BIFFI F01-2000 Page 6 Installation, Operation And Maintenance Manual Download

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Notes

September 2021

Installation, Operation and Maintenance Manual

VCIOM-01249-EN Rev. 0

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Summary of Contents for F01-2000

Page 1: ...rest Biffi Center Biffi Italia s r l Strada Biffi 165 29017 Fiorenzuola d Arda PC Italy PH 39 0523 944 411 biffi_italia biffi it Biffi F01 2000 Electric Actuator Installation Operation and Maintenance...

Page 2: ...ptember 2021 Installation Operation and Maintenance Manual VCIOM 01249 EN Rev 0 Revision Details Rev Date Description Prepared Checked Approved 0 September 2021 General update Migration to new templat...

Page 3: ...2 1 General 5 2 2 2 Storage for a Brief Period Less Than One Year 5 2 2 3 Long Period Storage More Than One Year 5 2 3 Checks to be Performed Before Installation 7 Section 3 Installation 3 1 Working...

Page 4: ...ldbus Interface for Remote Control via Fieldbus 32 5 9 2 Ain Aout Card 33 5 10 Base Card of the F01 2000 V4 35 Section 6 Local Controls 6 1 Description of the Local Operator Interface 38 6 2 Configura...

Page 5: ...og 84 10 4 5 Maintenance Date 87 10 4 6 Data Logger 87 10 5 Example of View Routine 91 10 5 1 View Torque Set Up 91 Section 11 Maintenance 11 1 Standard Maintenance 92 11 2 Special Maintenance 93 11 3...

Page 6: ...Notes September 2021 Installation Operation and Maintenance Manual VCIOM 01249 EN Rev 0 This page is intentionally left blank...

Page 7: ...but the following regulations must be observed in any case The general installation and safety regulations The plant specific regulations and requirements The proper use of personal protective device...

Page 8: ...ndards and Regulations EN ISO 12100 1 Safety of machinery Basic concepts general principles for design Part 1 Basic terminology methodology EN ISO 12100 2 Safety of machinery Basic concepts general pr...

Page 9: ...The warranty period is one year from the date of installation by the first user or eighteen months from the date of shipment to the first user whichever occurs first No warranty is given for products...

Page 10: ...closed position Check that the display reads 0 indicating that the valve is completely closed If the test result is satisfactory the actuator has already been adjusted and you can proceed with the ele...

Page 11: ...tected from dust 2 2 2 2 Outdoor Storage Make sure that the actuators are protected from the direct action of weather agents protection by a canvas tarp or similar cover Place the actuators on a woode...

Page 12: ...September 2021 Installation Operation and Maintenance Manual VCIOM 01249 EN Rev 0 Storage and Pre Installation 6 Section 2 Storage and Pre Installation Figure 2 Figure 3 Figure 4...

Page 13: ...power rating see the test certificate that comes with the actuator Gather the right tools for the assembly and for setting the actuator controls If a long storage period has occurred before reinstall...

Page 14: ...ersions For other ambient temperature range refer to the applicable addendum NOTICE Check the temperature environment range embossed on the nameplate for the correct utilization with respect to the en...

Page 15: ...September 2021 Installation Operation and Maintenance Manual VCIOM 01249 EN Rev 0 Installation 9 Section 3 Installation Figure 8 Figure 9...

Page 16: ...ally operate the actuator with devices other than the handwheel Using cheater bars wheel wrenches pipe wrenches or other such devices on the actuator handwheel may cause serious personal injury and or...

Page 17: ...ve stem in order to avoid any axial thrusts to the internal parts of the actuator or the valve when the screws are tightened Place the actuator vertically on the valve stem Carry out the coupling oper...

Page 18: ...plant Access to terminals for electrical connections and commissioning is through the terminal cover since all settings are non intrusive The removal of any other covers without Biffi s approval will...

Page 19: ...at Customer care to protect the mains line in case of motor overcurrent or loss of insulation between phases and earth 3 6 Removing the Electrical Enclosures Covers Using a 8 mm Allen key loosen the f...

