BIFFI OLGAS User manual

Installation, Operation and Maintenance Manual
MAN 608 Rev. 5
December 2020
Bif OLGAS
Spring-Return Hydraulic Actuators
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

Revision Details
December 2020
Installation, Operation and Maintenance Manual
MAN 608 Rev. 5
Revision Details
Revision Details
Revision Date Description Prepared Checked Approved
5 December 2020 Migration to new template
4April 2020 Updated DATAPLATE Ermanni Oreci Vigliano
3April 2018 Updated applicable regulation (chapter 1.1.1) Ermanni Oreci Vigliano
2July 2012 General update Ermanni Stoto Vigliano
1 February 2010 General update Ermanni Stoto Vigliano
0May 1999 Document release Lazzarini Aliani Ziveri

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Installation, Operation and Maintenance Manual
MAN 608 Rev. 5
Table of Contents
December 2020
Table of Contents
Table of Contents
Section 1: General Warnings
1.1 Generalities................................................................................................... 1
1.1.1 Applicable regulation ......................................................................... 1
1.1.2 Terms and conditions ......................................................................... 2
1.2 Identication Plate ........................................................................................ 2
1.3 Introducing the Actuator............................................................................... 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.................................................................... 8
2.4.1 Types of Assembly.............................................................................. 8
2.4.2 Assembly Procedure......................................................................... 13
2.5 Hydraulic Connections................................................................................ 14
2.6 Electrical Connections (If Any)..................................................................... 14
2.7 Commissioning........................................................................................... 15
Section 3: Operation and Use
3.1 Operation Description................................................................................. 16
3.2 Residual Risks.............................................................................................. 17
3.3 Operations.................................................................................................. 17
3.3.1 Emergency Manual Operation .......................................................... 17
3.3.2 Remote Control Operations.............................................................. 19
3.4 Calibration of the Angular Stroke ................................................................ 21
3.5 Calibration of Micro-Switches (If Foreseen).................................................. 25
3.6 Calibration of the Operation Time (If Required)........................................... 26

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Table of Contents
December 2020
Installation, Operation and Maintenance Manual
MAN 608 Rev. 5
Table of Contents
Section 4: Operational Tests and Inspections
Operational Tests and Inspections......................................................................... 27
Section 5: Maintenance
5.1 Periodic Maintenance.................................................................................. 28
5.1.1 Check and Restore Oil Level in the Hydraulic Manual Handpump...... 29
5.2 Extraordinary Maintenance ......................................................................... 31
5.2.1 Replacement of Cylinder Seals .......................................................... 32
5.3 Lubrication of Mechanism........................................................................... 35
5.4 Dismantling and Demolition ....................................................................... 36
Section 6: Troubleshooting
6.1 Failure or Breakdown Research.................................................................... 37
Section 7: Layouts
7.1 Spare Parts Order........................................................................................ 38
7.2 Parts List for Maintenance and Replacing Procedure.................................... 39
Section 8: Date Report for Maintenance Operations
Date Report for Maintenance Operations .............................................................. 46

Installation, Operation and Maintenance Manual
MAN 608 Rev. 5 December 2020
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
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 con-
tained 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 608 Rev. 5
General Warnings2
Section 1: General Warnings
1.1.2 Terms and conditions
Bif Italia s.r.l. guarantees that all the items produced are free of defects in workmanship
and manufacturing materials and meet relevant current specications, provided they
are installed, used and serviced according to the instructions contained in the present
manual. The warranty can last either one year from the date of installation by the initial
user of the product, or eighteen months from the date of shipment to the initial user,
depending on which event occurs rst. All detailed warranty conditions are specied in the
documentation forwarded together with the product. This warranty does not cover special
products or components not warranted by subcontractors, or materials that were used or
installed improperly or were modied or repaired by unauthorized staff. In the event that
a fault condition be caused by improper installation, maintenance or use, or by irregular
working conditions, the repairs will be charged according to applicable fees.
The warranty and Bif Italia s.r.l. liability shall lapse in the event that any modication
or tampering whatsoever be performed on the actuator.
1.2 Identication Plate
It is forbidden to modify the information and the marks without previous written
authorization by Bif Italia s.r.l.
The plate fastened on the actuator contains the following information (Figure1).
Figure 1 Data plate

