC ACTUATOR INSTALLATION OPERATION AND MAINTENANCE MANUAL 3 4 2 3 Field wiring and installation WARNING The 2600 series should always be handled with care when the cover is removed and wired to electrical power source NOTE Before electrical installation please read and follow the wiring diagram located inside the cover The electrical ratings can be found on the product I D label 1 Field wi
45. iption 1 Cover 17 Head flange 33 Yoke bushing 2 Screw 18 Tie rod 34 Retainer ring 3 Guide block pin 19 Cylinder tube 35 Flange 4 Vent valve 20 Piston rod 36 Gasket 3 Sliding block 21 Piston 37 Washer 6 Screw ZZ End flange 38 Piston rod bushing 7 Screw 23 Lifting eyelet 39 O ring 8 Housing 24 Spring washer 40 O ring 9 Guide bar 25 Nut 41 Guide sliding ring for piston 10 Cover gasket 26 Stop setting screw 42 O ring 11 Yoke 27 Nut 43 Sealing washer T Plug 28 Nut 44 Washer 13 Bushing 29 Stopper bush 14 Guide block 30 Adaptor bush 15 Screw 31 Washer 16 Nut 32 O ring 26 BIFFI ALGA DOUBLE ACTING PNEUMATIC ACTUATOR INSTALLATION OPERATION AND MAINTENANCE MANUAL b2 Replacement of hydraulic cylinder seals see figure 32 If there are leaks in the hydraulic cylinder ora 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 30 Fig 26 of guide block item 14 Fig 26 5 Slide off the piston rod from the head flange item 2 6 Di
46. lve control monitor provides two methods of end of travel indication by the means of mechanical switches inductive proximity sensors or proximity switches and an external visual indicator For applications that require position feed back ancillary components such as a 4 20 mA current signal transmitter or a resistive signal feed back can be installed The 2600 series enclosure IS available in two materials cast aluminium or 316 stainless steel The enclosure construction comprises of a housing with a screwed cover The housing has the option of upto three cable entries for connection to an external power source via appropriate ATEX certified cable glands M20 x 1 5p M25 x 1 5p 1 2 14 NPT or Y 14 NPT Note Before installation of this product please ensure that the product and its certification is suitable for the intended application This product uses various O ring material and an Eastar Copolyester visual indicator If the equipment is likely to come into contact with aggressive substances then it is the responsibility of the user to take suitable precautions that prevent it from being adversely affected thus ensuring that the type of protection provided by the equipment IS not compromised Installation of any cable entry devices conduit entry devices or blanking devices shall not compromise the degree of ingress protection level IP6X for use in the presence of combustible dusts The unit has an ingress pr
47. n the same protrusion with reference to the flange surface 9 Check that the O ring 17 is inside the groove into the end flange and in contact with the groove bottom surface Reassemble 1 Assemble the new gasket item 36 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 30 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 film the tube inside surface and the bevels at the ends Slide the tube onto the piston taking care not to damaged the PTFE seal ring litem 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 flan
48. oil tank relief valve and two unidirectional flow regulators The directional control valve has three operating positions remote the actuator is operated by pneumatic supply to open the actuator operation is opening by hand pump On request the hydraulic manual override type MHP2 double hand pump version can be Supplied which allows the remote control to automatically override manual operation FIGURE 9A EMERGENCENCY MANUAL OVERRIDE FIGURE 9B MHP HYDRAULIC MANUAL OVERRIDE BIFFI ALGA DOUBLE ACTING PNEUMATIC ACTUATOR INSTALLATION OPERATION AND MAINTENANCE MANUAL FIGURE 10A PNEUMATIC OPERATION The diagram is drawn with actuator under pneumatic operation in opening The flow regulator Fa allows control of the stroke time Scotch yoke mechanism 1 E Pneumatic cylinde 3 mm Hydraulic cylinder 4 Hydraulic manual override MN High pressure oil C Intermediate pressure oil NA Low pressure oil HM Pressurized air 7 Atmospheric pressure air 3 2 RESIDUAL RISKS WARNING lt is recommended to pipe exhaust gas The actuator has parts under pressure Use the due caution Use individual protections provided for by the laws and provisions in force 3 3 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 mechani