Page 20: ...ng must be to an approved standard and cable glands reducers plugs and adapters must be approved and separately certified Certified cable entries Standard ASA NPT cable entries 2x1 1x1 1 2 Metric ISO...

Page 21: ...appropriate crimping tool This operation will ensure easy and correct electrical connection Connect the motor supply cable previously sized in accordance with The absorbed current correspondent to th...

Page 22: ...September 2021 Installation Operation and Maintenance Manual VCIOM 01249 EN Rev 0 Installation 16 Section 3 Installation Figure 15 Figure 16...

Page 23: ...following method see connection in Table 6 Power cables Control cables Type of terminal Insulated ring tongue Eye dimensions mm 5 50 3 20 Recommended tightening torques Nm 2 0 2 8 1 0 1 5 Wires secti...

Page 24: ...recommended grease see Section 4 Lubrication So please Do not damage the explosionproof mating surfaces on the housing and on the electrical enclosures covers Reinstall all the screws that go with the...

Page 25: ...or F01 2000 shall be installed and maintained according to the applicable rules regarding the electrical installations in hazardous area other than mines classified as zone 21 dust example EN 61241 14...

Page 26: ...with oil and greased where necessary In case of maintenance the following oils are recommended Ambient temperature from 30 C to 85 C 20 C to 60 C only for Ex d e or Ex tb versions SHELL TIVELA OIL SC...

Page 27: ...rate the actuator it is sufficient to turn the handwheel in the desired direction The manual operation is always possible without any clutching mechanism Figure 19 WARNING Do not manually operate the...

Page 28: ...key According to the type of valve to be operated the actuator can be stopped by means of torque or position limit switches as detailed in the following list Valve type metal seated butterfly valve Cl...

Page 29: ...Hold the mechanical stop by means of a suitable Allen key and in the same time loosen the lock nut by one turn Screw the closing or opening mechanical stop until it reaches the end stroke From here u...

Page 30: ...es can do this see Section 6 4 Figure 23 5 4 Local Control After configuring the actuator if no alarm is present place the 3 position selector in LOCAL and control the actuator by OPEN CLOSE and STOP...

Page 31: ...ay 3 1 2 LCD indicates the valve position as a percentage of opening open 100 The lower display has two alphanumeric lines The upper line indicates the actuator status and the 3 position selector stat...

Page 32: ...the OPEN or CLOSE signal switched to ON the motor is energized and it runs on after the signal returns to OFF To stop the motor press STOP To reverse the direction press STOP and then press the butto...

Page 33: ...AC Minimum signal duration 300 ms Total current drawn from remote controls 25 mA 5 7 2 Output Contacts Monitor relay on the terminal board the voltage free change over contacts of the monitor relay ar...

Page 34: ...ent The VIEW and SET UP features can configure different ESD options The ESD command is opto coupled The circuits associated to the input can be supplied by the internally generated 24 V DC or by an e...

Page 35: ...mber 2021 Installation Operation and Maintenance Manual VCIOM 01249 EN Rev 0 29 Operating the F01 2000 Section 5 Operating the F01 2000 Figure 27 OPTION A1 OPTION B1 OPTION A2 OPTION B2 OPTION A3 OPTI...

Page 36: ...The interlock inputs are opto coupled and can be supplied by the internally generated 24 V DC or by an external 20 125 V DC or 20 120 V AC 50 60 Hz The signal levels are the following Minimum ON sign...

Page 37: ...appears the base card is F01 2000 v4 type but the actuator is equipped with an F01 2000 v0 series terminal board This may happen if the F01 2000 v4 base card was supplied as a spare card to replace th...

Page 38: ...us Interface for Remote Control via Fieldbus This card allows to connect the F01 2000 to FIELDBUS The following bus interface cards are available Profibus DPVO Profibus DPV1 with or without redundancy...

Page 39: ...ally generated and the maximum load including the cable resistance should be less than 300 ohm Figure 29 shows the wiring diagram Figure 29 B6 B7 B7 C10 Actuator terminals ACTIVE LOOP Cable GROUND Shi...

Page 40: ...nd 20 mA corresponds to request R 100 valve open The relationship between position and request signals can be reversed by the Polarity function The 4 20 mA input is opto coupled The input impedance is...

