BIFFI ALGAS User manual

Installation, Operation and Maintenance Manual
MAN 604A Rev. 5
June 2020
Bif ALGAS
Spring-Return 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

MAN 604A Rev. 5
Installation, Operation and Maintenance Manual
June 2020
Revision Details
Revision Details
Rev. Date Description Prepared Checked Approved
5 June 2020 General update (Migration to new template)
4March 2018 Updated data-plate Ermanni Oreci Vigliano
3April 2016 Updated applicable regulation (chapter 1.1.1) Ermanni Oreci Vigliano
2June 2012 Updated chapter 5 Ermanni Stoto Vigliano
1 January 2012 Added vertical assembly description Ermanni Stoto Vigliano
Revision Details

i
MAN 604A Rev. 5
Table of Contents
Installation, Operation and Maintenance Manual 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......................................................................... 1
1.2 Identication Plate ........................................................................................ 2
1.3 Description of the Actuator........................................................................... 2
Section 2: Installation
2.1 Checks to Be Carried Out on Receiving the Actuator...................................... 4
2.2 Storage ......................................................................................................... 4
2.3 Assembling the Actuator onto the Valve ....................................................... 5
2.3.1 Types of Assembly.............................................................................. 5
2.3.2 Valve Stem with Vertical Axis ............................................................ 13
2.3.3 Valve Stem with Horizontal Axis........................................................ 17
Section 3: Operation and Use
3.1 Setting of the Angular Stroke ...................................................................... 19
3.1.1 Travel Stop Screw Screwed on the End Flange of
Pneumatic Cylinder .......................................................................... 19
3.1.2 Stop Screw Screwed on the End Flange of Spring Container.............. 21
3.2 Calibration of Micro-switches (If Foreseen).................................................. 23
3.3 Calibration of Operating Time..................................................................... 23
3.4 Preparation for Start-up .............................................................................. 24
3.4.1 Pneumatic Connections ................................................................... 24
3.4.2 Electrical Connections...................................................................... 25
3.5 Start-up ...................................................................................................... 25
Section 4: Operational Tests and Inspections
Operational Tests and Inspections......................................................................... 26
June 2020

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MAN 604A Rev. 5
Table of Contents
Table of Contents Installation, Operation and Maintenance Manual
June 2020
Section 5: Maintenance
5.1 Routine Maintenance .................................................................................. 27
5.2 Extraordinary Maintenance ......................................................................... 28
5.2.1 Replacement of Cylinder Seals ......................................................... 30
5.3 Lubrication of Mechanism........................................................................... 34
5.4 Dismantling and Demolition ....................................................................... 35
Section 6: Troubleshooting
6.1 Failure or Breakdown Research.................................................................... 36
Section 7: Layouts and Sectional Drawings
7.1 Parts List for Maintenance and Replacing Procedure.................................... 37
Section 8: Spare Parts
Spare Parts............................................................................................................ 42
Section 9: Date Report for Maintenance Operations
Date Report for Maintenance Operations .............................................................. 43

1
MAN 604A Rev. 5
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
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.
Section 1: General Warnings
NOTICE
Bif Italia has taken every care in collecting and verifying the documentation contained in
this instruction and operating manual. Nevertheless Bif Italia does not provide any
guarantees for this instruction manual. Bif Italia will not be responsible for any mistakes
contained in it or for any damage either accidental or due to the use of this manual.
The information herein contained is reserved property of Bif Italia and is subject to
being modied without notice.
Installation, Operation and Maintenance Manual
June 2020

2
MAN 604A Rev. 5
General Warnings
June 2020
Installation, Operation and Maintenance Manual
1.2 Identication Plate
! WARNING
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 (Figure1).
1.3 Description of the Actuator
ALGAS low pressure pneumatic spring-return, are suitable for the operation of
quarter-turn valves (ball valves, buttery valves, plug valves) in both ON-OFF and
modulating heavy-duty service.
The actuator is made up of a weatherproof scotch yoke mechanism transforming the linear
movement of the pneumatic cylinder (or mechanical manual override, if foreseen) and of
the spring into the rotary movement, which is necessary for operation.
The spring-return pack incorporates up to four springs, fully encapsulated in a factory
welded cartridge: this ensures safety to personnel and simplies assembly. The spring
action can be easily changed in the eld from to close in to open or from to open in to close
(modular design).
The angular stroke of the yoke is adjustable between 82° and 98° by means of the external
mechanical stops screwed into the end ange of the pneumatic cylinder and into the end
ange of the spring-return pack. The cover of the scotch yoke mechanism is arranged for
the assembly of the required accessories (position-transmitter, signaling-limit switches,
positioner, etc.) by means of proper matching units. The above mentioned accessories are
operated by the actuator drive sleeve.
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 or a
stem extension. Their internal hole 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.
Section 1: General Warnings
Figure 1 Data Plate

