BIFFI ALGAS-MHW 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
Bif ALGAS-MHW or MRHW
Spring-Return Pneumatic Actuator with Handwheel Manual Override
Installation, Operation and Maintenance Manual
MAN 604-1A Rev. 6
March 2021

Installation, Operation and Maintenance Manual
MAN 604-1A Rev. 6
Revision Details
March 2021
Revision Date Description Prepared Checked Approved
6 March 2021 Migration to new template
5 December 2019 Added Declutch-able type Ermanni Oreci Vigliano
4 March 2018 Update Data-plate Ermanni Oreci Vigliano
3April 2016 Updated applicable regulation (chapter 1.1.1) Ermanni Oreci Vigliano
2 June 2012 Updated chapter G and chapter H Ermanni Stoto Vigliano
Revision Details
Revision Details

i
Installation, Operation and Maintenance Manual
MAN 604-1A Rev. 6
Table of Contents
March 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 ......................................................................... 2
1.2 Identication Plate ........................................................................................ 2
1.3 Description of the Actuator ........................................................................... 3
Section 2: Installation
2.1 Checks to be Carried Out on Receiving the Actuator .......................................... 4
2.2 Storage ......................................................................................................... 4
2.3 Assembling the Actuator onto the Valve ....................................................... 5
2.3.1 Types of Assembly .............................................................................. 5
2.3.2 Valve Stem with Vertical Axis ............................................................ 10
2.3.3 Valve Stem with Horizontal Axis ........................................................ 13
Section 3: Operation and Use
3.1 Setting of the Angular Stroke ...................................................................... 16
3.1.1 Travel Stop-screw Screwed on the End of Manual Override ................. 16
3.1.2 Travel Stop-screw Screwed on the End of Mechanical
Manual Override .............................................................................. 17
3.1.3 Travel Stop-screw Screwed on the End Flange of Spring Container .... 18
3.2 Calibration of Microswitches (If Foreseen) ................................................... 20
3.3 Calibration of Operating Time in Supply Operation ..................................... 20
3.4 Preparation for Start-up .............................................................................. 21
3.4.1 Pneumatic Connections ................................................................... 21
3.4.2 Electrical Connections ...................................................................... 22
3.5 Start-up ...................................................................................................... 22
Section 4: Operational Tests and Inspections
Operational Tests and Inspections ......................................................................... 23

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Table of Contents
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Installation, Operation and Maintenance Manual
MAN 604-1A Rev. 6
Table of Contents
Section 5: Maintenance
5.1 Routine Maintenance .................................................................................. 24
5.2 Special Maintenance ................................................................................... 25
5.2.1 Replacement of Cylinder Seals .......................................................... 26
5.2.2 Replacement of the Seals of Manual Override “MHW” ...................... 28
5.2.3 Replacement of the Seals of Reduced-Manual Override “MRHW” ..... 29
5.3 Lubrication of Mechanism ........................................................................... 35
5.4 Dismantling and Demolition ....................................................................... 36
Section 6: Troubleshooting
6.1 Failure or Breakdown Research .................................................................... 37
Section 7: Parts List
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 .............................................................. 43

Installation, Operation and Maintenance Manual
MAN 604-1A Rev. 6 March 2021
General Warnings 1
Section 1: General Warnings
NOTICE
Bif Italia has taken every care in collecting and verifying the documentation contained
in this instruction and operating manual. Nevertheless Bif Italia does not provide any
guarantees for this instruction manual. Bif Italia will not be responsible for any mistakes
contained in it or for any damage either accidental or due to the use of this manual. The
information herein contained is reserved property of Bif Italia and is subject to being
modied without notice.
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
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.

