BIFFI COMPACT Series User manual

HLAS-C –Single acting hydraulic linear compact actuator
Use and maintenance manual
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MAN 707
Use and maintenance manual
HLAS-C
“COMPACT series”
HIGH PRESSURE SPRING-RETURN
HYDRAULIC LINEAR ACTUATOR
2
09/05/18
Updated applicable
regulation (chapter 1.1.1)
Ermanni
Orefici
Vigliano
1
18/04/16
Updated applicable
regulation (chapter 1.1.1)
Ermanni
Orefici
Vigliano
0
25/07/11
Document release
Ermanni E.
Montagna E.
Stoto M.
Rev.
Date
Description
Prepared
Checked
Approved

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TABLE OF CONTENTS
1General warnings ................................................................ 4
1.1 GENERALITIES..........................................................................4
1.1.1Applicable regulation...............................................................4
1.1.2Terms and conditions..............................................................4
1.2 Identification plate .......................................................................5
1.3 INTRODUCING THE ACTUATOR..............................................5
1.4 DATA SHEET..............................................................................7
2Installation........................................................................... 7
2.1 CHECKS UPON ACTUATOR RECEIPT.....................................7
2.2 ACTUATOR HANDLING.............................................................8
2.3 STORAGE...................................................................................9
2.4 ACTUATOR ASSEMBLY ON THE VALVE ...............................10
2.4.1Types of assembly ................................................................10
2.4.2Assembly procedure..............................................................10
2.5 HYDRAULIC CONNECTIONS..................................................14
2.6 ELECTRICAL CONNECTIONS (IF ANY)..................................14
2.7 COMMISSIONING ....................................................................15
3Operation and use ............................................................. 16
3.1 OPERATION DESCRIPTION....................................................16
3.2 RESIDUAL RISKS.....................................................................16
3.3 OPERATIONS...........................................................................17
3.3.1Emergency manual operation MHP (optional*) .....................17
3.3.2Remote control operations (for information only) ..................17
3.4 CALIBRATION OF THE ANGULAR STROKE ..........................18
3.5 CALIBRATION OF MICROSWITCHES (*for biffi limit switch box) ...21
3.5 CALIBRATION OF THE OPERATION TIME .............................23
4Operational tests and inspections...................................... 24
5Maintenance ...................................................................... 25
5.1 PERIODIC MAINTENANCE......................................................25
5.2 EXTRAORDINARY MAINTENANCE ........................................28
5.3 DISMANTLING AND DEMOLITION...........................................32
6Troubleshooting ................................................................ 33
6.1 FAILURE OR BREAKDOWN RESEARCH ...............................33
7Layouts.............................................................................. 34
7.1 Spare parts order ......................................................................34
7.2 parts-list for maintenance and replacing procedure...................35
8Date report for maintenance operations ............................ 41

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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. All rights reserved.

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1General warnings
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 12100:2010: 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
Biffi Italia srl guarantees that all the items produced are free of
defects in workmanship and manufacturing materials and meet
relevant current specifications, provided they are installed, used and
serviced according to the instructions contained in the present
manual. The warranty can last either one year from the date of
installation by the initial user of the product, or eighteen months from
the date of shipment to the initial user, depending on which event
occurs first. All detailed warranty conditions are specified in the
documentation forwarded together with the product. This warranty
does not cover special products or components not warranted by
subcontractors, or materials that were used or installed improperly or
were modified or repaired by unauthorized staff. In the event that a
fault condition be caused by improper installation, maintenance or
use, or by irregular working conditions, the repairs will be charged
according to applicable fees. The warranty and Biffi Italia srl
liability shall lapse in the event that any modification or
tampering whatsoever be performed on the actuator.