Page 41: ...rating the F01 2000 Section 5 Operating the F01 2000 5 10 Base Card of the F01 2000 V4 Terminal Board Adaptor card TBA Figure 32 Bottom view of base card Figure 33 Top view of base card Top view of ba...

Page 42: ...d Maintenance Manual VCIOM 01249 EN Rev 0 36 Operating the F01 2000 Section 5 Operating the F01 2000 Figure 34 Fieldbus interface card Fieldbus interface card The type of card depends on the fieldbus...

Page 43: ...e base card to read position and torque values from the potentiometers installed on the actuator Figure 37 Ain Aout card Ain Aout card This optional card is used in place of the Terminal Board Adaptor...

Page 44: ...gure 38 Section 6 Local Controls 6 1 Description of the Local Operator Interface The following functions are available by the F01 2000 local operator interface actuator control actuator configuration...

Page 45: ...the relevant modules are present 2 3 position selector to set the following operation modes LOCAL for local control only OFF no control is active but the actuator is still connected to the mains REMO...

Page 46: ...ith green green with red and yellow with red during actuator setting operations 6 Local controls OPEN YES CLOSE NO and STOP pushbuttons The STOP pushbutton resets any existing command and is active bo...

Page 47: ...t report of bus interface card only present if the bus card is present see the relevant instruction manual FDI report report of FDI function only present if the LonWorks bus card is present see the re...

Page 48: ...ly to enter VIEW and SET UP menus Press YES or NO to answer the prompt view next If the prompt is next press YES to view the next variable press NO to return to the beginning If the prompt is view pre...

Page 49: ...mode to change the present configuration Unauthorized access to the set up mode is prevented by a 4 character alphanumeric password The actuator is supplied by Biffi with the default password 0 0 0 0...

Page 50: ...de List of routines serial number actuator type torque thrust actuator speed power supply motor data test date wiring diagram enclosure certificate lubricant revision torque sensor Valve data This men...

Page 51: ...n choose to either re enter by pressing YES or to move on to a next routine by pressing NO 6 3 Entering the View Mode The existing actuator configuration should be checked before commissioning The par...

Page 52: ...roke limits it is necessary to enter the correct password Ensure the electrical main power or the external auxiliary supply is applied Move the 3 position selector to OFF and then simultaneously press...

Page 53: ...ORD OK 0 0 0 0 DIGIT 2 OK 0 0 0 0 DIGIT 3 OK 0 0 0 0 DIGIT 4 OK 0 0 0 0 DIGIT 1 OK Z 0 0 0 DIGIT 1 OK Z K 0 0 DIGIT 2 OK Z K 9 0 DIGIT 3 OK Z K 9 R DIGIT 4 OK SETUP MODE OK PASSWORD CORRECT PASSWORD W...

Page 54: ...Interlock change 2 speed timer change Bus change Miscellaneous change To exit from SETUP menu press YES and NO simultaneously or move the 3 position selector to LOCAL or REMOTE 1 Routines with are on...

Page 55: ...CHANGE YES YES STROKE LIMITS CHANGE XXXXXX XXXXXX CHANGE NO YES MISCELLANEOUS CHANGE YES MISCELLANEOUS ROUTINE ROUTINE STROKE LIMITS ROUTINE NO VALVE DATA CHANGE YES YES TAG NAME CHANGE YES TAG NAME...

Page 56: ...NAMEPLATE VIEW VALVE DATA VIEW MAINTENANCE VIEW EXIT Routines Stroke limits view Torque set up view ESD set up view Remote controls view Local controls view Output relays view Positioner view Fail saf...

Page 57: ...ES NO NO YES YES YES YES YES YES YES YES YES SERIAL NUMBER VIEW VALVE DATA VIEW MAINTENANCE VIEW ALARM LOG VIEW XXXXXX XXXXXX VIEW MAINTENANCE DATE VIEW TAGE NAME VIEW SERIAL NUMBER VIEW XXXXXX XXXXXX...

Page 58: ...low to choose Set up procedure Engage the manual override and move the valve to the mid travel position Move the local selector to OFF and then simultaneously press OPEN and STOP Select the language a...

