BIFFI ALGA-EAC Series User manual

Installation, Operation and Maintenance Manual
MAN 564_EAC Rev. 2
June 2020
Bif ALGA - EAC
Double-Acting Pneumatic Actuator
Copyright © Bif. The information in this document is subject to change without notice. Updated data sheets can be obtained from our website www.bif.it or from your nearest Bif Center:
Bif Italia s.r.l. - Strada Bif 165, 29017 Fiorenzuola d'Arda (PC) – Italy PH: [phone] – bif_italia@bif.it

June 2020
Installation, Operation and Maintenance Manual
MAN 564_EAC Rev. 2
Revision Details
Revision Details
Rev. Date Description Prepared Checked Approved
2 June 2020 General update (migration to new template)
1 March 2018 Updated data-plate Ermanni Oreci Vigliano
0January 2017 Document release Ermanni Oreci Vigliano
Revision Details

i
Installation, Operation and Maintenance Manual
MAN 564_EAC Rev. 2 June 2020
Table of Contents
Table of Contents
Table of Contents
Section 1: General warnings
1.1 Generalities.................................................................................................... 1
1.1.1 Applicable Regulation ......................................................................... 1
1.1.2 Terms and Conditions.......................................................................... 2
1.2 Identication Plate ......................................................................................... 2
1.3 Introducing the Actuator................................................................................ 2
1.4 Data Sheet ..................................................................................................... 3
Section 2: Installation
2.1 Checks Upon Actuator Receipt ....................................................................... 4
2.2 Actuator Handling.......................................................................................... 4
2.3 Storage .......................................................................................................... 7
2.4 Actuator Assembly on the Valve..................................................................... 7
2.4.1 Types of Assembly............................................................................... 7
2.4.2 Assembly Procedure.......................................................................... 12
2.5 Pneumatic Connections ............................................................................... 13
2.6 Electrical Connections (If Any)...................................................................... 14
2.7 Commissioning............................................................................................ 15
Section 3: Operation and Use
3.1 Operation Description.................................................................................. 16
3.2 Residual Risks............................................................................................... 22
3.3 Calibration of the Angular Stroke ................................................................. 22
3.4 Calibration of Micro-switches (If Foreseen)................................................... 28
3.5 Calibration of the Operation Time (Optional - If Foreseen)............................ 29
Section 4: Operational Tests and Inspections
Operational Tests and Inspections................................................................ 31

ii
June 2020
Installation, Operation and Maintenance Manual
MAN 564_EAC Rev. 2
Table of Contents
Table of Contents
Section 5: Maintenance
5.1 Periodic Maintenance................................................................................... 32
5.1.1 Check and Restore Oil Level in the Hydraulic Manual Override ........... 33
5.1.2 Gas Supply Dehydrating Filter Maintenance (If Foreseen)................... 35
5.2 Extraordinary Maintenance .......................................................................... 36
5.2.1 Replacement of Cylinder Seals ........................................................... 36
5.3 MHP Hydraulic Manual Override Maintenance and Trouble Shooting............ 45
5.3.1 Operation.......................................................................................... 45
5.3.2 Manual Operation ............................................................................. 45
5.3.3 Remote Operation............................................................................. 45
5.3.4 Setting .............................................................................................. 46
5.4 Lubrication of Mechanism ............................................................................ 48
5.5 Dismantling and Demolition ........................................................................ 49
Section 6: Troubleshooting
6.1 Failure or Breakdown Research ..................................................................... 50
Section 7: Layouts
7.1 Spare Parts Order......................................................................................... 51
7.2 Parts List for Maintenance and Replacing Procedure..................................... 52
Section 8: Date Report for Maintenance Operations
Date Report for Maintenance Operations ..................................................... 60

