Biffi

QTC Series Electric Actuator
instruction and operating manual
INSTRUCTION AND OPERATING MANUAL
INDEX
CHAPTER 1
Storage and Pre-Installation page 3 Installation page 5 Setting of Electrical Cam Control Group page 9 Setting of the Dial Position Local Indicator page 15 Setting of the Resistive-Type PositionTransmitter page 16 Seal Application to the Electrical Enclosures page 18 Lubrication page 19 Maintenance page 21 Trouble Shooting page 22 Recommended Spare Parts and Sectional Drawings page 24
CHAPTER 2
CHAPTER 3
CHAPTER 4
CHAPTER 5
CHAPTER 6
CHAPTER 7
CHAPTER 8
CHAPTER 9
CHAPTER 10
Contents may change without notice.
Copyright by BIFFI Italia. All rights reserved. BIFFI is a subsidiary of Keystone International, Inc.
BIFFC-0040-EN-9603

DETAILED INDEX CHAPTER 1, page 3 Storage and Pre-Installation

1) Tests to be carried out on receipt of the actuator 2) Storage procedure 3) Checks to be performed before installation
3) Electrical connections 4) Torque and position setting 5) Setting the trip point of the auxiliary limit switches
CHAPTER 8, page 21 Maintenance

1) Standard maintenance 2) Special maintenance
CHAPTER 4, page 15 Setting of the Local Position Dial Indicator

1) Adjustment of the closing indication 2) Adjustment of the opening indication
CHAPTER 9, page 22 Trouble Shooting
CHAPTER 2, page 5 Installation

1) Identification of the main parts 2) Bush: disassembly from the actuator 3) Manual operation 4) Mounting of the actuator onto the valve 5) Removal of the electrical enclosures covers 6) Cables entries 7) Electrical connections 8) Instructions for the explosion-proof enclosures
1) The actuator does not work electrically 2) The motor cannot unseat the valve 3) The motor is very hot and does not start
CHAPTER 5, page 16 Setting of the Resistive-Type Position Transmitter
4) The actuator works electrically without operating the valve 5) Excessive torque for the valve operation; the motor overheats during operation 6) Incorrect valve seating
CHAPTER 6, page 18 Seal Application to the Electrical Enclosures
7) Jammed valve in closed position 8) The actuator does not stop in fully open or closed position
CHAPTER 7, page 19 CHAPTER 3, page 9 Setting of Electrical Cam Control Group

1) Electrical cam control group 2) Checking the setting of motorized valves 3) Comparison table of approved lubricant substitutes
CHAPTER 10, page 24 Recommended Spare Parts and Sectional Drawings

1) Commissioning spare parts kits 2) Recommended spare parts for two years operation
Lubrication
1) Lubrication inspection 2) Lubrication tables
NOTES: BIFFI Italia has taken every care in collecting and verifying the documentation contained in this instruction and operating manual. Nevertheless Biffi Italia does not provide any guarantees for this instruction manual. BIFFI 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 BIFFI Italia and is subject to being modified without notice. All rights are reserved.
BIFFC-0040-EN-9603

CHAPTER 1 Storage and Pre-Installation INDEX

1) Tests to be carried out on receipt of the actuator 2) Storage procedure 3) Checks to be performed before installation
1.4) Check on the name-plate the serial number and the performance data (nominal torque, operation speed, protection class, motor supply voltage, etc...). 1.5) Check the presence of the visible accessories, as described in the delivery note.
2 - Storage Procedure
Important: The non-observation of the following procedure will invalidate the guarantee. 2.1) GENERAL Actuators leave the factory in perfect conditions (as guaranteed by an individual test certificate); therefore, in order to maintain these characteristics until they are installed on site, take the necessary measures for a correct preservation during the storage period. Biffi actuators are weatherproof to IP 68; this condition is maintained only if they are perfectly installed and connected on site and if they have been correctly stored. The standard plastic plugs closing the cable entries are not weatherproof; their purpose is only to avoid the entry of undesired objects during transport.
1 - Tests to be Carried Out on Receipt of the Actuator