49. oof enclosure in the hazardous area only suitably rated 1P66 67 ATEX certified flameproof glands must be used All unused cable entries must be plugged with a suitably rated IP66 67 ATEX certified blanking devices The first two digits of the Westlock nomenclature signifies the series with the third digit defining whether the product has a visual beacon or not The table below details the applicable ambient ranges 7 6 Series code Cover type T class Ambient range 224 Beacon T6 80 C 30 C to 60 C 224 Beacon 15 05 C 30 C to 75 C 224 Beacon T4 130 C 30 C to 85 C 220 Flat T 80 C 20 C to 60 C 226 Flat TLC 20 C to 75 C 22o Flat T4 130 C 20 C to 85 C 7 The forth digit designates the switch sensor type The following table details the most common switch sensor types together with their electrical ratings Series code Switch designation Electrical rating 22 5 Mechanical SPDT 15A 125 or 250 V AC 0 5 A 125 V DC 0 25 A 250 V DC 22 6 Mechanical DPDT 10 A 125 or 250 V AC 10 A 28 V DC 0 2 A 125 V DC 22 7 Inductive proximity sensors 22 9 Magnum ratings 3A 120V AC 1 5A 240 VAC or 2A 24V DC NOTE he series code signifies the maximum electrical rating of the product suitable overloading protection must be provided to prevent these values being exceeded 8 The 2200 series valve position monitor has the option for position feedback by the me
50. or loosening of threaded connections occur e Make the connections according to the operating diagram e Check the absence of leakages from pneumatic connections 2 6 ELECTRICAL CONNECTIONS IF ANY IMPORTANT Use components appropriate as for type material and dimensions WARNING The connections should be made by qualified staff Before carrying out any operation cut line power off 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 e Screw firmly the cable glands e Introduce connection cables e Make the connections in compliance with applicable wiring diagrams on the documentation supplied e Screw the cable gland e Replace the plastic plugs of unused entries with metal plugs 2 7 COMMISSIONING WARNING Check that values of electrical supply to the control group lif foreseen are compatible with those on the plate on the junction box figure 5 Installation commissioning and maintenance and repair works should be made by qualified staff FIGURE 5 Junction box on control group if foreseen Upon actuator commissioning please carry out the following checks e Check that paint is not be damaged during transport If necessary repair the damages to paint coat e Check that the pressure and quality of the
51. otection of IP66 67 and therefore any conduit device fitted must maintain this Note These products have been certified with a cable entry temperature rise of 4 C Ensure that this is taken into consideration when selecting suitable cabling for the ambient temperature in which the product is to be used Note hese products are not intended to be assembled directly to process pipe work etc that is heated or cooled to temperatures outside of the range as indicated above WARNING Do not open when energized or when an explosive atmosphere IS present WARNING Electrostatic hazard clean only with damp cloth 3 4 2 2 Mounting instructions 1 Attach a mounting bracket to the housing base with the M8 fasteners provided with the mounting bracket Install shaft adaptor coupler as appropriate to either the actuator pinion or Accutrak shaft To ensure that the 2600 series Accutrak is mounted correctly it may necessary to stroke the actuator to the fully closed position Z WARNING Before stroking the actuator to the fully closed position please ensure that the process Is safe to do So 3 With the actuator in the correct position attach the 2600 series Accutrak bracket to the actuator using the hardware provided in the mounting kit 4 Unscrew the cover Fig 22 and keep in a safe place Ensure that the Jack screw M4 socket head cap screw remains in the housing Fig 23 5 To set the switches lift t