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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
(Figure1).
Figure 1 –Data plate
1.3 INTRODUCING THE ACTUATOR
HLAS-C, high pressure hydraulic compact actuator series, up or
down model, was engineered and it’s manufactured to provide
maximum thrust output with minimum supply pressure and minimum
space requirement. Simplicity, reliability and economy are at the top
of the list of design parameters. The HLAS-C actuator is suitable for
any linear valve type such as gate, knife, through conduit, globe,
orbit, in both On-Off and Modulating heavy duty service.
Totally enclosed, weatherproof all-in-one spring housing and cylinder
in fabricated carbon steel for maximum strength
The actuator is made up of a totally enclosed, weatherproof all-in-one
spring housing and cylinder in fabricated carbon steel for maximum
strength, and a mounting pedestal complete with a joint for the
coupling to the valve stem of actuator output stem. The valve is
actuated in opening and in closing position by the actuator hydraulic
cylinder in one direction and by the spring unit in the other direction.
The output thrust of spring unit can be downward or upward
according to valve operation requirements ( spring to open, spring to
close, direct acting valve , reverse acting valve).

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The spring return pack incorporates up to four spring , fully
encapsulated in a factory welded cartridge: this assures safety
conditions to personnel and simplifies the assembly.
The linear stroke of the valve is adjustable by means of the external
mechanical stop for upward position and by the adjustment of the
coupling of valve stem to actuator joint for the downward position.
The actuator pedestal has a flange with threaded holes to fix the
actuator to the valve. BIFFI can supply different types of control
system following Customer’s requirements.
The expected lifetime of actuator is approximately 25 years .
Figure 2 –Identification of actuator parts
Hydraulic cylinder
Valve coupling
Valve position indicator
Lifting eyelets suitable
for horizontal transport
Spring cartridge
Lifting eyelet suitable
for vertical transport
Valve position visual
indicator

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1.4 DATA SHEET
2Installation
2.1 CHECKS UPON ACTUATOR RECEIPT
❑Check that the model, the serial number of the actuator and the
technical data reported on the identification plate correspond with
those of order confirmation (Sect. 1.2).
❑Check that the actuator is equipped with the fittings as provided for
by order confirmation.
❑Check that the actuator was not damaged during transportation: if
necessary renovate the painting according to the specification
reported on the order confirmation.
❑If the actuator is received already assembled with the valve, its
settings have already been made at the factory.
If the actuator is delivered separately from the valve, it is necessary
to check, and, if required, to adjust, the settings of the mechanical
stops (Sect. 3.4) and of micro-switches (if any) (Sect. 3.5).
Supply fluid
Mineral oil, synthetic or fire-resistant fluids
Operating temperature
Design pressure range for
cylinder
Max oil operating thrust :
Max spring operating
thrust
Standard: from –30°C to +100°C
Optional: from –60° to +100°C
105÷352 barg (1500÷5000 psig)
up to 1.500.000 N
up to 250000 N
Applications
On-Off and
modulating service (on request)

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2.2 ACTUATOR HANDLING
The lifting and handling should be made by qualified staff and
in compliance with the laws and provisions in force.
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 and on overall-dimensions drawings furnished
Picture 1-2 –Lifting points for HLAS-C actuators

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For the transport of HLAS-C with hydraulic manual hand-pump, when it
was necessary put in horizontal position the tank of MHP, to avoid
leakage on oil level stick, substitute these with a blind-plug during the
transport (a specific warning label for transport in horizontal position is
attached on the MHP body); remove the blind plug and restore the
dipstick before operate the actuator with MHP. BIFFI hydraulic manual
hand-pump must be maintained with tank under the hand-pump to
operate the actuator with MHP properly.
2.3 STORAGE
If the actuator needs storage, before installation follow these steps:
❑Place it on a wood surface in order not to deteriorate the area of
valve coupling.
❑Make sure that plastic plugs are present on the hydraulic and
electrical connections (if present).
❑Check that the cover of the control group and of the limit switch box
(if any) are properly closed.
If the storage is long-term or outdoor:
❑Keep the actuator protected from direct weather conditions.
❑Replace plastic plugs of hydraulic 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 (Sect. 3.3).

