BIFFI GIGS 0.3 User manual

GIGS –Spring return direct gas actuator
Use and maintenance manual
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MAN 611
Use and mantenance manual
GIGS
SPRING RETURN DIRECT
GAS ACTUATOR

GIGS –Spring return direct gas actuator
Use and maintenance manual
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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.
5
17/04/18
Updated Data-plate
Ermanni
Orefici
Vigliano
4
18/04/16
Updated applicable
regulation (chapter
1.1.1)
Ermanni
Orefici
Vigliano
3
16/04/13
Update chapter 5.1.1
Ermanni
Stoto
Vigliano
2
31/07/12
General update
Ermanni
Stoto
Vigliano
1
25/03/09
General update
Ermanni
Stoto
Vigliano
0
05/05/99
Document release
Lazzarini
Aliani
Ziveri
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 ...................................................................................6
2Installation........................................................................... 7
2.1 checks upon actuator receipt ......................................................7
2.2 actuator handling.........................................................................7
2.3 storage......................................................................................10
2.4 actuator assembly on the valve.................................................10
2.4.1Types of assembly ................................................................10
2.4.2Assembly procedure..............................................................15
2.5 pneumatic connections..............................................................16
2.6 electrical connections (if any)....................................................16
2.7 commissioning...........................................................................17
3Operation and use ............................................................. 18
3.1 operation description.................................................................18
3.2 residual risks .............................................................................22
3.3 operations .................................................................................22
3.3.1Local pneumatic operation....................................................22
3.3.2Local hydraulic manual operation..........................................23
3.3.3Remote operation..................................................................23
3.4 calibration of the angular stroke ................................................24
3.5 calibration of microswitches (if foreseen) ..................................26
3.6 calibration of the operation time ................................................32
4Operational tests and inspections...................................... 33
5Maintenance ...................................................................... 34
5.1 periodic maintenance................................................................34
5.1.1Check and restore oil level in the gas-hydraulic tanks...........35
5.2 Extraordinary maintenance .......................................................36
5.2.1Replacing the seals ..............................................................36
5.3 Dismantling and demolition........................................................42
5.4 Lubrication of mechanism..........................................................43
6Troubleshooting ................................................................ 44
6.1 failure or breakdown research...................................................44
7Layouts.............................................................................. 45
7.1 Spare parts order ......................................................................45
7.2 parts-list for maintenance and replacing procedure...................46
8 Date report for maintenance operations ............................ 55

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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
The direct gas actuator GIGS was engineered and is manufactured
to provide fail safe operation for any quarter turn application such as
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 spring module incorporates up to four
springs, fully encapsulated in a factory-welded cartridge: this ensure
safety to personnel and simplifies assembly. The spring action can
be easily changed in the field from “to close” in “to open” or vice-
versa. 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 above 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

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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 25 years .
Figure 2 –Identification of actuator parts
1.4 DATA SHEET
Supply fluid
Natural gas, compressed air, nitrogen
Operating temperature
Standard: from –30°C to +100°C
Optional: from –60° to +140°C
Supply pressure
Please refer to technical document:
“actuator data-sheet”
Spring cartridge
Pneumatic cylinder
Scotch-yoke
mechanism
Valve coupling
Valve position indicator

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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).
2.2 ACTUATOR HANDLING
The lifting and handling of the actuator must be done by
qualified personnel and in accordance with the laws and
regulations in force. Avoid the lifted actuator to be hung
above the personnel.
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
fitted with safety latch, like the one, for example, shown
in follow figure 2.1
Picture 2.2 –Lifting points for GIGS actuators
Figure 2.1 Example of hook with
safety latch

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1-2 = Lifting points ( obligatory ) 3 = Balancing point
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 override,
pneumatic control group etc. )

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•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 (MAX < 20°).
•During handling, do not transport the suspended actuator
above staff members in charge of the operation.
DO NOT USE the lifting eyelets on actuator to lift valve +
actuator assembly
Figure 2.3

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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 (Sect. 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
SCN6201). 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 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.

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Use and maintenance manual
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Use and maintenance manual
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If required, for the standard models size 0.3 to 6, Biffi can supply an
insert bush with un-machined bore in accordance with Biffi standard
table SCN6202 enclosed ( see following pages ). On request the
insert bush bore can be machined by Biffi to couple the valve stem,
provided its dimensions match the maximum stem acceptance of the
bush according to Biffi doc.: TN1005. The particular execution of the
flange and bushing allow the actuator to be rotated by 90° in 4
different positions according to the following figure:

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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 3 –Insert bush + intermediate coupling flange
The Biffi 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.

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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.
❑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 flange 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 (Sect. 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 flanges are not aligned, adequately
operate the actuator if necessary move the mechanical stops
backwards (Sect. 3.4).
❑Fasten threaded connections. Please refer to Table 1.
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

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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.
2.5 PNEUMATIC CONNECTIONS
Check that the values of pneumatic 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.
❑Properly de-burr 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 pneumatic connections.
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 :
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 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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Picture 2 –Junction box on Control group (if foreseen)
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 (Picture 2).
Installation, commissioning and maintenance and repair
works should be made by qualified staff.
Upon actuator commissioning please carry out the following checks:
❑Check that the pressure and quality of the gas supply (filtering
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 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.
❑Check that paint is not be damaged during transport, if necessary
repair the damages to paint coat.
❑Carry out all kinds of operations and check their proper execution
(Sect. 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.
Ground

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3Operation and use
3.1 OPERATION DESCRIPTION
In the normal operating situation, the direct gas actuator is fed by
pressurised gas which flows into pneumatic cylinder. The cylinder
piston stroke causes the actuator operation and the consequent
valve movement to the operational position requested (for example to
the “open” position).
Upon a demand, the gas is discharged from the cylinder into the
return line: the actuator performs the closing operation driven by the
spring movement, and the valve moves from the open position to the
close (safety-related) position.
For local or remote operations, please refer to par. 3.3.1 , 3.3.2 ,
3.3.3 and 3.34 and prior to technical documentation furnished with
actuators.
Typical schematics for various applications are follow attached for
information only. As shown in these schematics, actuator operation
speed (see chapt. 3.5) is adjustable by unidirectional flow regulators
(item 278) ( refer to follow GIGS typical control schematics ) ;
For all the relevant information please refer to the specific
documentation supplied.

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Typical control schematics
Spring return direct gas actuator with local / remote
controls

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Use and maintenance manual
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Spring return direct gas actuator with manual
override - local / remote controls