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MAN 604-1A Rev. 6
General Warnings2
Section 1: General Warnings
1.2 Identication Plate
! WARNING
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).
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.
Figure 1 Data plate

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MAN 604-1A Rev. 6 March 2021
General Warnings 3
Section 1: General Warnings
Codes ALGAS XXX K -YYYYY -ZZZZ -FSC
Actuator Series
Scotch yoke Mechanism
Yoke Shape
C = Canted
S = Symmetric
Spring Cartridge Size
Cylinder Size
Internal diameter in mm
Spring Action
CL = Closing
OP = Opening
Service
Blank = Standard
QA = Quick Acting
Manual Override
Blank = No Manual Override
MHP = Manual Pump
MHW = Manual Handwheel
MRHW = Manual Reduced Handwheel
1.3 Description of the Actuator
ALGAS low pressure pneumatic spring-return, are suitable for the operation of
quarter-turn valves (ball valves, buttery valves, plug valves) in both ON-OFF and
modulating heavy-duty service.
The actuator is made up of a weatherproof scotch yoke mechanism transforming the linear
movement of the pneumatic cylinder (or mechanical manual override, if foreseen) and of
the spring into the rotary movement, which is necessary for operation.
The spring-return pack incorporates up to four springs, fully encapsulated in a factory
welded cartridge: this ensures safety to personnel and simplies assembly. The spring
action can be easily changed in the eld from to close in to open or from to open in to
close (modular design).
The angular stroke of the yoke is adjustable between 82° and 98° by means of the external
mechanical stops screwed into the end ange of the pneumatic cylinder and into the end
ange of the spring-return pack. The cover of the scotch yoke mechanism is arranged for
the assembly of the required accessories (position-transmitter, signaling-limit switches,
positioner , 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 or a
stem extension. Their internal hole 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 .
Table 1. Single Acting Low Pressure Pneumatic Actuators (Coding System)

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Installation
4
Section 2: Installation
Section 2: Installation
2.1 Checks to be Carried Out on Receiving the Actuator
1. If the actuator arrives already assembled onto the valve, the settings of the
mechanical stops and of the microswitches (if existing) has already been made
by the person who assembled the actuator onto the valve. If the actuator arrives
separately from the valve, the settings of the mechanical stops and of the
microswitches (if existing) must be checked and, if necessary, carried out while
assembling the actuator onto the valve.
2. Check that the actuator has not been damaged during transport. If necessary,
repair all damages to the paint-coat, etc.
3. Check that the model, the serial number of the actuator and the performance
data written on the data-plate are in accordance with those described on the order
acknowledgement, test certicate and delivery note.
4. Check that the tted accessories comply with those listed in the order
acknowledgement and the delivery note.
2.2 Storage
(For handling and lifting procedure, please refer to following Figures 6, 7 and 8).
The actuators leave the factory in excellent working conditions and with an excellent
nish (these conditions are guaranteed by an individual inspection certicate); in order to
maintain these characteristics until the actuator is installed on the plant, it is necessary to
observe a few rules and take appropriate measures during the storage period.
1. Make sure that plugs are tted in the air connections and in the cable entries. The
plastic plugs, which close the inlets, do not have a weatherproof function, but are
only a means of protection against the entry of foreign matter during transport.
If long-term storage is necessary and especially if the storage is outdoors, metal
plugs must replace the plastic protection plugs, which guarantee a complete
weatherproof protection.
2. If the actuators are supplied separately from the valves, they must be placed onto
a wooden pallet so as not to damage the coupling ange to the valve. In case of
long-term storage, the coupling parts (ange, drive sleeve, insert bush) must
be coated with protective oil or grease. If possible, blank off the ange by a
protection disk.
3. In case of long-term storage, it is advisable to keep the actuators in a dry place
or to provide at least some means of weather protection. If possible, it is also
advisable, to periodically operate the actuator with ltered, dehydrated and
lubricated air; after such operations all the threaded connections of the actuator
and the valves of the control panel (if existing) should be carefully plugged.

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Installation 5
Section 2: Installation
2.3 Assembling the Actuator onto the Valve
2.3.1 Types of Assembly
For coupling to the valve, the housing is provided with a ange with threaded holes
according to Bif standard tables (SCN6200; SCN6200-1; SCN6201; SCN6201-1). 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 cannot 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*.