1.1) If the actuator is received mounted on the valve, all operations should have been already performed during valve-actuator assembly. In order to check if the adjustment of the actuator mounted on the valve has been carried out: - engage the manual operation; - turn the handwheel until the valve is in a completely open position; - check that the pointer on the local indicator dial shows that the valve is completely open; - rotate the handwheel clock-wise and bring the valve to a completely closed position; - check that the pointer on the local indicator dial shows that the valve is completely closed. If the tests result satisfactory, the actuator has already been adjusted and you can proceed with the electrical connection. 1.2) If the actuator is delivered separately from the valve, all the operations described in this manual must be carried out. 1.3) Check that no damage has occured during transport.
2.2) STORAGE FOR A BRIEF PERIOD (less than one year): 2.2.1) Indoor storage: - make sure that the actuators are kept in a dry place, laid on a wooden pallet and protected from dust. 2.2.2) Outdoor storage: - make sure that the actuators are protected from the direct action of weather agents (protection by a canvas or similar); - lie the actuators on a wooden pallet, or something similar, so that they are not in direct contact with the ground;
BIFFC-0040-EN-9603

- if the actuators are supplied with standard plastic plugs, remove them from the cable entries and replace them with proper plugs guaranteeing a perfect weatherproof protection; - connect the anticondensate heaters following all the indications (power supply, terminal numbers etc...) given in the wiring diagram which can be found inside the terminal board compartment; - make sure that the external connection to the heater is through one of the available cable entries and by a proper IP 68 weatherproof cable gland.
2.3.2) Outdoor storage: - after following all the instructions at point 2.2.2., verify periodically (approximately once a year) the general conditions of the actuator, paying particular attention to the inside of the switches and terminal board enclosures; - if these inspections should reveal the presence of water or condensation it is necessary to examine: the status of the O-ring seals
3 - Checks to be Performed Before Installation

3.1) The valve to be motorized must be suitable for coupling to the actuator. 3.2) The electrical supply cables must be suitable for the power rating (see the test certificate attached to the actuator). 3.3) The necessary tools for the assembly and setting of the actuator controls must be available. 3.4) In case of long storage periods, check the oil level in the actuator.
the installation of the plugs or cable glands on the cable entries the functioning of anticondensate heaters the status of the local dial indicator glass if the enclosure covers or the actuator body are cracked or broken
2.3) LONG PERIOD STORAGE (more than one year):
2.3.1) Indoor storage: - in addition to the instructions at point 2.2.1., if the actuators are supplied with standard plastic plugs, replace them and connect the heater as described at point 2.2.2.
- after long storage periods, before start-up, verify the oil level inside the gearbox and top-up if necessary.
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CHAPTER 2 Installation
6
INDEX
1) Identification of the main parts 2) Bush: disassembly from the actuator 3) Manual operation 4) Mounting of the actuator onto the valve 5) Removal of the electrical enclosures covers 6) Cables entries 7) Electrical connections 8) Instruction for the explosion-proof enclosures 3 8 1
4 1
1 - Identification of the Main Parts

2 Legenda 1: Gearbox 2: Electric motor 3: Terminal board enclosure 4: Limit switch enclosure 7 5: Handwheel for manual operation 6: Dial indicator 7: Mechanical stops 8: Cable entries 9: Coupling flange
5 9
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2 - Bush: Disassembly from the Actuator

The bush is delivered already assembled to the drive sleeve, even when it is unmachined. In order to carry out the necessary machining, it is necessary to remove it from its housing.
2.2) RE-ASSEMBLY OF THE BUSH It is advisable to wash the dismantled parts with a suitable solvent; dry them with compressed air; make sure that there are no metal filings or foreign bodies; spread a film of grease on all parts (for grease type, see chapt. 7). Important: During the re-assembly of the bush into its drive sleeve, take into account the final position of the actuator on the valve.
4 - Mounting of the Actuator onto the Valve

Lubricate the valve stem. Clean well the coupling surfaces of the valve and actuator flanges, degreasing them carefully since the torque is transmitted by the friction of the flanges.
2.1) PREPARATION OF THE BUSH
For this purpose proceed as follows: - control the position of the stem keyway, with the valve in closed position; - manually drive the actuator in closed position, by means of the handwheel; - determine the final orientation of the actuator with respect to the valve; - mount the bush in the drive sleeve, in a position that satisfies the above considerations.
Remove the safety ring from its holder by means of a strong tool and extract the bush from the drive sleeve.
Lift the actuator with slings suitable for its weight.
3 - Manual Operation
Size F 50 F100 F200 F400 F800
Max. weight 41 Kg 46 Kg 47 Kg 69 Kg 80 Kg
Now the bore can be machined to suit coupling requirements. The procedure is the same for possible maintenance. Important: before mounting the bushing, make sure that the coupling tolerances to the valve stem are correct.
To manually operate the actuator it is sufficient to turn the handwheel in the desired direction. The manual operation is always possible without any clutching mechanism.
Check the dimensions of the valve mounting details, paying particular attention to the protrusion of the valve 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 operations (if necessary with the help of manual operation); pay attention that no mating parts are forced.
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Unscrew the cover completely by using a bar to force on the two lugs. DO NOT HAMMER THE LUGS TO AVOID BREAKING.
6 - Cable Entries
Fix the actuator to the valve using tension rods, nuts and stud bolts in carbon steel, (minimum material required: ISO class 8.8 or AISI SAE 1040 or 8G-UNI 3740-65 or higher), and tighten according to the recommended torques: Size F 50 F100 F200 F400 F800 Tightening torque 130 Nm 300 Nm 300 Nm 130 Nm 130 Nm
If it is difficult to remove the cover, use 2 of the removed fixing screws as extractors, screwing them in the appropriate threaded holes; unscrew them alternatively until the cover is completely removed. 5.2) TERMINAL BOARD ENCLOSURE
Important: - be sure that the terminal board is positioned with the cable entries in the lowest position, to avoid any water infiltration through the line cables - if the connection is made by rigid conduits, we suggest to place a flexible pipe connection between the conduit and the terminal board.
5 - Removal of the Electrical Enclosures Covers