1
Installation, Operation and Maintenance Manual
MAN 564_EAC Rev. 2 June 2020
General Warnings
Section 1: General Warnings
NOTICE
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
Bif Italia s.r.l. actuators are conceived, manufactured and controlled according to the
Quality Control System in compliance with EN-ISO 9001 international regulation.
1.1.1 Applicable Regulation
EN ISO 12100:2010: Safety of machinery – General principles for design –
Risk assessment and risk reduction
2006/42/EC: Machine directive
2014/68/EU: Directive for pressure PED equipment
2014/35/EU: Directive for low voltage equipment
2014/30/EU: Directive for the electromagnetic compatibility
2014/34/EU: Directive and safety instructions for use in hazardous area
TR TS 004/2011 Customs Union Technical Regulation
(For safety of low voltage equipment)
TR TS 010/2011 Customs Union Technical Regulation
(For safety of equipment and machines)
TR TS 012/2011 Customs Union Technical Regulation
(For safety of equipment operated in explosive atmosphere)
TR TS 020/2011 Customs Union Technical Regulation
(Electromagnetic Compatibility of Technical Products)
TR TS 032/2013 Customs Union Technical Regulation
(For safety of Excess Pressure Equipment)
Section 1: General Warnings
NOTICE
Bif Italia s.r.l. pays the highest attention to collecting and verifying the documentation
contained in this user manual. However Bif 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 Bif Italia s.r.l. and may
be modied without prior notice. All rights reserved.

2
June 2020
Installation, Operation and Maintenance Manual
MAN 564_EAC Rev. 2
General Warnings
1.1.2 Terms and Conditions
Bif Italia s.r.l. guarantees that all the items produced are free of defects in workmanship
and manufacturing materials and meet relevant current specications, 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 rst. All detailed warranty conditions are specied 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 modied or repaired by unauthorized staff. In the event that
a fault condition be caused by improper installation, maintenance or use, or by irregular
working conditions, the repairs will be charged according to applicable fees.
The warranty and Bif Italia s.r.l. liability shall lapse in the event that any modication
or tampering whatsoever be performed on the actuator.
1.2 Identication Plate
It is forbidden to modify the information and the marks without previous written
authorization by Bif Italia s.r.l.
The plate fastened on the actuator contains the following information (Figure 1).
Figure 1 Data Plate
Section 1: General Warnings
1.3 Introducing the Actuator
The ALGA actuators was engineered and is 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, buttery valves or dampers, in both ON-OFF and
Modulating heavy duty service.

3
Installation, Operation and Maintenance Manual
MAN 564_EAC Rev. 2 June 2020
General Warnings
Section 1: General Warnings
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 ange of the pneumatic cylinder.
The cover of the scotch yoke mechanism is arranged for the assembly of the required
accessories (positioner, signalling limit switches, position transducer, etc.) by means of
proper matching units. The above mentioned accessories are operated by the actuator
drive sleeve. The housing of the scotch yoke mechanism has a ange with threaded holes
to x the actuator to the valve either directly or, if required, with the interposition of an
adaptor ange 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 Bif or at
Customer's care), according to the shape and dimensions of the valve stem. Bif can
supply different types of control system following Customer's requirements.
The expected lifetime of actuator is approximately 25 years.
Figure 2 Identication of Actuator Parts
Manual handpump
MHP (optional)
Control system
(optional)
Valve
coupling
Pneumatic
cylinder
Valve position
indicator
Scotch yoke
mechanism
Hydraulic cylinder for ALGA-MHP
models or second pneumatic
cylinder for ALGA*2 double
cylinder models (optional)
1.4 Data Sheet
Supply uid Air, nitrogen or sweet gas, special version available for sour gas
Operating temperature Standard: from –30 °C to +100 °C
Optional: from –60 °C to +200 °C
Supply pressure Please refer to technical document: “actuator data-sheet”
Output torque Up to 750000 Nm (higher value with special version)

4
June 2020
Installation, Operation and Maintenance Manual
MAN 564_EAC Rev. 2
Installation
Section 2: Installation
2.1 Checks Upon Actuator Receipt
• Check that the model, the serial number of the actuator and the technical data
reported on the identication plate correspond with those of order conrmation
(Section 1.2).
• Check that the actuator is equipped with the ttings as provided for by order
conrmation.
• Check that the actuator was not damaged during transportation: if necessary
renovate the painting according to the specication reported on the order
conrmation.
• If the actuator is received already assembled with the valve, its settings have
already been made at the factory.
• If the actuator is delivered separately from the valve, it is necessary to check, and,
if required, to adjust, the settings of the mechanical stops (Section 3.4) and of
micro-switches (if any) (Section 3.5).
2.2 Actuator Handling
NOTICE
The lifting and handling should be made by qualied 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 + 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.
For lifting and moving the actuator, use only hooks tted with safety latch, like the one,
for example, shown in Figure 3.
Figure 3 Example of Hook with Safety Latch
Section 2: Installation

