BIFFI GIGS Series User manual

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
Installation, Operation and Maintenance Manual
MAN 611 Rev. 6
February 2021
Bif GIGS
Spring-Return Hydraulic Actuator

February 2021
Revision Details
Installation, Operation and Maintenance Manual
MAN 611 Rev. 6
Revision Details
Rev. Date Description Prepared Checked Approved
6 February 2021 Migration to new template
5 April 2018 Updated Data-plate Ermanni Oreci Vigliano
4 April 2018 Revised data-plate Ermanni Oreci Vigliano
3 April 2018 Updated applicable regulation
(Chapter 1.1.1) Ermanni Oreci Vigliano
2 July 2012 General update Ermanni Stoto Vigliano
1 November 2010 General update Ermanni Stoto Vigliano
0 May 1999 Document Release Lazzarini Aliani Ziveri
Revision Details

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Installation, Operation and Maintenance Manual
MAN 611 Rev. 6
Table of Contents
February 2021
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 Table........................................................................................ 2
1.3 Introducing the Actuator............................................................................... 3
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 Commisioning ............................................................................................ 15
Section 3: Operation and Use
3.1 Operation Description................................................................................. 16
3.2 Residual Risks.............................................................................................. 20
3.3 Operations.................................................................................................. 21
3.3.1 Local Pneumatic Operation .............................................................. 21
3.3.2 Electric Remote Control to Open and to Close .................................. 21
3.3.3 Emergency Manual Operation by MHW or MRHW ............................ 22
3.3.4 Emergency Manual Operation by MHP ............................................. 22
3.4 Calibration of the Angular Stroke ................................................................ 23
3.5 Calibration of Micro-switches (Bif Limit Switch Box Only) .......................... 28
3.6 Calibration of the Operation Time............................................................... 31
Section 4: Operational Tests and Inspections
Operational Tests and Inspections.........................................................................32
Section 5: Maintenance
5.1 Periodic Maintenance.................................................................................. 33
5.1.1 Check and Restore Oil Level in the Hydraulic Control Unit................. 34
5.1.2 Gas Supply Dehydrating Filter Maintenance (If Foreseen).................. 36
5.2 Extraordinary Maintenance ......................................................................... 37
5.2.1 Replacement of Cylinder Seal............................................................ 38
5.3 Dismantling and Demolition ....................................................................... 41
5.4 Lubrication of Mechanism........................................................................... 42

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Table of Contents
February 2021
Installation, Operation and Maintenance Manual
MAN 611 Rev. 6
Table of Contents
Section 6: Troubleshooting
6.1 Failure or Breakdown Research.................................................................... 43
Section 7: Layouts
7.1 Spare Parts Order........................................................................................ 44
7.2 Parts List for Maintenance and Replacing Procedure.................................... 45
Section 8: Date Report for Maintenance Operations
Date Report for Maintenance Operations...............................................................54

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Installation, Operation and Maintenance Manual
MAN 611 Rev. 6
General Warnings 1
Section 1: 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.
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.

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Installation, Operation and Maintenance Manual
MAN 611 Rev. 6
General Warnings2
Section 1: General Warnings
1.2 Identication Table
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

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Installation, Operation and Maintenance Manual
MAN 611 Rev. 6
General Warnings 3
Section 1: General Warnings
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, buttery 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 simplies assembly. The spring action can be easily changed in the eld
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 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
1.4 Data Sheet
Supply uid Hydraulic oil, special version for re-resistant uids
Operating temperature Standard: from –30 °C to +100 °C
Optional: from –60 °C to +140 °C
Supply pressure Please refer to technical document:
“actuator datasheet”
Spiring cartridge
Valve coupling
Pneumatic cylinder
Valve position indicator
Scotch yoke mechanism

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Installation, Operation and Maintenance Manual
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Installation
4
Section 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 of the actuator must be done by qualied personnel and in
accordance with the laws and regulations in force. Avoid the lifted actuator to be hung
above the personnel.
! 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 Figure 3.
Figure 3 Example of Hook with Safety Latch

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Installation 5
Section 2: Installation
Figure 4 Lifting points for GIGS Actuators
1, 2 = Lifting points (obligatory)
3 = Balancing point
1 = Point of support
2 = Supports for lateral positioning
3 = Do not lay the actuator on tie rods of cylinder/s and do not lay the actuator on
accessories (manual override, pneumatic control group etc.).