52. ove 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 Control system optional Valve position indicator 1 4 DATA SHEET Supply fluid Air nitrogen or sweet gas special version available for sour gas Operating Standard from 30 C to 100 C temperature Optional from 60 to 200 C Supply pressure Please refer to technical document Actuator data sheet Up to 750 000 Nm higher value with special version Output torque Manual hand pump MHP optional Pneumatic cylinder FIGURE 2 Identification of actuator parts Scotch yoke mechanism Valve coupling Hydraulic cylinder for ALGA MHP models or second pneumatic cylinder for ALGA 2 double cylinder models optional BIFFI ALGA DOUBLE ACTING PNEUMATIC ACTUATOR INSTALLATION OPERATION AND MAINTENANCE MANUAL 2 INSTALLATION 2 1 CHECKS UPON ACTUATOR RECEIPT e Check that the model
53. rck sensors KEMA 02 ATEX 1090X type group A Ui 20 V li 60 mA Pi 200 mW Ci 150 nF Li 150 yA 1 P amp F sensor number Certificate number Cat no P amp F sensor number Certificate number Cat no NJ2 V3 N PTB 00ATEX2032X SUPP 2 1 NJ2 12GM N PTB 00ATEX2048X SUPP 1 NCB2 V3 NO PTB 00ATEX2032X SUPP 2 1 NJ4 12GM N PTB 00ATEX2048X SUPP 1 NJ5 18GM N PTB 00ATEX2048X SUPP 1 NCE oo vee Oe PTB 00ATEX2048X SUPP 1 1 NJ8 18GM N PTB 00ATEX2048X SUPP 1 NCB2 12GM NO PTB 00ATEX2048X SUPP 1 1 NCN4 12GM NO PTB 00ATEX2048X SUPP 1 1 NIT SIRET PTB OOATEX2049X SUPP 1 NCB5 18GM NO0 PTB 00ATEX2048X SUPP 1 1 NJ2 11 SN PTB 00ATEX2049X SUPP 1 NCN8 18GM NO PTB 00ATEX2048X SUPP 1 1 NE Ze LS I PTB 00ATEX2049X SUPP 1 NCB10 30GM NO PTB 00ATEX2048X SUPP 1 1 NJ3 18GK S1N PTB 00ATEX2049X SUPP 1 NCN15 30GM NO0 PTB 00ATEX2048X SUPP 1 1 Nae ees PTB 00ATEX2049X SUPP 1 NJ2 11 N PTB 00ATEX2048X SUPP 1 1 NJ5 18GK SN PTB 00ATEX2049X SUPP 1 NU ZI Naas PTB 00ATEX2048X SUPP 1 1 NYSSOGKSINE PTB OOATEX2049X SUPP 1 NJ8 18GK SN PTB OOATEX2049X SUPP 1 7 Before replacing the enclosure cover ensure that both of the housing and cover sealing surfaces are clean and undamaged Tighten the cover screws hand tight using a suitably sized screwdriver or a metric 8mm A F spanner socket 3 4 3 4 Product repair and service 1 Inspection of this product shall be carried out
54. ring must be carried out in accordance with site local and national electrical codes requirements This includes special attention to earth bond to the aluminium enclosure using the internal and external earth points provided Installation of this product shall be carried out by competent personnel in accordance with the applicable code of practice such as EN 60079 14 The 2600 control monitor housing can offer up to three of the following conduit entries M20 x 1 5p M25 x 1 5p TR 14 NPT or Y 14 NPT These entries are detailed on the product I D label found on the product cover Please see figure 25 for conduit positions 2 3 a Beacon fixing screw M4 Visual indicator Beacon Enclosure base FIGURE 22 Standard enclosure Conduit C Conduit A Conduit B Conduit D Beacon fixing screw 8 32 UNC Visual indicator Beacon Enclosure base FIGURE 23 Alternative enclosure Top cam Push down turn amp release Bottom cam Lift up turn amp release FIGURE 24 Conduit C Conduit A Conduit B FIGURE 25 2600 conduit designations alternative enclosure BIFFI ALGA DOUBLE ACTING PNEUMATIC ACTUATOR INSTALLATION OPERATION AND MAINTENANCE MANUAL 4 The certification applies to equipment without cable glands When mounting the flameproof enclosure in the hazardous area only suitably rated 1P66 67 ATEX certifi
55. rried out by suitably trained competent personnel in accordance with the applicable code of practice such as EN 60079 19 The certification of this product has been approved based on the material of construction as per the drawings listed in the schedule within this certificate Any replacement parts that are not made in accordance to the listed drawing will invalidate the approval certification Replacement parts must be purchased through Westlock Controls UK Ltd or via an approved Westlock Controls distributor BIFFI ALGA DOUBLE ACTING PNEUMATIC ACTUATOR INSTALLATION OPERATION AND MAINTENANCE MANUAL 3 4 2 Westlock 2600 Series ATEX certified ITS 11 ATEX 17438X Ex d IIC Gb T Tamb C to C Ex tb IIIC Db T C Tamb C to C IP6X Ambient variation 60 C to 110 C T4 T1309C 60 C to 85 C T5 T95 C 60 C to 65 C T6 T80 C Environmental parameters 80 kPa 0 8 bar to 110 kPa 1 1 bar Air with normal oxygen content typically 21 The 2600 certification is compliant against the following standards EN 60079 0 2011 Ed 6 Electrical apparatus for explosive gas atmospheres Part 0 General requirements EN 60079 1 2007 Electrical apparatus for explosive gas atmospheres Part 1 Flameproof enclosures d EN 60079 31 2009 Electrical apparatus for use in the presence of combustible dust Part 31 Protection by enclosure t 3 4 2 1 Product description The 2600 series va