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 93.6
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
6 520 250 406 M36 8 14 29 260 200 28 212.8
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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
6
Section 2: Installation
Dimensions in millimeters
Actuator model Ø d1Ø d2Ø d3Ø d4N h1h2H max Ø d5WK
Table 2. SCN6200
max
H max
Figure 2 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

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
Installation, Operation and Maintenance Manual
MAN 604-1A Rev. 6 March 2021
Installation
Ø d1
Ø d4
h2
Ø d2+0.1
0
Ø d3±0.2
h1 +0.5
0
Ø d5+0.2
+0.1
K+0.4
0
WD10
7
Section 2: Installation
N.12 holes flangeN.16 holes flange
max
Table 3. SCN6201
Dimensions in millimeters
Actuator model Ø d1Ø d2Ø d3Ø d4N h1h2H max Ø d5WK
Figure 3 Coupling dimensions - Models 14 to 42
Drive sleeve
N. THREADED HOLES
PCD, number and
size according to ISO 5211
Flow line
Top view of the scotch yoke mechanism
(actuator shown in closed position)
H max

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
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Installation
Ø d1
Ø d4
h2
Ø d2+0.1
0
Ø d3±0.2
h1 +0.5
0
Ø d5+0.2
+0.1
K+0.4
0
WD10
8
Section 2: Installation
max
Figure 4 Coupling dimensions - Models 50 and 60
Dimensions in millimetersw
Actuator model Ø d1Ø d2Ø d3Ø d4N h1h2H max Ø d5WK
Drive sleeve
N. THREADED HOLES
Flange sizing according to ISO
Flow line
Top view of the scotch yoke mechanism
(actuator shown in closed position)
Table 4. SCN6201-1
H max

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Installation 9
Section 2: Installation
Figure 5 Insert bush + intermediate coupling ange
Drive sleeve
Adaptor ange
Flow line
Drive sleeve
Insert bush
N.4 holes ange N.8 holes ange
Insert bush
Housing
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
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. 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 table TN1005,
enclosed. The particular execution of the ange and bushing allow the actuator to be
rotated by 90° in 4 different positions according to the Figure 5.
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.
Table 5.
Snap ring

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Installation
10
Section 2: Installation
Figure 7
Lifting points:
1-2 = obligatory
3 = balancing
2.3.2 Valve Stem with Vertical Axis
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 6.
Figure 6 Example of hook with safety latch

Installation, Operation and Maintenance Manual
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Installation 11
Section 2: Installation
Figure 8
Lift ALGAS actuators (pneumatic spring-return) by means of the proper lifting points
represented and indicated on actuator by sticking labels. Also refer to Figure 8 for lifting
points positions.
Lifting points
Pneumatic cylinder
Manual override
Lifting eyelet
Lifting eyelet
Spring
cartridge
• 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.
! WARNING
Any lifting method different from what described above is strictly forbidden.
Bif reject any responsibility for damages to goods or injuries to persons coming from
wrong lifting operations.
lifting point applicable for ALGAS
models: 3-6-14-18-32-50-80 lifting point applicable for
ALGAS models: 0.3-0.9-1.5

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Installation
12
Section 2: Installation
The actuator can be assembled onto the valve ange either by using the actuator-housing
ange with threaded holes, or by the interposition of an adaptor ange or a spool piece. The
actuator drive sleeve is generally connected to the valve stem by an insert bush or a stem
extension. 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).
To assemble the actuator onto the valve proceed as follows:
1. Check that the coupling dimensions of the valve ange and stem, or of the relevant
extension, meet the actuator coupling dimensions.
2. Bring the valve to the position related to the actuator spring operation.
3. Lubricate the valve stem with oil or grease in order to make the assembly easier. Be
careful not to pour any of it onto the ange.
4. Clean the valve ange and remove anything that might prevent a perfect
adherence to the actuator ange and especially all traces of grease, since the
torque is transmitted by friction.
5. If an insert bush or stem extension for the connection to the valve is supplied
separately, assemble it onto the valve stem and fasten it by tightening the proper
stop dowels.
6. Bring the actuator to the position caused by the spring operation.
7. Connect a sling to the support points of the actuator and lift it: make sure the
sling is suitable for the actuator weight. When possible, it is easier to assemble the
actuator to the valve if the valve stem is in the vertical position. In this case the
actuator must be lifted while keeping the ange in the horizontal position.
LIFTING LUGS TO BE USED FOR THE
ACTUATOR ONLY. DO NOT LIFT VALVE
AND ACTUATOR TOGETHER
DO NOT DISASSEMBLE TOP OR
BOTTOM COVER.
SPRING LOADED.
POTENTIAL ELECTROSTATIC CHARGE HAZARD
BIFFI IS NOT LIABLE FOR ANY
PERSONNEL INJURY DUE TO
INCORRECT USE
REFER TO IOM
Figure 9