5.1) LIMIT SWITCHES ENCLOSURE
Remove the cable entry plugs. Screw the cable glands tightly so as to guarantee a weather-proof and explosion-proof tightness. Using a 2 mm hexagonal key, loosen the securing screw placed in the cover. If some parts of the cable glands have been removed to facilitate the operation illustrated in the preceding figure, put them back into place immediately to avoid losing the dismantled parts. Unused entries: - for explosion-proof construction, they must be sealed with metal plugs (repeat the same operations described in this chapter);
Using a 6 mm hexagonal key remove the fixing screws from the cover. Remove the cover with care in order to avoid damaging either the coupling surfaces or the O-Ring seal.
- for weather-proof construction, the plastic standard protection plugs supplied with the actuator must be removed and replaced with proper plugs ensuring perfect weather-proof protection.
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7 - Electrical Connections
Ground Studs First terminated the ground connections to the ground stud marked . One internal end two external ground studs are provided.
Connect the motor supply cable previously sized according to: - the absorbed current correspondent to the actuator nominal torque with the torque limiting device set at 100% (see the test certificate attached to the actuator) - applicable plant and safety norms. Assemble the power terminals protective barrier, always present into the terminal board compartment, by the enclosed fixing screws. The control circuit (controls and signals) must be connected by means of a multicore cable to the corresponding numbered terminals according to the wiring diagram. The internal cables of the actuator are also numbered according to the wiring diagram.
8 - Instructions for the Explosion-Proof Enclosures
During the dismantling and subsequent re-assembling of the explosion-proof enclosures (covers, cable glands, joints) it is necessary to pay particular attention in bringing these enclosures back to their original condition so as to maintain their integrity. So please:
8.1) Do not damage the explosion-proof mating surfaces, both on the housing, and on the electrical enclosures covers.
8.2) Put all the fixing screws of the dismantled parts back. The actuators are delivered with the motors wound and connected in accordance to the customers requests: voltage and frequence values are stated on the motor name-plate.
If the actuator is not fitted with an integral starter, a motor control system with remote contactors, open-stop-close pushbuttons and signalling lamps must be provided to operate the actuator.
8.3) Check that the bolts and screws, that may have been replaced, are of the same dimension and quality as the original ones (these are stated on the nameplate), or of a better quality.
Important: To guarantee the protection of the internal circuit, the anticondensation heater must be powered immediately after the electrical connection has been made and they must never be disconnected.
8.4) Do not operate the actuator electrically when the electrical enclosures are removed.
8.5) Replace the weather-proof seals that may have been removed (O-ring for the covers, O-ring for the explosion-proof joint of the motor).
Check the wiring diagram (always enclosed with the actuator) and the layout present on the back of the terminals enclosure cover, to ensure a correct electrical connection.
BIFFC-0040-EN-9603

CHAPTER 3 Setting of Electrical Cam Control Group INDEX

1) Electrical cam control group 2) Checking the setting of motorized valves 3) Electrical connections 4) Torque and position setting 5) Setting the trip point of the auxiliary limit switches
1.2) GENERAL CHARACTERISTICS The electrical control group performs the following functions: - stops the actuator by means of CT/P and OT/P torque/limit switches when the valve has reached the extreme positions; - limits the output torque all along the stroke (in opening and in closing) to prevent damages to the valve trims by means of CT/P and OT/P torque limit switches; - stops the actuator by means of CT/P and OT/P torque/limit switches when the preset output torque value has been reached;
- provides an electrical signal, local and/or remote, by means of CS1, CS2, OS1 and OS2 limit switches, when the valve reaches the extreme positions; - continuously signals the position of the valve by means of a local mechanical dial indicator; - by-passes the torque limiting device mechanically excluding it in the initial part of the opening and closing strokes; this allows the actuator to supply the maximum possible torque, equal to about 1.5 times the nominal torque.
1 - Electrical Cam Control Group

