BIFFI RP14 User manual

RPS –Spring return pneumatic actuator
Use and maintenance manual
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MAN 573-C
Use and maintenance manual
RPS
SPRING RETURN
PNEUMATIC ACTUATOR
0
10/07/19
Issue document
Ermanni
Orefici
Vigliano
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..............................................................................9
2Installation........................................................................... 9
2.1 CHECKS UPON ACTUATOR RECEIPT.....................................9
2.2 ACTUATOR HANDLING...........................................................10
2.3 STORAGE.................................................................................13
2.4 ACTUATOR ASSEMBLY ON THE VALVE ...............................14
2.4.1Types of assembly ................................................................14
2.4.2Assembly procedure..............................................................16
2.5 PNEUMATIC CONNECTIONS..................................................17
2.6 ELECTRICAL CONNECTIONS (IF ANY)..................................17
2.7 COMMISSIONING ....................................................................18
3Operation and use ............................................................. 19
3.1 OPERATION DESCRIPTION....................................................19
3.2 RESIDUAL RISKS.....................................................................21
3.3 OPERATIONS...........................................................................21
3.4 CALIBRATION OF THE ANGULAR STROKE ..........................22
3.5 CALIBRATION OF MICROSWITCHES.....................................24
3.6 CALIBRATION OF THE OPERATION TIME .............................26
4Operational tests and inspections...................................... 27
5Maintenance ...................................................................... 28
5.1 PERIODIC MAINTENANCE......................................................28
5.2 EXTRAORDINARY MAINTENANCE ........................................29
5.3 LUBRICATION OF MECHANISM..............................................34
5.4 DISMANTLING AND DEMOLITION...........................................36
6Troubleshooting ................................................................ 37
6.1 FAILURE OR BREAKDOWN RESEARCH ...............................37
7Layouts.............................................................................. 38
7.1 Spare parts order ......................................................................38
7.2 parts-list for maintenance and replacing procedure...................39
8Date report for maintenance operations.................................. 41

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NOTE:
BIFFI Italia S.r.l pays the highest attention to collecting and verifying the
documentation contained in this user manual. However BIFFI Italia S.r.l. is not
liable for any mistakes contained in this manual, for damage or accidents due to
the use of the latter. The information contained is of exclusive reserved ownership
of BIFFI Italia S.r.l and may be modified without prior notice. All rights reserved.

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1General warnings
The manual is an integral part of the machine, it should
be carefully read before carrying out any operation and
it should be kept for future references.
1.1 GENERALITIES
BIFFI Italia S.r.l actuators are conceived, manufactured and
controlled according to the Quality Control System in compliance with
EN-ISO 9001 international regulation.
1.1.1 Applicable regulation
EN ISO 12100:2010: Safety of machinery –General principles for
design –Risk assessment and risk reduction
2006/42/EC: Machine directive.
2014/68/EU: Directive for pressure PED equipment
2014/35/EU: Directive for low voltage equipment
2014/30/EU: Directive for the electromagnetic compatibility
2014/34/EU: Directive and safety instructions for use in
hazardous area
1.1.2 Terms and conditions
Biffi Italia srl guarantees that all the items produced are free of
defects in workmanship and manufacturing materials and meet
relevant current specifications, provided they are installed, used and
serviced according to the instructions contained in the present
manual. The warranty can last either one year from the date of
installation by the initial user of the product, or eighteen months from
the date of shipment to the initial user, depending on which event
occurs first. All detailed warranty conditions are specified in the
documentation forwarded together with the product. This warranty
does not cover special products or components not warranted by
subcontractors, or materials that were used or installed improperly or
were modified or repaired by unauthorized staff. In the event that a
fault condition be caused by improper installation, maintenance or
use, or by irregular working conditions, the repairs will be charged
according to applicable fees. The warranty and Biffi Italia srl

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liability shall lapse in the event that any modification or
tampering whatsoever be performed on the actuator.
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
RPS actuators are pneumatic low-pressure spring return, suitable for
any quarter turn application such as ball, plug, butterfly valves or
dampers, in both ON-OFF and modulating heavy-duty service
The actuator is made up of a rack and pinion mechanism, which
transforms the linear movement of the pneumatic cylinder, in one
direction, and of the spring, in the opposite direction, into the rotary
movement for the valve operation. An adjustable bronze sliding block
supports the transverse force exerted on the rack by its engagement
with the pinion. The rack is nitride for ensure the minimal friction.
The spring module incorporates one or two springs in series,
depending on the model, and is fully encapsulated. This assures