56. s ENGINE Electrical apparatus for explosive gas atmospheres Part 1 Flameproof enclosures d EN 61241 0 2006 Electrical apparatus for use in the presence of combustible dust Part 0 General requirements EN 61241 1 2006 Electrical apparatus for use in the presence of combustible dust Part 1 Protection by enclosures tD 3 4 1 1 Product description The 2200 series valve control monitor provides two methods of end of travel indication by the means of mechanical switches inductive proximity sensors or proximity switches and an external visual indicator For applications that require position feed back ancillary components such as a 4 20 mA current signal transmitter or a resistive signal feed back can be installed To allow this product to be used with network communication bus protocols the 2200 series enclosure can house various network modules The 2200 series enclosure comprises of a two parts a cover and housing The cover has three variations flat cover standard beacon cover or a high cover to suit different applications The housing can offer up to two integral solenoid coils and upto three of the following conduit entries M20 x 1 5p M25 x 1 5p 2 14 NPT or Y 14 NPT cable entries for connection to an external power source via appropriate ATEX certified cable glands Note Before installation of this product please ensure that the product and its certification is suitable for
57. sassemble the head flange from the mechanism housing item 8 Fig 26 by removing the screws item 7 Fig 26 only if the gasket litem 36 Fig 26 has to be replaced because damaged Seals replacement Prior to reassemble check that the actuator components are In good conditions and clean Lubricate all the surfaces of the parts which move in contact with other components by recommended oil SHELL OMALA S4 WE or equivalent If the O ring must be replaced remove the existing one from its groove clean the groove carefully and lubricate it with protective oil film Assemble the new O ring into its groove and lubricate it with a protective oil film 1 Replace the O rings 3 of the head flange 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 Clean the groove carefully and lubricate it with a protective oil film Assemble the new O ring into its groove and lubricate it with a protective oil film 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 2 3 4 To r
58. teel Carbon steel Alloy steel Carbon steel Alloy steel Carbon steel Carbon steel Carbon steel Carbon steel Carbon steel PVC Carbon steel Carbon steel PTFE graphite NBR 32 BIFFI ALGA DOUBLE ACTING PNEUMATIC ACTUATOR INSTALLATION OPERATION AND MAINTENANCE MANUAL FIGURE 35 HYDRAULIC CYLINDER optional only for ALGA MHP hydraulic handwheel manual override Item Q ty Description 1 1 Piston rod bushing 2 1 Head flange ER 2 O ring at 1 Piston rod seal ring SN 1 O ring 6 1 Piston rod 7 1 Piston oF 2 Guide sliding ring for piston qe 1 Piston seal ring 10 4 Tie rod 11 1 Stop setting screw 12 1 Cylinder tube 13 1 End flange 14 1 Stop setting screw cover 15 4 Spring washer 16 4 Nut 17 1 O ring 18 6 Plug 19 1 Plug 20 1 Plug Recommended spare parts G LE Material Steel bronze PTFE Carbon steel NBR rubber PTFE graphite NBR rubber Alloy steel Nickel plated carbon steel PTFE graphite PTFE NBR rubber Alloy steel ASTM A320 gr L7 Alloy steel Nickel plated carbon steel Carbon steel Carbon steel Carbon steel Carbon steel ASTM A194 gr 7 NBR rubber Carbon steel Carbon steel Carbon steel 33 BIFFI ALGA DOUBLE ACTING PNEUMATIC ACTUATOR INSTALLATION OPERATION AND MAINTENANCE MANUAL FIGURE 36 ASSEMBLY KIT foo oe one gh oo oh afm le Le ee HH il bar fF OD ie l w Z E i 1 a 4 ATA e Q 1 f r E wa