Page 59: ...to exit from the stroke limits routine Open limit type Press YES if the open limit type is correct torque or position press NO to change it Press YES to confirm Open limit by position Move the local...

Page 60: ...tor may be damaged Therefore selecting ESD will invalidate the warranty Function ESD priority allows the ESD command to override the following additional situations motor thermostat alarm torque limit...

Page 61: ...heating Torque limit tripped Choosing ESD TORQUE LIMIT the ESD action will be carried out also in case of torque alarm Vice versa if ESD TORQUE LIMIT was chosen the ESD action will not be done in case...

Page 62: ...r set up Configuration procedure Move the local selector to OFF and then simultaneously press OPEN and STOP Select the language and then enter the password according to the instructions see Entering t...

Page 63: ...e OPEN or CLOSE local pushbuttons causes relays AS5 or AS6 to switch but no command is sent to motor The control PLC should read the status of the above mentioned relays and send an open or close comm...

Page 64: ...output relays For status indication or diagnostic purposes 8 voltage free contacts of 8 relays are available to be configured individually to switch for the following conditions Status open limit clo...

Page 65: ...t actuator set up menu press NO to scroll the list of available routines and then press YES to select Output relays Press YES to select DEFAULT 1 or press NO to change Press YES to select DEFAULT 2 or...

Page 66: ...ow lithium battery if present mid travel alarm Auxiliary relays AS1 open limit break AS2 close limit break AS3 position 90 break AS4 position 5 break AS5 motor running make AS6 remote selected make AS...

Page 67: ...to receive the position request R from the bus a fieldbus interface card must be present or a Hardware alarm will be generated If the F01 2000 is set to receive the position request R from the 4 20 mA...

Page 68: ...nput signal 8 mA the position request is 0 and the actuator is driven to close With input signal 16 mA the position request is 100 and the actuator is driven to open With input signal 12 mA the positi...

Page 69: ...OP or press NO to change it then press YES Press YES if the configured value of the Motion Inhibit Time is correct from 1 to 255 s or press NO to change it then press YES Press YES if the configured...

Page 70: ...locks ESD Figure 47 Configuration procedure Move the local selector to OFF and then simultaneously press OPEN and STOP Select the language and then enter the password according to the instructions see...

Page 71: ...sition 0 100 20 mA 4 mA OUTPUT POSITION POLARITY 4 mA OP Output mA Position 0 100 OUTPUT TORQUE POLARITY 4 mA CL OUTPUT TORQUE POLARITY 4 mA OP Output mA Output mA 20 mA 12 mA 12 mA 4 mA 20 mA 4 mA To...

Page 72: ...lect INTERLOCK Press YES if the configured value of the Open Interlock is correct PRESENT ABSENT OFF or press NO to change it then press YES Press YES if the configured value of the Close Interlock is...

Page 73: ...e of pulsing control is correct press NO to scroll the list of available values Press YES when the value is correct Opening direction Press YES if the status is OK or NO to change Press YES to confirm...

Page 74: ...9 1 13 1 Time and Date Time and date are used in maintenance functions to associate the time information to the memorized event torque profile alarm log maintenance request etc Time and date are enter...

Page 75: ...h instant reverse LED s color green open opening red close closing yellow alarm warning Output relay Default 1 2 speed timer Opening direction off Closing direction off Miscellaneous Lithium battery a...

Page 76: ...the torque set up and stroke limits routines see Figure 50 Configuration procedure Move the local selector to OFF and then simultaneously press OPEN and STOP Select the language and enter the passwor...

Page 77: ...ess No to scroll the list of routines and press YES to select lithium battery Press YES if the setting is correct press NO to change Press YES when the value is correct 9 1 13 5 Torque Bypass Since a...

Page 78: ...o exclude the routine Configuration procedure Move the local selector to OFF and then simultaneously press OPEN and STOP Select the language and enter the password according to the instructions see En...

Page 79: ...the 1st character of the string is correct Press NO to scroll the list of available characters Press YES to select the desired character Enter up to 28 characters Enter a blank character and as end o...