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2.4 ACTUATOR ASSEMBLY ON THE VALVE
2.4.1 Types of assembly
The adapter pedestal in fabricated carbon steel is specifically
designed for adaptation to any type of valve with provision for local
indicator, limit switches and other accessories (on request).
Lift the actuator by safety-hook for chains using the lifting-points (see
sect. 2.2) on the top of actuator for handling, transporting and
assembling in vertical position (see picture 1). For handling,
transporting and assembling the actuator in horizontal position by
safety-hook for chains use the lifting-points on the top of cylinder
head-flange and on coupling flange (see picture 2).
2.4.2 Assembly procedure
Failure to comply with the following procedures may
impair product warranty. 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:
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.
A) TO ASSEMBLE THE ACTUATOR ONTO THE VALVE BY BRACKET
WITH THREADED JOINT PROCEED AS FOLLOWS:

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1) Check that the coupling dimensions of the valve flange and stem,
or of the relevant extension, meet the actuator coupling
dimensions (valve stem and flange). Lubricate the valve stem with
grease in order to make the assembly easier.
2) Connect a sling to the support point of the actuator and lift it.
To make easier the assembly , the valve stem has to be in perfect
vertical position.
Note: the eyebolt is sized for the lifting of the only actuator (NOT
ACTUATOR+VALVE). Proper lifting points have to be foreseen for
the valve.
3) . Screw the actuator coupling joint onto the valve by rotating the
actuator, or screw down the valve stem stroke-ring with Red
Loctite 542 and fix the half-bearings. When the threaded holes of
the actuator flange are in correspondence with the holes on the
valve flange screw the proper stud bolts. Screw the nuts on the
stud bolts and tighten up the valve flange is in contact with the
actuator flange.
4) 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 as minimum.

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B) To assemble the actuator onto the valve by bracket with shell
joint, perform the following operations:
1) -Check that the coupling dimensions of the valve flange and stem, or of
the relevant extension, meet the actuator coupling dimensions (valve
stem and flange). Lubricate the valve stem with grease in order to make
the assembly easier
2) To make easier the assembly, the valve stem has to be in perfect
vertical position.
3) Disassemble the two halves of actuator pedestal shell joint (item 8) by
unscrewing the retaining screws (item 4 ),therefore disassemble the
valve stem joint (item 7).
4) Lift the actuator by utilizing the proper lifting eyelets, and unscrew the
nuts and the stud bolts from the actuator pedestal.
5) Assemble the actuator onto the valve, and arrange it in its correct vertical
position proper to connection between valve stem and actuator cylinder
rod.

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6) Screw the valve stem joint (item 7) on valve stem up to reach the proper
position which allow the reassembly of the two halves of shell joint (item
8), tighten the joint fastening screws (item 4).
7) Screw the stud bolts (item 1) into the actuator pedestal flange, and screw
the nuts on the stud bolts.
8) Tighten according to the nut (item 2) size torque requirements.
To operate refer to following table:
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
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.

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2.5 HYDRAULIC CONNECTIONS
Check that the values of hydraulic supply available are
compatible with those reported on the identification plate of the
actuator.
The connections should be made by qualified staff.
Use pipes and connections appropriate as for type, material and
dimensions.
Use motor fluid with purity degree ISO 4406 17/14 or NAS 1638
Class 8 (AS4059 Class 4B-F).
For special applications the lower contamination degree is
required. Please refer to dedicated documentation supplied.
❑Properly deburr the ends of rigid pipes
❑Properly clean the interior of pipes sending through them plenty of
the supply fluid 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 hydraulic connections. If
necessary tighten the nuts of the pipe-fittings
2.6 ELECTRICAL CONNECTIONS (IF ANY)
Use components appropriate as for type, material and
dimensions. The connections should be made by qualified staff.
Before carrying out any operation, cut line power off
Safety provisions as per CEI 64-8 regulation should be complied
with (same as IEC 60364).
Remove plastic plugs from cables entries
❑Screw firmly the cable glands.
❑Introduce connection cables.
❑Make the connections in compliance with applicable wiring diagrams
on the documentation supplied.
❑Screw the cable gland.
❑Replace the plastic plugs of unused entries with metal plugs.