Installation, Operation and Maintenance Manual
MAN 608 Rev. 5 December 2020
General Warnings 3
Section 1: General Warnings
1.3 Introducing the Actuator
The hydraulic actuator OLGAS 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 hydraulic 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 spring
cartridge and into the end ange of the hydraulic 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 .
1.4 Data Sheet
Supply uid Hydraulic oil, special versions for re-resistant uids
Operating temperature Standard: from –30 °C to +100 °C
Optional: from –60 °C to +140 °C
Design pressure 12 bar maximum
Supply pressure Please refer to technical document: “actuator data-sheet”
Figure 2 Identication of actuator parts
Spring cartridge
Valve position indicator
Hydraulic Cylinder
Valve Coupling
Scotch yoke
mechanism

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Installation, Operation and Maintenance Manual
MAN 608 Rev. 5
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,
see 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

Installation, Operation and Maintenance Manual
MAN 608 Rev. 5 December 2020
Installation 5
Section 2: Installation
Figure 4 Lifting points for OLGAS actuators
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.)
• 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.

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Installation, Operation and Maintenance Manual
MAN 608 Rev. 5
Installation
6
Section 2: Installation
Figure 6
For the transport of OLGAS with hydraulic manual handpump, 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 specic 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.
Bif hydraulic manual handpump must be maintained with tank under the handpump to
operate the actuator with MHP correctly.
Figure 5

B
A
Installation, Operation and Maintenance Manual
MAN 608 Rev. 5 December 2020
Installation 7
Section 2: Installation
Figure 7 Fixing positions
Position 1
Standard application
Position 2
Standard application
Position 3
Change the position of suction
pipe from A to B and the
breather cap to top side
Invert the position of the breather cap
OMFB manual handpump should be transported and used with MHP tank in
horizontal position, but in position 3 of follow picture (extracted from OMFB technical
documentation) it’s necessary change the position of suction pipe and breather cap.
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).

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Installation, Operation and Maintenance Manual
MAN 608 Rev. 5
Installation
8
Section 2: Installation
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.
NOTICE
To x the actuator to the valve ange must be used the stud bolts and nuts supplied by
Bif. In case the actuator is supplied without stud bolts and nuts the following materials
must be used as a minimum:
• ASTM A 193 Grade L7 for Stud Bolts
• ASTM A 194 Grade 4 for Nuts

0.3 240 93 165 M20 4517 127 70 12 75.6
0.9 310 112 254 M16 8 5 19 150 86 14 93.6
1.5 360 144 298 M20 8 6 19 190 112 18 119.0
3430 195 356 M30 8 923 200 157 25 167.8
6 520 250 406 M36 8 14 29 260 200 28 212.8
Installation, Operation and Maintenance Manual
MAN 608 Rev. 5 December 2020
Installation
45°
Ø d2
+0.1
Ø d3
±0.2
Ø d1
0
h1
+0.5
Ø d4
h2
Ød5
+0.2
+0.1
K+
0.4
0
W D10
0
9
Section 2: Installation
Figure 8 Coupling dimensions - Models 0.3 to 6
Drive sleeve
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
max
Dimensions in millimeters
Actuator model Ø d1Ø d2Ø d3Ø d4N h1h2H max Ø d5WK
H max
Table 1. SCN6200

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
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Installation, Operation and Maintenance Manual
MAN 608 Rev. 5
Installation
Ød1
Ød4
h2
Ød2+0.1
0
Ød3±0.2
h1 +0.5
0
H max
Ød5+0.2
+0.1
K+0.4
0
WD10
10
Section 2: Installation
Dimensions in millimeters
Actuator model Ø d1Ø d2Ø d3Ø d4N h1h2H max Ø d5WK
Flow line
Drive sleeve
Figure 9 Coupling dimensions - Models 14 to 42
N.12 holes flangeN.16 holes flange
max
Table 2. SCN6201
Top view of the Scotch yoke mechanism
(actuator shown in closed position)
N. threaded holes
PCD, number and
size according to ISO 5211

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
Installation, Operation and Maintenance Manual
MAN 608 Rev. 5 December 2020
Installation
Ød1
Ød4
h2
Ød2+0.1
0
Ød3±0.2
h1 +0.5
0
H max
Ød5+0.2
+0.1
K+0.4
0
WD10
Dimensions in millimetersw
Actuator model Ø d1Ø d2Ø d3Ø d4N h1h2H max Ø d5WK
Drive sleeve
N. THREADED HOLES
Flange sizing according to ISO
Top view of the scotch yoke mechanism
(actuator shown in closed position)
Flow line
Table 3. SCN6201-1
11
Section 2: Installation
Figure 10 Coupling dimensions - Models 50 and 60
max