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safety to personnel and ease of assembly. External travel stops allow
precise angular stroke adjustment between 80° and 100°.
Totally enclosed, weatherproof housing, made of nodular cast iron for
maximum strength and suitable for use in hostile environments.
The mounting flange is identical on both (upper and lower) faces of
the housing; the shaft output drives have the same dimensions but is
positioned at 90°. This allows the actuator to be used as spring to
close or spring to open without modification.
The actuator is assembled onto the valve by connecting the actuator
housing flange to the valve flange by a spool piece and the actuator
shaft to the valve stem by a stem extension.
Actuator manual emergency operation in opposition to the spring
action, is performed by rotating the jackscrew by a wrench or by a
hand-wheel (available on request).
The mounting flange, on the housing top, can be utilised for the
assembly of limit switches, position transmitter, positioner etc., which
are actuated by the actuator output shaft.

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The actuator housing is provided, on the front face and in the back
face (optional), with threaded holes for the assembly of accessories
(control panels, air storage tank, etc.).

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The expected lifetime of actuator is approximately 25 years .

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1.4 DATA SHEET
2Installation
2.1 CHECKS UPON ACTUATOR RECEIPT
❑Check that the model, the serial number of the actuator and the
technical data reported on the identification plate correspond with
those of order confirmation (Sect. 1.2).
❑Check that the actuator is equipped with the fittings as provided for
by order confirmation.
❑Check that the actuator was not damaged during transportation: if
necessary renovate the painting according to the specification
reported on the order confirmation.
❑If the actuator is received already assembled with the valve, its
settings have already been made at the factory.
If the actuator is delivered separately from the valve, it is
necessary to check, and, if required, to adjust, the settings of the
mechanical stops (Sect. 3.4) and of micro-switches (if any) (Sect.
3.5).
Supply fluid
Air, Nitrogen or sweet gas
Operating temperature
Standard: from –30°C to +100°C
Optional: from –60° to +140°C
Design pressure
Supply pressure
Output torque
12 bar maximum
Please refer to technical document:
“actuator data-sheet”
up to 3700 Nm

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2.2 ACTUATOR HANDLING
a) Valve stem with vertical axis :
The lifting and handling should be made by qualified staff and in
compliance with the laws and provisions in force.
The fastening points are appropriate for the lifting of the
actuator alone and not for the valve + actuator assembly.
Avoid that during the handling, the actuator passes above the
staff.
The actuator should be handled with appropriate lifting means.
The weight of the actuator is reported on the delivery bill.
For a correct lifting procedure, please refer to following figures :
1-2 = LIFTING EYELETS
b) Valve stem with horizontal axis :
The actuator can also be lifted to assemble directly onto the valve
with stem with horizontal axis. To make easier this operations, BIFFI
suggest to move the lifting eyelet from its standard position, and
place it in this suggested position:

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Use and maintenance manual
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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 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 (Sect. 3.3).
1 = POINTS OF SUPPORT
2 = DON’T LAY THE ACTUATOR ON TIE-RODS
DON’T LAY THE ACTUATOR ON ACCESSORIES (manual hand-
pump, manual jack-screw, pneumatic control system etc.)

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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 (TN1182 attached).
The number, dimensions and diameter of the holes are made in
accordance with ISO 5211.The actuator is provided with a spool
piece and a stem extension for coupling to the valve. The assembly
position of the actuator, with reference to the valve, must comply with
the plant requirements (cylinder axis parallel or perpendicular to the
pipeline axis).
Important:
To fix the actuator to the valve flange must be used
the stud bolts and nuts supplied by BIFFI!
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

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.