59. th a screwdriver the setting screw to decrease the operating time e After the adjustment is over screw the locknut For ALGA actuator models with manual hand pump MHP the operating time is adjustable through two regulation valves placed on manual hand pump body see par 7 2 figure 37 sectional drawing for hydraulic control unit MHP To carry out the adjustment use a suitable Allen wrench and follow these steps figure 14B e Remove the cap nut e Loosen the locknut e Screw with a screwdriver the setting screw to increase the operating time e Unscrew with a screwdriver the setting screw to decrease the operating time e After the adjustment is over screw the locknut and put back in place the cap nut Pneumatic connection Screwdriver A open unscrew for increase speed of operation FIGURE 28 Example of operating time adjustment if foreseen Lock nut l Acorn nut OA EPN Adjustment screw FIGURE 29 Flow regulators placed on manual hand pump MHP optional if foreseen Pneumatic connection 4 The a 22 BIFFI ALGA DOUBLE ACTING PNEUMATIC ACTUATOR INSTALLATION OPERATION AND MAINTENANCE MANUAL 4 OPERATIONAL TESTS AND INSPECTIONS IMPORTANT To ensure the guaranteed S L 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
60. the intended application This product uses various O ring material and an Eastar Copolyester visual indicator If the equipment is likely to come into contact with aggressive substances then it is the responsibility of the user to take suitable precautions that prevent it from being adversely affected thus ensuring that the type of protection provided by the equipment is not compromised Installation of any cable entry devices conduit entry devices or blanking devices shall not compromise the degree of ingress protection level IP6X for use in the presence of combustible dusts The unit has an ingress protection of 1P66 67 and therefore any conduit device fitted must maintain this Note These products have been certified with a cable entry temperature rise of 4 C Ensure that this is taken into consideration when selecting suitable cabling for the ambient temperature in which the product is to be used Note These products are not intended to be assembled directly to process pipe work etc that Is heated or cooled to temperatures outside of the range as indicated above WARNING Do not open when energized or when an explosive atmosphere is present WARNING Electrostatic hazard clean only with damp cloth BIFFI ALGA DOUBLE ACTING PNEUMATIC ACTUATOR INSTALLATION OPERATION AND MAINTENANCE MANUAL mr l l Twist 45 3 4 1 2 Mounting instructions 2 Installation of this product shall be carried then lift straight up
61. tighten the plug t q FIGURE 18 Mechanical stop of the MHP cylinder BIFFI ALGA DOUBLE ACTING PNEUMATIC ACTUATOR INSTALLATION OPERATION AND MAINTENANCE MANUAL 3 4 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 3 4 1 Westlock 2200 Series Quantum ATEX certified EPSILON 08 ATEX 2370X Ex 0 UB 42 T Tamb 0 to4 C Ex tD A21 IP6X T C Tamb C to C Flat cover 20 C to 85 C T4 20 C to 75 C T5 20 C to 60 C T6 Beacon cover 30 C to 85 C T4 30 C to 75 C T5 30 C to 60 C T6 Environmental parameters 80 kPa 0 8 bar to 110 kPa 1 1 bar Air with normal oxygen content typically 21 The 2200 certification is compliant against the following standards EN 60079 0 2006 Electrical apparatus for explosive gas atmospheres Part 0 General requirement
62. trol signal Hu Pressurized air suppy EA Reduced pressurized air opening chamber pm Reduced pressurized air closing chamber BIFFI ALGA DOUBLE ACTING PNEUMATIC ACTUATOR INSTALLATION OPERATION AND MAINTENANCE MANUAL The MHW MSJ jackscrew manual override can be supplied for model up to 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 of the screw container by a lever for MSJ models or by a handwheel for MHW models The MHP hydraulic manual override is used to manually operate the actuator in lack of air Supply It also allows to accurately adjust the actuator operating times independently in opening and in closing by way of the hydraulic regulators which work on the oil flow from one chamber to the other of the hydraulic cylinder during pneumatic operation Moreover it permits a smooth angular speed all along the stroke During manual operation the flow regulators are by passed to make the force on the hand pump lever easy The MHP unit consists of a hydraulic cylinder mounted directly on the actuator The piston rod end is screwed into the guide block The compact hydraulic control unit consists of ahand pump directional control valve
