BIFFI PLA User manual

Installation, Operation and Maintenance Manual
MAN 619 Rev. 4
June 2020
Biffi PLA
Double-Acting Pneumatic Linear Actuator
Copyright © Bif. The information in this document is subject to change without notice. Updated data sheets can be obtained from our website www.bif.it or from your nearest Bif Center:
Bif Italia s.r.l. - Strada Bif 165, 29017 Fiorenzuola d'Arda (PC) – Italy PH: [phone] – bif_italia@bif.it

June 2020
Installation, Operation and Maintenance Manual
MAN 619 Rev. 4
Revision Details
Revision Details
Revision Details
Rev. Date Description Prepared Checked Approved
4 June 2020 General update (Migration to new template)
3 May 2018 Updated Data-plate Ermanni Oreci Vigliano
2 April 2016 Updated applicable regulation (Section 1.1.1) Ermanni Oreci Vigliano
1October 2009 General update Ermanni Oreci Vigliano
0May 1999 Document release Lazzarini Aliani Ziveri

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Installation, Operation and Maintenance Manual
MAN 619 Rev. 4
Table of Contents
Table of Contents
June 2020
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 .................................................................................................. 4
Section 2: Installation
2.1 Checks Upon Actuator Receipt .................................................................... 5
2.2 Actuator Handling ...................................................................................... 5
2.3 Storage ....................................................................................................... 6
2.4 Actuator Assembly on the Valve.................................................................. 7
2.4.1 Types of Assembly ............................................................................ 7
2.4.2 Assembly Procedure......................................................................... 7
2.5 Pneumatic Connections ............................................................................ 12
2.6 Electrical Connections (If Any)................................................................... 12
2.7 Commissioning......................................................................................... 13
Section 3: Operation and Use
3.1 Operation Description .............................................................................. 14
3.2 Residual Risks ............................................................................................ 15
3.3 Operations ................................................................................................. 15
3.3.1 Local Pneumatic Operation ............................................................ 15
3.3.2 Electric Remote Control to Open and to Close ................................ 16
3.3.3 Emergency Manual Operation by MSJ / MH ........................................ 16
3.3.4 Emergency Manual Operation by MHP ............................................... 17
3.4 Calibration of The Linear Stroke ................................................................. 17
3.5 Calibration of Micro-Switches (for Bif limit switch box*) ......................... 20
3.6 Calibration of the Operation Time ............................................................ 22
Section 4: Operational Tests and Inspections
Operational Tests and Inspections ...................................................................... 24

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Table of Contents
June 2020
Installation, Operation and Maintenance Manual
MAN 619 Rev. 4
Table of Contents
Section 5: Maintenance
5.1 Periodic Maintenance................................................................................ 25
5.1.1 Check and Restore Oil Level in the Gas-Hydraulic Tanks................... 26
5.1.2 Gas Supply Dehydrating Filter Maintenance (if foreseen)................. 27
5.1.3 Lubrication of Actuator................................................................... 28
5.2 Extraordinary Maintenance....................................................................... 29
5.2.1 Replacement of Cylinder Seals ........................................................ 29
5.3 Dismantling and Demolition ..................................................................... 33
Section 6: Troubleshooting
6.1 Failure or Breakdown Research.................................................................. 34
Section 7: Layouts
7.1 Spare Parts Order...................................................................................... 35
7.2 Parts List for Maintenance and Replacing Procedure.................................. 36
Section 8: Date Report for Maintenance Operations
Date Report for Maintenance Operations ............................................................ 45

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Installation, Operation and Maintenance Manual
MAN 619 Rev. 4 June 2020
Section 1: General Warnings
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
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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June 2020
Installation, Operation and Maintenance Manual
MAN 619 Rev. 4
Section 1: General Warnings
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 (Figure 1).
Figure 1 Data Plate

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Installation, Operation and Maintenance Manual
MAN 619 Rev. 4 June 2020
Section 1: General Warnings
General Warnings
1.3 Introducing the Actuator
PLA Double-Acting Pneumatic Low-Pressure Linear Actuators, are suitable for the
operation of linear valves (wedge gate valves, through conduit gate valves) for ON-OFF and
modulating heavy-duty service.
The actuator is made up of a pneumatic cylinder 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 pneumatic cylinder that is pressurized in
one or in the other direction.
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 ange with threaded holes to x the actuator to the valve.
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
Manual handpump MHP (optional)
Pneumatic cylinder
Lifting eyelets
MHP (optional) Hydraulic cylinder (for MHP models)
Valve coupling
Valve position indicator

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June 2020
Installation, Operation and Maintenance Manual
MAN 619 Rev. 4
Section 1: General Warnings
General Warnings
1.4 Data sheet
Supply uid Air, Nitrogen or sweet gas
Operating temperature Standard: from –30 °C to +100 °C
Optional: from –60 °C to +140 °C
Supply pressure 10.5 bar max.
Manual override
Stroke (mm)
Cylider diameter (mm)
Max. allowable thrust (N)
Double-Acting actuator
PLA 250k 585 300 MHP

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Installation, Operation and Maintenance Manual
MAN 619 Rev. 4 June 2020
Section 2: Installation
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, (refer to
Section 3.4) and of micro-switches (if any) refer to Section 3.5.
2.2 Actuator Handling
NOTICE
The lifting and handling should be made by qualied staff and in compliance with the laws
and provisions in force.
! WARNING
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.
For a correct lifting procedure, please refer to following Figures.
Figure 3 Lifting Points for PLA Actuators
1 = Lifting points
(obligatory)

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Installation, Operation and Maintenance Manual
MAN 619 Rev. 4
Section 2: Installation
Installation
Figure 4 Positioning by chains and by slings
1. Point of support
2. Don’t lay the actuator on tie-rods of cylinder
3. Don’t lay the actuator on accessories
(manual handpump, manual jackscrew, pneumatic control group etc.)
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 protection of the control system 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, refer to Section 3.3.