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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 matching valve position
(Section 3.3).
❑Lubricate valve stem with oil or grease.
❑Properly clean and remove grease from valve coupling flange
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 (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
M16
160

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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
Connect the actuator to the pneumatic feed line with fittings and
pipes in accordance to the plant specifications. They must be sized
correctly in order to guarantee the necessary air flow 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 pneumatic pipe-work 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 air or nitrogen.
The ends of the tubes must be well deburred 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 pneumatic
connections
2.6 ELECTRICAL CONNECTIONS (IF ANY)
The connections should be made by qualified staff.
Before carrying out any operation, cut line power off .
Safety provisions as per CEI 64-8 regulation should be
complied with (same as IEC 60364).
Connect the electrical feed, control and signal lines to the actuator,
by linking them up with the terminal blocks of the electrical
components. In order to do this, the housing covers must be
removed without damaging the coupling surfaces, the O-rings or the
gaskets. Remove the plugs from the cable entries. For electrical
connections use components (cable glands, cables, hoses, conduits)
which meet the requirements and codes applicable to the plant
specifications (mechanical protection and/or explosion-proof
protection). Screw the cable glands tightly into the threaded inlets, so
as to guarantee the weatherproof and explosion-proof protection
(when applicable). Insert the connection cables into the electrical
enclosures through the cable glands, and connect the cable wires to

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the terminals according to the applicable wiring diagram. If conduits
are used, it is advisable to carry out the connection to the electrical
enclosures by inserting hoses so as not to cause anomalous stress
on the housing cable entries. Replace the plastic plugs of the unused
enclosure entries by metal ones, to guarantee perfect weatherproof
tightness and to comply with the explosion-proof protection codes
(where applicable).Once the connections are completed, check that
the controls and signals work properly.
2.7 COMMISSIONING
Installation, commissioning and maintenance and
repair works should be made by qualified staff.
Any calibration relative to functional aspects of the
actuator are preset at the factory, except the angular
stroke setting because for this setting operation, the
actuator must be placed on to the valve (see
paragraph 3.4)
Before any modifications please contact BIFFI Italia
S.r.l.
Upon actuator commissioning please carry out the following checks:
❑Check that the pressure and quality of the air supply (filtering
degree, dehydration) are as prescribed. Check that the feed
voltage values of the electrical components (solenoid valve coils,
micro-switches, pressure switches, etc.) are as prescribed
❑Check that the actuator controls work properly (remote control,
local control, emergency controls, etc.)
❑Check that the required remote signals (valve position, air
pressure, etc.) are correct.
❑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 there are no leakages in the pneumatic connections. If
necessary tighten the nuts of the pipe fittings
❑Remove all rust and, in accordance with the applicable painting
specifications, repair paint-coat that has been damaged during
transport, storage or assembly.

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3Operation and use
3.1 OPERATION DESCRIPTION
The air pressurizes the cylinder chamber and this pressure starts the
linear motion of the piston and the consequent rotation motion of the
rack and pinion mechanism, to which the valve stem is coupled, in
one direction. The operation in the opposite direction is made by the
linear movement generated from the spring releasing, when the
opposition of pneumatic supply is discharged from the cylinder.
For local or remote operations related to the actuator, please refer to
technical documentation furnished with actuators.
Typical schematics for various applications are follow attached for
information only
On-Off service : three way control valve
The diagram shows the simplest On-Off control. The control valve (2)
has two positions. In one position the gas supply pressure is
connected to the cylinder chamber, and the actuator performs the
“pneumatic” operation.
In the other position the cylinder is connected to the exhaust and the
actuator moves under the operation of the spring.
The control valve can have many types of actuating devices
(solenoid, manual control, pneumatic pilot, spring, etc.)
Spring return control valves allow “fail safe” operation.
Pneumatic
connection

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On-Off service : quick spring operation
When fast action is required under spring operation, a quick exhaust
valve (3) is installed in the cylinder directly port to exhaust the gas
from the cylinder directly to the atmosphere.
When the control valve (2) opens to the atmosphere a differential
pressure is created across the quick exhaust valve (3) causing it to
open. The resultant high flow capacity from cylinder to atmosphere
allows quick spring operation of the actuator.
Modulating service
When modulating control is required as a function of a pneumatic or
electric control signal, a positioner (5) is used, which controls the
supply to the actuator cylinder to keep the valve in the required
angular position.
The positioner has a mechanical linkage to the actuator, for a
feedback of the valve position.