5
Installation, Operation and Maintenance Manual
MAN 564_EAC Rev. 2 June 2020
Installation
Section 2: Installation
Figure 4 Lifting points for ALGA / ALGA-MHP / ALGA-MSJ actuators
Figure 5 Lifting points for ALGA / ALGA-MHP / ALGA-MSJ actuators
1 = Point of support
2 = Supports for lateral positioning
3 = Don’t lay the actuator on tie-rods of cylinder /s and don’t lay the actuator on
accessories (manual handpump, manual jackscrew, pneumatic control group etc.)
1, 2 = Lifting points (obligatory)
3 = Balancing point

6
June 2020
Installation, Operation and Maintenance Manual
MAN 564_EAC Rev. 2
Installation
Section 2: Installation
• For lifting unbalanced loads, use ropes of different lengths or chains with
adjustable length.
• Check each time the conditions of all lifting equipment used and discard it if
not in perfect working order.
• Do not knot or twist the ropes so as not to reduce the lifting capacity or
produce torsional effects on the load being lifted.
• Use the utmost caution and remain at a safe distance from lifted actuator
unless absolutely necessary; do not stand or pass under suspended loads.
• Pay attention in putting under tension the ropes to prevent the load shifting
sideways in an uncontrolled manner.
• Use slings of such length that the angles of the leg from vertical are as narrow
as possible (αMAX < 20°).
• During handling, do not transport the suspended actuator above staff
members in charge of the operation.
!WARNING
Do not use the lifting eyelets on actuator to lift valve + actuator assembly.
Figure 6
!WARNING
Any lifting method different from what described above is strictly forbidden.
Bif reject any responsibility for damages to goods or injuries to persons coming from
wrong lifting operations.
BIFFI IS NOT LIABLE FOR ANY
PERSONEL INJURY DUE TO
INCORRECT USE
DO NOT DISASSEMBLE TOP OR
BOTTOM COVER.
SPRING LOADED.
POTENTIAL ELECTROSTATIC CHARGE HAZARD
REFER TO IOM
LIFTING LUGS TO BE USED FOR THE
ACTUATOR ONLY. DO NOT LIFT
VALVE AND ACTUATOR TOGETHER

7
Installation, Operation and Maintenance Manual
MAN 564_EAC Rev. 2 June 2020
Installation
Section 2: Installation
2.3 Storage
If the actuator needs storage, before installation follow these steps:
• Place it on a wood surface in order not to deteriorate the area of valve coupling.
• Make sure that plastic plugs are present on the pneumatic and electrical
connections (if present).
• Check that the cover of the control group and of the limit switch box (if any) are
properly closed.
If the storage is long-term or outdoor:
• Keep the actuator protected from direct weather conditions.
• Replace plastic plugs of pneumatic and electrical connections (if any) with metal
plugs that guarantee perfect tightness.
• Coat with oil, grease or protection disc, the valve coupling area.
• Periodically operate the actuator (Section 3.3).
2.4 Actuator Assembly on the Valve
2.4.1 Types of Assembly
For coupling to the valve, the housing is provided with a ange with threaded holes
according to Bif standard tables (SCN6200; SCN6200-1; SCN6201; SCN6201-1). The
number, dimensions and diameter of the holes are made in accordance with ISO 5211,
but for actuator models 0.3 to 6 the holes are drilled on the centreline in order to allow
an easier assembly of an intermediate ange, when required. This intermediate ange
(or spool-piece) can be supplied when the valve ange can not directly match the actuator
ange in its “standard” conguration. For the biggest actuator models, the actuator ange
can be machined in accordance with the valve ange dimensions.

8
Ø d1 max
Ø d4
h2
Ø d2+0.1
0
Ø d5+0.2
+0.1
K+0.4
0
Ø d3±0.2
h1 +0.5
0
H max
45°
WD10
0.3 240 93 165 M20 4 5 17 127 70 12 75.6
0.9 310 112 254 M16 8 519 150 86 14 96.6
1.5 360 144 298 M20 8619 190 112 18 119.0
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
June 2020
Installation, Operation and Maintenance Manual
MAN 564_EAC Rev. 2
Installation
Section 2: Installation
Dimensions in millimeters
Actuator model Ø d1Ø d2Ø d3Ø d4Nh1h2H max Ø d5WK
Drive sleeve
N. THREADED HOLES
PCD, holes, number and size
according to ISO 5211
(but the holes are on centerline
instead of straddle the centerline)
Top view of the scotch yoke mechanism
(actuator shown in closed position)
Flow line
N.8 holes angeN.4 holes ange
Table 1.
The yoke has bored with keyways for coupling to the valve stem, the dimensions of which
are according to Bif standard tables SCN6200 and SCN6201:
Figure 7