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Installation, Operation and Maintenance Manual
MAN 608 Rev. 5
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 enclosed
(see following pages). On request the insert bush bore can be machined by Bif to couple
the valve stem. The particular execution of the ange and bushing allow the actuator to be
rotated by 90° in 4 different positions according to the Figure 11.
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 11 Insert bush + intermediate coupling ange
Table 4.
12
Section 2: Installation

Installation, Operation and Maintenance Manual
MAN 608 Rev. 5 December 2020
Installation 13
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 matching valve position (Section 3.3).
• Lubricate valve stem with oil or grease.
• Properly clean and remove grease from valve coupling ange surfaces.
• Connect, if supplied separately, the stem extension onto the 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.
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.
Table 5. Nuts tightening torque

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Installation, Operation and Maintenance Manual
MAN 608 Rev. 5
Installation
14
Section 2: Installation
2.5 Hydraulic Connections
! WARNING
Check that the values of hydraulic supply available are compatible with those reported on
the identication plate of the actuator.
NOTICE
The connections should be made by qualied staff. Use pipes, ttings and connections
appropriate as for type, material and dimensions.
Connect the actuator to the hydraulic feed line with ttings and pipes in accordance to the
plant specications. They must be sized correctly in order to guarantee the necessary oil
ow for the operation of the actuator, with pressure drops not exceeding the maximum
allowable value. The shape of the connecting piping must not cause excessive stress
to the inlets of the actuator. The piping must be suitably fastened so as not to cause
excessive stress or loosening of threaded connections, if the system undergoes strong
vibrations. Every precaution must be taken to ensure that any solid or liquid contaminants,
which may be present in the hydraulic pipework to the actuator, are removed to avoid
possible damages to the unit or loss of performance. The inside of the pipes used for the
connections must be well-cleaned before use: wash them with suitable substances and
blow through them with oil or nitrogen. The ends of the tubes must be well debarred and
cleaned. Once the connections are completed, operate the actuator and check that it
functions correctly, that the operation times meet the plant requirements and that there
are no leakages in the hydraulic connections.
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.

Installation, Operation and Maintenance Manual
MAN 608 Rev. 5 December 2020
Installation 15
Section 2: Installation
2.7 Commissioning
! WARNING
Installation, commissioning and maintenance and repair works should be made by
qualied staff. Any calibration relative to functional aspects of the actuator are preset at
the factory. Before any modications please contact Bif Italia s.r.l.
Upon actuator commissioning please carry out the following checks:
• Check that the values of hydraulic supply available in the system are compatible
with those reported on the identication plate of the actuator (Figure 1) and on
the documentation supplied.
• Check the power voltage of electrical components complies with the one
reported on the documentation supplied and with specic data-plate placed on
electrical components.
• Check the absence of leakages in the cylinder and in hydraulic connections.
• Check that paint is intact and in case renovate it according to the specication on
order conrmation.
• Carry out all kinds of operations and check their proper execution (Section 3.3).
• Make a complete functional test in order to verify all the operations are executed
according to operating schematic diagram supplied.
NOTICE
if necessary to mount components not in Bif scope of supply, please check the accessories
mounting hole details in the documents TN 1028 ( for metric dimension) or TN 1028U
(for imperial dimension).

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Installation, Operation and Maintenance Manual
MAN 608 Rev. 5
Operation and Use16
Section 3: Operation and Use
Figure 12
Section 3: Operation and Use
3.1 Operation Description
The actuator is operated by:
1. Pressurized motor uid.
2. Elastic return of compression helicoidally spring.
In the rst case the alimentation uid pressurizes a chamber of the cylinder and compresses
the spring (Figure 4); this determines the linear motion of the piston and the consequent
rotation motion of the scotch yoke mechanism to which valve stem is coupled. The uid
contained in the other chamber is discharged through the return line.
In the second case, cutting off or in case of lack of pressure to the cylinder and to the pilot
of the fast discharge valve, the opening of the latter is determined, the fast discharge of
motor uid, the quick extension of the spring and the consequent fast operation of the
actuator. The motor uid going out from one chamber of the cylinder partially returns in
the other chamber and partially ows through the discharge line.
For local or remote operations, please refer to technical documentation furnished
with actuators.
! WARNING
For all the relevant information please refer to the specic documentation supplied.