Installation, Operation and Maintenance Manual
MAN 604-1A Rev. 6 March 2021
Installation 13
Section 2: Installation
M8 20
M10 40
M12 70
M14 110
M16 160
M20 320
M22 420
M24 550
M27 800
M30 1100
M33 1400
M36 1700
8. Clean the actuator ange and remove anything that might prevent a perfect
adherence to the valve ange and especially all traces of grease.
9. Lower the actuator onto the valve in such a way that the insert bush, assembled
on the valve stem, enters the actuator drive sleeve. This coupling must take place
without forcing and only with the weight of the actuator. When the insert bush
has entered the actuator drive sleeve, check the holes of the valve ange. If they
do not meet with the holes of the actuator ange or the stud bolts screwed into
them, the actuator drive sleeve must be rotated; feed the actuator cylinder with
air at proper pressure, indicated on data-sheet for actuator.
10. 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.
11. If possible, operate the actuator to check that it moves the valve smoothly.
2.3.3 Valve Stem with Horizontal Axis
The actuator can also be lifted to assemble directly onto the valve with stem with
horizontal axis. Remove the manual override (unscrewing the 4 xing-screws with its
washers) to make easier the lifting operations:
Lifting eyelets (1)
Support brackets (2)
Support brackets (3)
washer
screw
Manual override
Lifting eyelets (1)
Table 6.
Thread size Recommended tightening torque (Nm)
Figure 10

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Installation
14
Section 2: Installation
2. Balance the weight and lift the actuator until to make possible the rotation of
actuator in its nal mounting position, with cylinder on top, or spring container
placed on top, as showed in the following images:
Figure 11
1. Connect properly the actuator lifting points 1 with chains, and connect by suitable
slings the support brackets 2 and 3.
Figure 12

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Installation 15
Section 2: Installation
3. Clean the actuator ange and remove anything that might prevent a perfect
adherence to the valve ange and especially all traces of grease.
4. Lift the actuator near to the valve in such a way that the insert bush, assembled
on the valve stem, enters the actuator drive sleeve without forcing the coupling.
When the insert bush has entered the actuator drive sleeve, check the holes of
the valve ange. If they do not meet with the holes of the actuator ange or the
stud bolts screwed into them, the actuator drive sleeve must be rotated; feed the
actuator cylinder with air at proper pressure, indicated on data-sheet for actuator.
5. 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.
6. Reassemble the manual override with 4 xing screws and washers.
7. If possible, operate the actuator to check that it moves the valve smoothly.
Figure 13

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Operation and Use16
Section 3: Operation and Use
3.1.1 Travel Stop-screw Screwed on the End of Manual Override
For the adjustment of the travel stop screws proceed as follows (see Figure 14 and 15):
1. Loosen the lock nut (item 2)
2. If the actuator angular stroke is stopped before reaching the end position
(fully open or closed), unscrew the stop screw (item 1) by turning it anticlockwise,
and actuate the handwheel of manual override until the valve reaches the right
position. When unscrewing the stop screw, keep the lock nut still with a wrench so
that the sealing washer does not withdraw together with the screw.
3. Tighten the lock nut, after having correctly placed the threaded seal washer
(item 3 and 4).
4. If the actuator angular stroke is stopped beyond the end position (fully open or
closed valve), actuate the handwheel of manual override and screw the
stop-screw by turning it clockwise until the valve reaches the right position.
5. Tighten the lock nut, after having correctly placed the threaded seal washer
(item 3 and 4).
Section 3: Operation and Use
3.1 Setting of the Angular Stroke
It is important that the mechanical stops of the actuator (and not those of the valve) stop
the angular stroke at both extreme valve position (fully open and fully closed), except when
this is required by the valve operation (e.g. metal seated buttery valves).
The travel stop screws are screwed into the end ange of the manual override, depending
on actuator different conguration (i.e. spring to open or spring to close), and spring
cartridge. The setting of the open valve position is performed by adjusting the travel stop
screw on the left side of the actuator. The setting of the closed valve position is performed
by adjusting the travel stop screw on the right side of the actuator.