9
Ø d1 max
Ø d4
h2
Ø d2+0.1
0
Ø d5+0.2
+0.1
K+0.4
0
Ø d3±0.2
h1 +0.5
0
H max
WD10
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
Installation, Operation and Maintenance Manual
MAN 564_EAC Rev. 2 June 2020
Installation
Section 2: Installation
Dimensions in millimeters
Actuator model Ø d1Ø d2Ø d3Ø d4Nh1h2H max Ø d5WK
Figure 8
Drive sleeve
N. THREADED HOLES
PCD, holes, number and
size according to ISO 5211
Top view of the scotch yoke mechanism
(actuator shown in closed position)
Flow line
Table 2.
N.12 holes angeN.16 holes ange

10
Ø d1 max
Ø d4
h2
Ø d2+0.1
0
Ø d3±0.2
h1 +0.5
0
H max
Ø d5+0.2
+0.1
K+0.4
0
WD10
50 800 315 698 M36 24 10 32 430 240 56 264.8
60 840 315 698 M36 24 10 32 430 240 56 264.8
June 2020
Installation, Operation and Maintenance Manual
MAN 564_EAC Rev. 2
Installation
Section 2: Installation
Dimensions in millimeters
Actuator model Ø d1Ø d2Ø d3Ø d4Nh1h2H max Ø d5WK
Figure 9
Drive sleeve
N. THREADED HOLES
Flange sizing according to ISO
Top view of the scotch yoke mechanism
(actuator shown in closed position)
Flow line
Table 3.
If required, for the standard models size 0.3 to 6, Bif can supply an insert bush with
un-machined bore in accordance with Bif standard table SCN6202. On request the insert
bush bore can be machined by Bif to couple the valve stem, provided its dimensions
match the maximum stem acceptance of the bush according to Bif doc.: TN1005. The
particular execution of the ange and bushing allow the actuator to be rotated by 90°
in 4 different positions according to the Figure 10.

11
Installation, Operation and Maintenance Manual
MAN 564_EAC Rev. 2 June 2020
Installation
Section 2: Installation
The Bif insert bush with 2 external keys at 45° allows to position the keyway for the valve
every 90°. Consequently actuator can be mounted in 4 positions at 90° on top of the valve.
For biggest actuator models, the bore of the yoke can be machined according to the
dimensions of valve stem.
Flow line
N.4 holes ange N.8 holes ange
Drive sleeve
Snap ring
Housing
Insert bush
Insert bush
Adaptor ange
Drive sleeve
Standard position 1
Position 2 Position 3 Position 4
Position 2 Position 3 Position 4
Rotate insert-bush 180° around
vertical-standard position (1)
Rotate insert-bush 180° around
axis A-A, from position (2)
Rotate insert-bush 180° around
axis A-A, from position (1)
Insert bush turned upside down
Figure 10 Insert bush + intermediate coupling ange
Table 4.

12
June 2020
Installation, Operation and Maintenance Manual
MAN 564_EAC Rev. 2
Installation
Section 2: Installation
2.4.2 Assembly Procedure
NOTICE
Failure to comply with the following procedures may impair product warranty.
!WARNING
Installation, commissioning and maintenance and repair works should be carried out by
qualied staff. A non-conforming assembly could be the source of serious accidents.
For actuator assembly on the valve:
NOTICE
If necessary to mount components not in Bif scope of supply please check the accessories
mounting hole details in the documents TN 1028 (for metric dimension) or TN 1028U
(for imperial dimension).
NOTICE
Check that the assembly position, as shown on the documentation, complies with system’s
geometry. Check the consistency of the parts of actuator-valve coupling.
• Operate the actuator so that it reaches the position matching valve position
(Section 3.3).
• Lubricate valve stem with oil or grease.
• Properly clean and remove grease from coupling ange surfaces.
• Connect, if supplied separately, the adjustment insert to valve stem and fasten it
with the special fastening pins.
• Lift the actuator using the special lifting points (Section 2.2).
• Install the actuator so that valve stem inserts in the coupling area. This coupling
should be made without forcing.
• Fasten the two parts with the threaded connections (screws, tie rods, nuts).
If holes of coupling anges are not aligned, adequately operate the actuator if
necessary move the mechanical stops backwards (Section 3.4).
• Fasten threaded connections. Please refer to Table 5.