Page 80: ...list of available characters and then press YES to select Enter 4 digits When the display shows the message Password changed the old password is no longer valid 9 3 2 Clear Alarm Log Clear Procedure...

Page 81: ...to scroll the list of available routines and then press YES to select Set curve reference Press NO to scroll the list and then press YES to select the desired curves in opening and closing Press YES...

Page 82: ...en YES to select the maintenance menu Press NO to scroll the list of available routines and press YES to select maintenance date Press YES to set the last maintenance date Press NO to skip to next mai...

Page 83: ...then enter the password according to the instructions see Entering the set up mode When the message displayed is SET UP MODE OK press YES Press NO to scroll the list of available menus and then press...

Page 84: ...SETUP CHANGE STROKE LIMIT CHANGE TORQUE SETUP CHANGE CLOSING TORQUE 55 OK CLOSING TORQUE 70 OK OPENING TORQUE 60 OK OPENING TORQUE 65 OK YES YES YES YES YES YES YES YES NO NO NO NO NO TO NEXT TO VIEW...

Page 85: ...ction delay Out 4 20 mA Output signal position or torque polarity Interlock Signal type in OP signal type in CL 2 speed timer Close direction status start stop on time off time Open direction status s...

Page 86: ...ty S2 15 min etc Poles 2 4 etc Biffi name max 28 characters Gear ratio max 1000 Test date date of the in house functional test of actuator Wiring diagram WD wiring diagram number max 28 characters Enc...

Page 87: ...ge displayed is VIEW MODE OK press YES Press NO to scroll the list of available menus and press YES to select the valve data menu Press YES to answer prompts view or next and see the data in the above...

Page 88: ...allows to save the torque profile data in the torque profile reference with date and time The torque profile reference will not be updated until a new set torque reference command is entered The user...

Page 89: ...100 curves in closing can be saved When a new curve is available the oldest one is cancelled and the new one is memorized The above data are updated at the end of every full valve stroke Data relevant...

Page 90: ...ve 1 is the latest and the curve 5 is the oldest Press YES to select Press YES to select the opening or closing curve Press NO to exit Press YES to scroll the list of values Press NO to exit 10 4 4 Op...

Page 91: ...d by the general and recent data log Routine Parameters Opening time Closing time Contactor cycles Contactor cycles Motor run time Motor run time No power time No power time Utilization rate Utilizati...

Page 92: ...y to the valve to move from the open position to the close position expressed in hours minutes and seconds Contactor cycles This number counts the cycles of contactors K1 and K2 The value indicated in...

Page 93: ...actuator maintenance When the date is reached the F01 2000 generates a maintenance request warning The date should be updated by the user after all maintenance operations see Section 9 3 Start up date...

Page 94: ...r stops recording or overwrites the previous data according to the selected MEMORY MODE stop when full or continuous If continuous was selected as a new set of measures is achieved the oldest one is c...

Page 95: ...mode after a recording stop for OVER TORQUE alarm 1 Torque limit in OP reached 2 Curve selector Torque Motor temperature Main voltage Torque limit in CL is set to 90 torque limit in OP is set to 100...

Page 96: ...s of full memory overwriting is done then the logger stops The START DATE and START TIME fix date and time to start recording operation By a PDA or PC the collected data can be viewed by a graph or ev...

Page 97: ...re 56 CLOSING TORQUE 55 NEXT CLOSING TORQUE 70 NEXT TORQUE SETUP VIEW STROKE LIMIT VIEW ACTUATOR SETUP VIEW VIEW MODE OK YES YES YES YES YES NO NO NO NO YES TO NEXT ROUTINE TO SETUP MENU SELECT LANGUA...

Page 98: ...il quality more often Replace all seals that permit oil leakage or water ingress NOTICE Before starting any maintenance operation make sure that the mains and all other service voltage connected to te...

Page 99: ...s remove rust from surfaces and protect with a rust preventative Check that all nuts and bolts securing the actuator to the valve are tight If necessary re tighten with a dynamometric key for tighteni...

Page 100: ...nes Section 11 Maintenance 11 3 Lithium Battery Change Figure 59 Figure 57 Figure 58 Isolate the main supply to the actuator and all other control voltages Open the terminal boards cover Disconnect tw...