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2.7 COMMISSIONING
Installation, commissioning and maintenance and repair works
should be made by qualified staff.
Upon actuator commissioning please carry out the following checks:
❑Check that paint is not be damaged during transport, if necessary
repair the damages to paint coat.
❑Check that the values of hydraulic supply available in the system are
compatible with those reported on the identification plate of the
actuator (Figure 2) and on the documentation supplied.
❑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 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
(Sect. 3.3).
❑Check the absence of leakages in the hydraulic connections.
If necessary tighten the nuts of the pipe-fittings
❑Check proper operation of all the due signalling ( valve position,
hydraulic supply pressure etc. )
❑Make a complete functional test in order to verify all the operations
are executed according to operating schematic diagram supplied.

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3Operation and use
3.1 OPERATION DESCRIPTION
The supply fluid pressurizes the hydraulic-cylinder chamber relevant
to the operation to carry out (opening or closing) (see following
pages). This pressure starts the linear motion of the piston and the
consequent motion of the valve stem that is coupled. The spring
action operate the valve stem in the opposite direction (fail safe
position)
For local or remote operations, please refer to technical
documentation furnished with actuators. Electro-hydraulic power
pack and control systems are supplied on specific customer demand.
For all the relevant information please refer to the specific
documentation supplied.
3.2 RESIDUAL RISKS
The actuator has parts under pressure. Use the due caution.
Use individual protections provided for by the laws and provisions
in force.
Hydraulic return
connection
Hydraulic supply
connection

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3.3 OPERATIONS
( *refer to specific document: operating diagram furnished )
3.3.1 Emergency manual operation MHP (optional*)
Refer to applicable control schematic in supplied
documentation.
The HLAS-C actuators can have an emergency manual override in
addition to the local and/or remote control system which controls the
oil supplied by a power pack for the “normal” actuator operation.
The emergency manual override mounted on the actuator, consists
of an hydraulic manual override and a manual selector to choose the
actuator “Normal operation”, with oil supply from a power pack, or the
“Emergency manual operation”. The manual override will be OMFB
for carbon steel material, or dedicated model engineered by BIFFI for
stainless steel material
3.3.2 Remote control operations (for information only)

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3.4 CALIBRATION OF THE ANGULAR STROKE
It is important that the mechanical stops of the actuator (and not
those of the valve) stop the linear stroke at both extreme valve
position (fully open and fully closed), except when this is required by
the valve operation).
The setting of the open/closed valve position (upward position)is
performed by adjusting the travel stop screw into the end flange of
the assembly spring cartridge-cylinder and by the adjustment of the
coupling of valve stem to actuator joint for the downward position.
Figure 3 –Mechanical stop on spring cartridge end flange
Figure 4 –Coupling joint used as mechanical stopper
placed on actuator pedestal
For the adjustment of the mechanical stop on the end flange of
cylinder, follow these steps (see follow picture and refer to chapter
7.2 table 3 for items reference ) :
❑Unscrew the protection lifting eyebolt (7)
❑Insert a wrench for Allen keys in the through hole of protection
flange (2) until reaching the stop setting screw (3).
❑If the actuator angular stroke is stopped before reaching the
upward position (fully open or closed), unscrew the stop setting

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screw by turning it anticlockwise with a proper wrench , until the
valve reaches the right position
❑If the actuator angular stroke is stopped beyond the upward
position (fully open or closed valve), screw the stop screw by
turning it clockwise until the valve reaches the right position.
❑When the adjustment is over tighten the protection eyebolt (7)
paying attention not to deteriorate the O-ring (6)
Figure 5 –Mechanical stop on spring cartridge end flange
For the adjustment of linear stroke in the lower position, operate the
two regulation rings (see chapter 7.2 table 4 item 10)

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To increase the linear stroke unscrew the regulation rings from
threaded surface of stem valve joint (see chapter 7.2 table 4 item 8)
To decrease the linear stroke screw the regulation rings on stem
valve joint, until the valve reaches the right position.
Figure 6 –Coupling joint used as mechanical stopper
placed on actuator pedestal
Regulation rings