13
M8 20
M10 40
M12 70
M14 110
M16 160
M20 320
M22 420
M24 550
M27 800
M30 1100
M33 1400
M36 1700
Installation, Operation and Maintenance Manual
MAN 564_EAC Rev. 2 June 2020
Installation
Section 2: Installation
2.5 Pneumatic Connections
!WARNING
Check that the values of pneumatic supply available are compatible with those reported on
the identication plate of the actuator.
NOTICE
The connections should be made by qualied staff. Use pipes and connections appropriate
as for type, material and dimensions.
• Properly de-burr the ends of rigid pipes.
• Properly clean the interior of pipes sending through them plenty of the supply
uid used in the system.
• Mould and fasten the connection pipes so that no irregular strains at entries or
loosening of threaded connections occur.
• Make the connections according to the operating diagram.
• Check the absence of leakages from pneumatic connections.
The screwing values in Table 5 were calculated considering the materials ASTM A320 L7
for screws or tie rods and ASTM A194 gr.2H for the nuts.
Threading Tightening torque (Nm)
Table 5. Nuts Tightening Torque

14
June 2020
Installation, Operation and Maintenance Manual
MAN 564_EAC Rev. 2
Section 2: Installation
Installation
2.6 Electrical Connections (If Any)
NOTICE
Use components appropriate as for type, material and dimensions.
!WARNING
The connections should be made by qualied staff.
Before carrying out any operation, cut line power off.
Safety provisions:
2006/95/EC: Directive for low voltage equipment (until 19 April 2016) 2014/35/EU
from 20 April 2016
2004/108/EC: Directive for the electromagnetic compatibility (until19 April 2016)
2014/30/EU from 20 April 2016
94/9/CE: Directive and safety instructions for use in hazardous Area
(until 19 April 2016) 2014/34/EU from 20 April 2016
Remove plastic plugs from cables entries
• Screw rmly the cable glands.
• Introduce connection cables.
• Make the connections in compliance with applicable wiring diagrams
on the documentation supplied.
• Screw the cable gland.
• Replace the plastic plugs of unused entries with metal plugs.
Figure 11 Junction box on Control group (if foreseen)
Ground

15
Installation, Operation and Maintenance Manual
MAN 564_EAC Rev. 2 June 2020
Installation
Section 2: Installation
2.7 Commissioning
Check that values of electrical supply to the control group (if foreseen) are compatible
with those on the plate on the junction box (Figure 11).
!WARNING
Installation, commissioning and maintenance and repair works should be made by
qualied staff.
Upon actuator commissioning please carry out the following checks:
• Check that paint is not be damaged during transport, if necessary repair the
damages to paint coat.
• Check that the pressure and quality of the gas supply (ltering degree,
dehydration) are as prescribed. Check that the feed voltage values of the electric
components (solenoid valve coils, micro-switches, pressure switches, etc.)
are compatible with those reported on the identication plate of the actuator
(Figure 1).
• Check that the setting of the components of the actuator control unit
(pressure regulator, pressure switches, ow control valves, etc.) meet the
plant requirements.
• Carry out all kinds of operations and check their proper execution (Section 3.3).
• Check the absence of leakages in the pneumatic connections. If necessary
tighten the nuts of the pipe-ttings.
• 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.

16
June 2020
Installation, Operation and Maintenance Manual
MAN 564_EAC Rev. 2
Operation and Use
Section 3: Operation and Use
Pneumatic connection
Section 3: Operation and Use
3.1 Operation Description
In the normal operating situation, the ALGA actuator is fed by pressurized gas which ows
into the relevant cylinder chamber (for example opening). The cylinder piston stroke causes
the actuator operation and the consequent valve movement to the operational position
requested (in this case to the “open” position).
Upon a demand, the closing chamber the cylinder is fed by pressurized gas and at the same
time the gas is discharged from the open chamber into the return line: the actuator performs
the closing operation driven by the piston movement, and the valve moves from the open
position to the close (safety-related) position.
Figure 12