Page 101: ...September 2021 Installation Operation and Maintenance Manual VCIOM 01249 EN Rev 0 95 View Routines Section 11 Maintenance Remove the battery cover Figure 61 Figure 62 Figure 60...

Page 102: ...September 2021 Installation Operation and Maintenance Manual VCIOM 01249 EN Rev 0 96 View Routines Section 11 Maintenance Figure 63 Replace the battery Figure 64 Figure 65...

Page 103: ...97 View Routines Section 11 Maintenance Figure 66 WARNING If the actuator is located in a hazardous area a hot work permit must be obtained unless the actuator can be moved to a non hazardous area NOT...

Page 104: ...he actuator can be moved to a non hazardous area If the actuator does not work before troubleshooting make sure that The numeric display indicates xx The local selector is not in OFF The main supply v...

Page 105: ...uld not exceed 4 W If the voltage is not correct replace the power card Figure 67 1 2 1 Power card 2 Fuse 12 3 The Actuator Does Not Work from Remote Controls Move the 3 position selector to LOCAL and...

Page 106: ...the actuator base Verify the stem nut has sufficient engagement with the valve stem Verify the key correctly fits in bore keyways applications Check that the valve works in manual operation 12 6 The...

Page 107: ...a maintenance action is required but all actuator functions are still available The flashing of the alarm warning LED indicates a warning condition Alarm is the condition that occurs when a variable...

Page 108: ...g Section 12 Troubleshooting Figure 68 XXXXXX XXXXXX XXXXXX NEXT ALARMS VIEW ALARM II I NEXT ALARM II N NEXT RESET OK RESET OK WARNING II N NEXT WARNING II 1 NEXT WARNINGS VIEW DISPLAY 3 POSITION SELE...

Page 109: ...heat source Not available Not available Not available Control temperature 90 C or 40 C Position sensor Value of the actuator position not valid Replace position sensor or re calibrate both stroke limi...

Page 110: ...Measured torque 10 lower than the relevant value configured in torque set up or stroke limits routines Check the torque necessary to move the valve Available Available Available Close control High to...

Page 111: ...roduction This chapter includes the drawings and parts list of each component and subassembly of F01 2000 actuators NOTICE When ordering spare parts please indicate the serial number embossed on the a...

Page 112: ...I O card 38 2 Mechanical stops nut 66 4 Column 11 1 O ring 39 2 Mechanical stops 67 1 Potentiometer card 12 1 Cover housing 40 2 Seal washer 68 1 Processor card 13 1 Earth stud 41 2 Nut 69 1 Display...

Page 113: ...Parts List and Drawings Figure 70 F01 2000 Planicentric Assembly 30 1 30 2 30 3 30 2 30 3 30 4 30 4 30 2 30 5 30 6 30 7 30 8 Table 20 Parts List Item Qty Description 30 1 1 Pin guide ring 30 2 3 Space...

Page 114: ...ings Section 13 Parts List and Drawings Figure 71 F01 2000 Worm Gear Assembly 49 3 49 4 49 2 49 5 49 1 49 6 49 7 Table 21 Parts List Item Qty Description 49 1 1 Stop ring 49 2 1 Spring support 49 3 1...

Page 115: ...2000 Torque Position Assembly Table 22 Parts List Item Qty Description 61 1 1 Gear cover 61 2 5 Screw 61 3 1 Gear 61 4 1 Gear 61 5 1 Screw 61 6 1 Gear 61 7 8 Screw 61 8 1 Gear 61 9 1 Torque fork 61 10...

Page 116: ...Parts List and Drawings Section 13 Parts List and Drawings Figure 73 F01 2000 Local Interface Assembly 72 3 72 4 72 2 72 5 72 1 72 6 Table 23 Parts List Item Qty Description 72 1 1 Plug 72 2 1 Screw...

Page 117: ...Notes September 2021 Installation Operation and Maintenance Manual VCIOM 01249 EN Rev 0 This page is intentionally left blank...

Page 118: ...ublication are presented for information purposes only and while every effort has been made to ensure their accuracy they are not to be construed as warranties or guarantees express or implied regardi...

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