3
MAN 604A Rev. 5
General Warnings
Section 1: General Warnings
Code: ALGAS XXX K - YYYYY -ZZZZ - F SC
Actuator series
Scotch yoke mechanism size
Yoke shape
C Canted
S Symmetric
Spring cartridge size
Cylinder size
Internal diameter in mm
Spring action
CL Closing
OP Opening
Service
Blank Standard
QA Quick acting
Manual override
Blank No manual override
MHP Manual handpump
MHW Manual handwheel
MRHW Manual reduced handwheel
The expected lifetime of actuator is approximately 25 years.
Installation, Operation and Maintenance Manual
June 2020
Table 1. Selection Guide

4
MAN 604A Rev. 5
Installation
Section 2: Installation
2.1 Checks to Be Carried Out on Receiving
the Actuator
1. If the actuator arrives already assembled onto the valve, the settings of the
mechanical stops and of the micro switches (if existing) has already been made
by the person who assembled the actuator onto the valve. If the actuator arrives
separately from the valve, the settings of the mechanical stops and of the
micro switches (if existing) must be checked and, if necessary, carried out while
assembling the actuator onto the valve.
2. Check that the actuator has not been damaged during transport. If necessary,
repair all damages to the paint-coat, etc.
3. Check that the model, the serial number of the actuator and the performance
data written on the data plate are in accordance with those described on the order
acknowledgement, test certicate and delivery note.
4. Check that the tted accessories comply with those listed in the order
acknowledgement and the delivery note.
2.2 Storage
(For handling and lifting procedure, please refer to Figures 10, 11 and 12).
The actuators leave the factory in excellent working conditions and with an excellent
nish (these conditions are guaranteed by an individual inspection certicate); in order to
maintain these characteristics until the actuator is installed on the plant, it is necessary to
observe a few rules and take appropriate measures during the storage period.
1. Make sure that plugs are tted in the air connections and in the cable entries. The
plastic plugs, which close the inlets, do not have a weatherproof function, but are
only a means of protection against the entry of foreign matter during transport.
If long-term storage is necessary and especially if the storage is outdoors, metal
plugs must replace the plastic protection plugs, which guarantee a complete
weatherproof protection.
2. If the actuators are supplied separately from the valves, they must be placed
onto a wooden pallet so as not to damage the coupling ange to the valve. In
case of long-term storage, the coupling parts (ange, drive sleeve, insert bush)
must be coated with protective oil or grease. If possible, blank off the ange
by a protection disk.
3. In case of long-term storage (>1 years), it is advisable to keep the actuators in a
dry place or to provide at least some means of weather protection. If possible, it is
also advisable, to periodically operate the actuator with ltered, dehydrated and
lubricated air; after such operations all the threaded connections of the actuator
and the valves of the control panel (if existing) should be carefully plugged.
Section 2: Installation
June 2020
Installation, Operation and Maintenance Manual

5
X
P
K
ØM
Ø d1 max
Ø d4
h1
Ø d3 ±0.2
H max
45°
W
0.1 220 102 M10 50 4 7 17 121 22 25 32
MAN 604A Rev. 5
Installation
Section 2: Installation
2.3 Assembling the Actuator onto the Valve
2.3.1 Types of Assembly
For coupling to the valve, the housing is provided with a ange with threaded holes
according to Bif standard tables (SCN6200; SCN6200-1; SCN6201; SCN6201-1
SCN6201-3 SCN6201-5). 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
cannot 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.
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 2
N. THREADED HOLES
PCD, holes, number and
size according to ISO 5211
Top view of the scotch yoke mechanism
(actuator shown in closed position)
Drive sleeve
Flow line
Dimensions in millimeters
Actuator model Ø d1Ø d3Ø d4ØM N P h1H max WK X
Installation, Operation and Maintenance Manual
June 2020
Table 2.

6
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
MAN 604A Rev. 5
Installation
Section 2: Installation
Dimensions in millimeters
Actuator model Ø d1Ø d2Ø d3Ø d4N h1h2H max Ø d5WK
Figure 3
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
June 2020
Installation, Operation and Maintenance Manual
Table 3.

7
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
MAN 604A Rev. 5
Installation
Section 2: Installation
Dimensions in millimeters
Actuator model Ø d1Ø d2Ø d3Ø d4N h1h2H max Ø d5WK
Figure 4
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
Installation, Operation and Maintenance Manual
June 2020
Table 4.

8
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
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
MAN 604A Rev. 5
Installation
Section 2: Installation
Dimensions in millimeters
Actuator model Ø d1Ø d2Ø d3Ø d4N h1h2H max Ø d5WK
Figure 5
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
June 2020
Installation, Operation and Maintenance Manual
Table 5.

9
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
MAN 604A Rev. 5
Installation
Section 2: Installation
Dimensions in millimetersw
Actuator model Ø d1Ø d2Ø d3Ø d4N h1h2H max Ø d5WK
Figure 6
Drive sleeve
N. THREADED HOLES
Top view of the scotch yoke mechanism
(actuator shown in closed position)
Flow line
Installation, Operation and Maintenance Manual
June 2020
Table 6.