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Installation
REFER TO IOM
6
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 5
BIFFI IS NOT LIABLE FOR ANY PERSONEL
INJURY DUE TO INCORRECT USE
POTENTIAL ELECTROTASTIC CHARGE HAZARD
DO NOT DISASSEMBLE TOP OR
BOTTOM COVER.
SPRING LOADED.
LIFTING LUGS TO BE USED FOR THE
ACTUATOR ONLY. DO NOT LIFT VALVE AND
ACTUATOR TOGETHER

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Installation 7
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 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 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.
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.

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Installation
8
Section 2: Installation
Figure 6 Actuator Models from 0.3 to 6
45º
Ø d2
+0.1
Ø d3
±0.2
Ø d1max
0
h1+0.5
H max
Ød4
h2
Ø d5
+0.2
+0.1
K
+0.4
0
W D10
N. threaded holes
PCD, number and size according to ISO 5211
(but the holes are on centerline
instead of straddle the centerline)
Flow line
Top view of the Scotch yoke mechanism
(actuator shown in closed position)
N.4 holes flange N.8 holes flange
Drive sleeve
Table 1. Coupling Dimensions Models 0.3 to 0.6 (mm)
Actuator Model Ø d₁Ø d₂Ø d₃Ø d₄N h₁h₂H max Ø d₅WK
0.3 240 93 165 M20 4 5 17 127 70 12 75.6
0.9 310 112 254 M16 8 5 19 150 86 14 96.6
1.5 360 144 298 M20 8 6 19 190 112 18 119.0
3430 195 356 M30 8 9 23 200 157 25 167.8
6520 250 406 M36 814 29 260 200 28 212.8
0

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Installation 9
Section 2: Installation
Figure 7 Actuator Models from 14 to 42
Ød4
h2
K
+0,4
0
N. threaded holes
PCD, number and size according to ISO 5211
Flow line
N.16 holes ange N.12 holes ange
Drive sleeve
Top view of the Scotch yoke mechanism
(actuator shown in closed position)
Table 2. Coupling Dimensions Models 14 to 42 (mm)
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
Actuator Model Ø d₁Ø d₂Ø d₃Ø d₄N h₁h₂H max Ø d₅WK
Ø d2
+01
H max
0
h1+0.5
Ø d5
+0.2
+0.1
0
Ø d1 max
Ø d3
±0.2
D10
'W'

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Installation
10
Section 2: Installation
H max
N. threaded holes
Flange sizing according to ISO 5211
Flow line
Top view of the Scotch yoke mechanism
(actuator shown in closed position)
Drive sleeve
Figure 8 Actuator Models from 50 and 60
Table 3. Coupling Dimensions Models 14 to 42 (mm)
Actuator Model Ø d₁Ø d₂Ø d₃Ø d₄N h₁h₂H max Ø d₅WK
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
Ø d2
+0.1
0
h1+0.5
Ød4
h2
Ø d5
+0.2
+0.1
K
+0.4
0
0
Ø d1 max
Ø d3
±0.2
'W'
D10

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Installation 11
Section 2: Installation
Figure 9 Insert Bush + Intermediate Coupling Flange
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 enclosed
(see following pages). 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 following gure:
Flow line
Drive sleeve
Drive sleeve
N.4 holes ange
Housing
Insert bush
Snap ring
Adaptor ange
Standard position 1
N.8 holes ange
Insert bush
Position 2 Position 3 Position 4
Table 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
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.

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Installation
12
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
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.

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Installation 13
Section 2: Installation
2.5 Pneumatic Connections
NOTICE
Check that the values of pneumatic supply available are compatible with those reported on
the identication plate of the actuator.
! WARNING
The connections should be made by qualied staff. Use pipes, ttings 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.
Table 5. 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 5 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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Installation
14
Section 2: Installation
Ground
Figure 10 Junction box on Control group (if foreseen)
2.6 Electrical Connections (If Any)
! WARNING
Use components appropriate as for type, material and dimensions. 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.

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Installation 15
Section 2: Installation
2.7 Commisioning
! WARNING
Check that values of electrical supply to the control group (if foreseen) are compatible
with those on the plate on the junction box (Figure 10). 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 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.
• 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 (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.

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Operation and Use16
Section 3: Operation and Use
Section 3: Operation and Use
3.1 Operation Description
In the normal operating situation, the direct gas actuator is fed by pressurised gas which
ows 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 Sections 3.3.1, 3.3.2, 3.3.3 and 3.3.4 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 Section 3.5) is adjustable by
unidirectional ow regulators (item 278) (refer to follow GIGS typical control schematics).
! WARNING
For all the relevant information please refer to the specic documentation supplied.
Figure 11 Pneumatic Connection
Pneumatic Connection