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Installation, Operation and Maintenance Manual
MAN 619 Rev. 4 June 2020
Section 2: Installation
Installation
2.4 Actuator Assembly on the Valve
2.4.1 Types of Assembly
The adapter pedestal in fabricated carbon steel is specically 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 Section 2.2)
on the top of actuator for handling, transporting and assembling in vertical position
(see Figure 3). 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-ange
and on coupling ange (see Figure 4).
2.4.2 Assembly Procedure
! WARNING
Failure to comply with the following procedures may impair product warranty.
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.

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Installation, Operation and Maintenance Manual
MAN 619 Rev. 4
Section 2: Installation
Installation
A. To assemble the actuator onto the valve by bracket with threaded joint proceed
as follows:
Table 1. Parts list
Item Description
1Nut
2Stud bolt
3Support joint
4Index
5 Screw
6Connecting joint
7 Screw
8Bushing
9Flange
Figure 5 Pedestal with threaded coupling joint

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Installation, Operation and Maintenance Manual
MAN 619 Rev. 4 June 2020
Section 2: Installation
Installation
1. Check that the coupling dimensions of the valve ange and stem, or of the
relevant extension, meet the actuator coupling dimensions (valve stem and
ange). 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.
NOTICE
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 x the half bearings.
When the threaded holes of the actuator ange are in correspondence with the
holes on the valve ange screw the proper stud bolts. Screw the nuts on the stud
bolts and tighten up the valve ange is in contact with the actuator ange.
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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MAN 619 Rev. 4
Section 2: Installation
Installation
B. To assemble the actuator onto the valve by bracket with shell joint,
perform the following operations:
Table 2. Parts list
Item Description
1Stud bolt
2Nut
3Nut
4Screw
5 Pedestal
6Actuator joint
7 Stem valve joint
8Shell joint
9Spacer
10 Screw
Figure 6 Pedestal with shell coupling joint

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Installation, Operation and Maintenance Manual
MAN 619 Rev. 4 June 2020
Section 2: Installation
Installation
1. Check that the coupling dimensions of the valve ange and stem, or of the
relevant extension, meet the actuator coupling dimensions (valve stem and
ange). 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.
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 ange, 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:
The screwing values in Table 3 were calculated considering the materials ASTM A320 L7
for screws or tie rods and ASTM A194 gr.2H for the nuts.
Table 3. 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

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Installation, Operation and Maintenance Manual
MAN 619 Rev. 4
Section 2: Installation
Installation
2.5 Pneumatic Connections
! WARNING
Check that the values of pneumatic 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 and connections appropriate
as for type, material and dimensions.
• Properly deburr 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.
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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MAN 619 Rev. 4 June 2020
Section 2: Installation
Installation
2.7 Commissioning
! WARNING
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 paint hasn't been damaged during transport, if necessary repair the
damages to paint coat.
• 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) and to specic
data-plate on electric components.
• Check that the setting of the components of the actuator control unit (pressure
regulator, pressure switches, ow control valves, etc.) meet the plant requirements.
• 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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MAN 619 Rev. 4
Section 3: Operation and Use
Operation and Use
Section 3: Operation and Use
3.1 Operation Description
The supply gas pressurizes the pneumatic-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.
For local or remote operations, please refer to technical documentation furnished
with actuators.
The power and control systems are supplied on specic customer demand.
NOTICE
For all the relevant information please refer to the specic documentation supplied.
Figure 8 Double-Acting function with jackscrew manual override type MHW
(direct action) or MSJ (that it can be engaged/disengaged by hand-lever)
Figure 7

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Installation, Operation and Maintenance Manual
MAN 619 Rev. 4 June 2020
Section 3: Operation and Use
Operation and Use
Figure 9 Double-Acting function with jackscrew manual override type MHP
3.2 Residual Risks
! WARNING
It is recommended to pipe exhaust gas.
The actuator has parts under pressure.
Use the due caution.
Use individual protections provided for by the laws and provisions in force.
3.3 Operations
3.3.1 Local Pneumatic Operation
! WARNING
Use the proper safety measures to protect from any pressurized gas not piped
and from excessive and harmful noise. Refer to applicable control schematic in
supplied documentation.

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Section 3: Operation and Use
Operation and Use
Figure 10 PLAS MHP without control system
Pressurize the pneumatic-cylinder chamber, this pressure starts the linear motion of the
piston and the consequent motion of the valve stem that is coupled.
The valve is actuated in opening and in closing position by the actuator pneumatic
cylinder in one direction and by the spring unit in the other direction. Check the correct
operation of the actuator through the visual position indicator.
3.3.2 Electric Remote Control to Open and to Close
When actuator is furnished of control system (panel or cabinet) remote operations
were possible:
• From the control room send the electric signal corresponding to the operation to
carry out: energize solenoid valve during all the valve stroke.
• Solenoid valve must be de-energized at the end of actuator operation.
3.3.3 Emergency Manual Operation by MSJ / MHW
(when sufcient line pressure is not available)
• Engage the manual override by rotating it’s handle.
• Turn by the lever the manual override clockwise to close, or counterclockwise to open.
• Check the correct operation of the actuator through the visual position indicator.
• If no other manual operation is carried out, disengaged the manual override to allow
the operation with pneumatic supply.
(see Section 7.2, Table 14: sectional drawing for Manual Jackscrew MSJ.)