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
65 910 370 813 M42 24 12 37 540 280 46 327.4
80 910 370 813 M42 24 12 37 540 280 46 327.4
MAN 604A Rev. 5
Installation
Section 2: Installation
Dimensions in millimeters
Actuator model Ø d1Ø d2Ø d3Ø d4N h1h2H max Ø d5WK
Figure 7
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
June 2020
Installation, Operation and Maintenance Manual
Table 7.

11
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
100 1200 450 1042 M42 32 8 57 600 300 70 328.8
MAN 604A Rev. 5
Installation
Section 2: Installation
Dimensions in millimeters
Actuator model Ø d1Ø d2Ø d3Ø d4N h1h2H max Ø d5WK
Figure 8
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
Installation, Operation and Maintenance Manual
June 2020
Table 8.

12
MAN 604A Rev. 5
Installation
Section 2: Installation
If required, for the standard models size 0.3 to 6, Bif can supply an insert bush with
unmachined 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 table TN1005,
enclosed. The particular execution of the ange and bushing allow the actuator to
be rotated by 90° in 4 different positions according to the Figure 9.
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 9 Insert bush + intermediate coupling ange
June 2020
Installation, Operation and Maintenance Manual
Table 9.

13
MAN 604A Rev. 5
Installation
Section 2: Installation
Figure 10 Example of hook with safety latch
Figure 11
2.3.2 Valve Stem with Vertical Axis
NOTICE
The lifting and handling of the actuator must be done by qualied personnel and in
accordance with the laws and regulations in force.
! WARNING
The actuator must be lifted by means of a suitable lifting apparatus. The weight of the
actuators is indicated in the technical documentation attached to the equipment itself.
For lifting and moving the actuator, use only hooks tted with safety latch, like the one, for
example, shown in follow Figure 10.
Installation, Operation and Maintenance Manual
June 2020
Lifting points: 1-2 (mandatory), 3 (balancing)

14
MAN 604A Rev. 5
Installation
Section 2: Installation
Spring cartridge
Lifting eyelet
Pneumatic cylinder
Lifting eyelet
Lifting point applicable for ALGAS models:
3-6-14-18-32-50-80
Lifting eyelet
Lifting point applicable for ALGAS models:
0.3-0.9-1.5
Figure 12
Lift ALGAS actuators (pneumatic spring-return) by means of the proper lifting points
represented and indicated on actuator by sticking labels. Also refer to Figure 12 for lifting
points positions.
• 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.
June 2020
Installation, Operation and Maintenance Manual

15
MAN 604A Rev. 5
Installation
Section 2: Installation
Figure 13
! 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.
The actuator can be assembled onto the valve ange either by using the actuator-housing
ange with threaded holes, or by the interposition of an adaptor ange or a spool piece.
The actuator drive sleeve is generally connected to the valve stem by an insert bush or a
stem extension.
The assembly position of the actuator, with reference to the valve, must comply with the
plant requirements (cylinder axis parallel or perpendicular to the pipeline axis).
To assemble the actuator onto the valve proceed as follows:
1. Check that the coupling dimensions of the valve ange and stem, or of the
relevant extension, meet the actuator coupling dimensions.
2. Bring the valve to the position related to the actuator spring operation.
3. Lubricate the valve stem with oil or grease in order to make the assembly easier.
Be careful not to pour any of it onto the ange.
4. Clean the valve ange and remove anything that might prevent a perfect
adherence to the actuator ange and especially all traces of grease, since the
torque is transmitted by friction.
5. If an insert bush or stem extension for the connection to the valve is supplied
separately, assemble it onto the valve stem and fasten it by tightening the proper
stop dowels.
6. Bring the actuator to the position caused by the spring operation.
Installation, Operation and Maintenance Manual
June 2020
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

16
M8 20
M10 40
M12 70
M14 110
M16 160
M20 320
M22 420
M24 550
M27 800
M30 1100
M33 1400
M36 1700
MAN 604A Rev. 5
Installation
Section 2: Installation
7. Connect a sling to the support points of the actuator and lift it: make sure the
sling is suitable for the actuator weight. When possible, it is easier to assemble the
actuator to the valve if the valve stem is in the vertical position. In this case the
actuator must be lifted while keeping the ange in the horizontal position.
8. Clean the actuator ange and remove anything that might prevent a perfect
adherence to the valve ange and especially all traces of grease.
9. Lower the actuator onto the valve in such a way that the insert bush, assembled
on the valve stem, enters the actuator drive sleeve. This coupling must take place
without forcing and only with the weight of the actuator. When the insert bush
has entered the actuator drive sleeve, check the holes of the valve ange. If they
do not meet with the holes of the actuator ange or the stud bolts screwed into
them, the actuator drive sleeve must be rotated; feed the actuator cylinder with
air at proper pressure, indicated on data sheet for actuator.
10. Tighten the nuts of the connecting stud bolts evenly with the torque prescribed in
the table. The stud bolts must be made of ASTM A320 L7 steel; the nuts must be
made of ASTM A194 grade 2 steel. See Table 10.
11. If possible, operate the actuator to check that it moves the valve smoothly.
Thread Size Recommended Tightening Torque (Nm)
Table 10.
June 2020
Installation, Operation and Maintenance Manual