63. turning it anticlockwise with a proper wrench c1 until the valve reaches the right position When unscrewing the stop screw keep the lock nut still with a wrench so that the sealing washer 3 does not withdraw together with the screw If the actuator angular stroke is stopped beyond the end position fully open or closed valve screw the stop screw by turning it clockwise until the valve reaches the right position 4 Tighten the lock nut 2 2 3 For the adjustment of the mechanical stop srewed into the left side of housing follow these steps figures 11 and 14A e Loosen the Locknut Ld with the specific wrench c2 e Adjust the pin g screw fv with the adequate wrench c1 e Turn counter clockwise to Increase the angular stroke turn clockwise to decrease It e When the adjustment is over tighten the locknut d Pneumatic Wrench c1 Wrench c2 cylinder size mm mm 85 30 41 100 30 41 135 30 30 175 30 30 235 30 30 Pneumatic Wrench c1 Wrench c2 cylinder size mm mm 280 17 55 S30 17 55 385 17 55 435 17 55 485 17 55 595 17 55 585 17 55 635 17 55 739 17 55 MSS 17 55 835 17 55 885 17 55 935 17 55 1000 17 55 1100 17 55 1200 17 55 1300 17 80 1450 17 80 Wrench c1 Wrench c2 Actuator model mm mm 0 3 30 30 0 9 30 30 Ne 41 41 3 41 41 6 46 46 4 na y L a pt ar LEGG LEN i L Y ct ce FIGURE 14A Mechanical stop on the housing 3 1 I 2 I 1 gt L
64. until the switch is activated WARNING Before stroking the actuator please ensure that the process is safe to do so and that all hands are kept away from the moving shaft 7 Stroke the actuator from one end of stroke to the other several times to check the switch operation If the switches require adjustment repeat steps 5 to 7 Protection by intrinsic safety iD 3 4 3 1 Product description The equipment may be used ina CAT 1 2 or 3 environment internal component dependant in the presence of flammable gases vapours and dusts The apparatus groups cover IIA IIB and IIC internal component dependant with temperature classes of 11 through to 14 or either T5 or T6 internal component dependant The maximum ambient temperature range IS 40 to 60 C dependant on enclosure material and internal components The 3000 series valve position monitor provides end of travel indication by the means of either electrical switch or inductive sensors mounted within the enclosure These are activated by cams mounted on the rotary shaft The 3000 series enclosure construction comprises of a shaft passing through the enclosure base and cover when fitted with visual beacon The two part enclosure has an integral gasket seal The shaft has up to two O ring seals in both the cover and housing bearings This product is available in three materials Zytel resin aluminium or stainless steel 316 The housing has the option of up to three
65. within this certificate Any replacement parts that are not made in accordance to the listed drawing will invalidate the approval certification Replacement parts must be purchased through Westlock Controls UK Ltd or via an approved Westlock Controls distributor BIFFI ALGA DOUBLE ACTING PNEUMATIC ACTUATOR INSTALLATION OPERATION AND MAINTENANCE MANUAL 3 4 3 Westlock 3000 Series ATEX certified SIRA 05 ATEX 2242X 1G Ex ia T G Il 1D Ex ia IIIC T120 C Da IP6X variables based on construction and internal components Ta 20 C to 40 C plastic enclosure Ta 40 C to 60 C metal enclosure subject to limitations of installed devices The 3000 certification is compliant against the following standards EN 60079 0 2009 EN 60079 11 2007 Explosive atmospheres Equipment General requirements Electrical apparatus for explosive gas atmospheres Part 11 Intrinsically Safe 1 EN 60079 26 2007 Explosive atmospheres Equipment with equipment protection level EPL Ga IEC 61241 0 2004 Electrical apparatus for use in the presence of combustible dust General requirements IEC 61241 11 2005 Electrical apparatus for use in the presence of combustible dust WARNING Before stroking the actuator please ensure that the process is safe to do so and that all hands are kept away from the moving shaft 6 Stroke the actuator to the opposite end of travel Set the top cam by pushing down and turning the cam

Biffi Pneumatic Actuators, Models Alga/Algas/Algas-QA

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