1.1) LOCATION AND IDENTIFICATION OF THE COMPONENTS
IBS1 IBS2
OPTIONAL FEATURES: - continuous remote signalling of the valve position by means of position transmitter PT; - feed-back of the valve position by means of PT position transmitter (in modulating service); - electrical signalling indicating the valve intermediate positions by means of IAS and IBS limit switches.
OT/P OS1 OS2
IAS1
IAS2
PT
CT/P
CS1
CS2
Legenda CT/P: Torque/position limit switch in closing OT/P: Torque/position limit switch in opening CS1 and CS2: Closed position signalling switches OS1 and OS2: Open position signalling switches H: Anticondensate heater IAS1 and IAS2; IBS1 and IBS2: Auxiliary limit switches adjustable at any point of the stroke (optional) PT: Potentiometric transmitter (optional) P : Torque/position swing lever.
CT/P
CS1 CS2
2 - Checking the Setting of Motorized Valves

2.1) IF THE VALVE IS DELIVERED COMPLETE WITH THE ACTUATOR, it is necessary to check that the setting operations have been carried out. Verify that the valve is not completely closed. Remove the cover of the terminal board enclosure and connect an ohmmeter to the terminals of the CS1 limit switch.
OT/P
H OS1
OS2
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Manually operate the actuator and, by rotating the handwheel, check that the indicator dial also rotates.
2.2) IF THE ACTUATOR IS DELIVERED SEPARATELY FROM THE VALVE, OR IF THE TESTS DESCRIBED UNDER THE PREVIOUS POINT PROVE NEGATIVE, it is necessary to adjust the electrical control group as described in the following paragraphs.
Run the motor again and manually operate the torque/position swing lever P to trip the open torque/position switch, so as to check the correct operation of the switch itself. The actuator must stop.
3 - Electrical Connections
Check the correspondence between the terminal numbers indicated on the wiring diagram and the position of terminals shown on the layout Bring the dial exactly to the closed mark. At this point the switch status must change. Connect the ohmmeter to the terminals of the OS1 limit switch and bring the valve to the completely open position. Press the opening button and verify that the actuator effectively moves to the open position. If the opening control signal causes the closure of the valve, immediately stop the operation by pressing the STOP pushbutton on the local control panel. 1) autophase corrector which allows Invert two phases of the supply line and repeat the operation. the actuator to run correctly indipendently from sense of rotation of the phases; 2) phase discriminator which blocks the Bring the dial indicator exactly to the open mark. As explained above, the switch status must change at this point. If these checks give a positive result, you can assume that the actuator setting has been carried out correctly and the paragraphs relevant to the electrical control group setting can be ignored. If, by pressing the button, the motor does not start, it is necessary to invert two phases of the supply line. actuator and gives a local and remote alarm in case of incorrect sense of rotation of the phases. Actuators fitted with integral starter IS 2000: an autophase corrector/ phase discriminator is built in the integral starter; two different working modes are selectable by dip-switch: Move the valve disk/ball from the fully closed position, by using the manual drive. Repeat the above mentioned operation for the closing stroke, too. present on the cover back.
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4 - Torque and Position Setting

Necessary equipment : a 3 mm hexagonal key.
Remove the seal washer.
For anti-clockwise closing, the wording closed should be replaced by open and vice-versa.
4.2) VALVE STOPPING ADJUSTMENT 4.1) VALVE TYPES AND SELECTION OF SETTING Electrically operate the valve until it 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 table: Hold the mechanical stop by means of a suitable Allen key and in the Valve type: front seal butterfly valve Closing: torque Opening: position same time loosen the lock nut by one turn. Unscrew the mechanical stop for about 10 mm. Repeat the above operations for the other mechanical Valve type: ball valve, butterfly valve, plug valve Closing: position Opening: position stop. comes to a nearly closed position. Manually bring the valve to the completely closed position by rotating the handwheel clockwise. IN CLOSING BY POSITION LIMIT
Zone B Zone A
Zone B Zone A
Loosen the lock screw of the closing cam and rotate the cam until the limit switch operates CT/P, by means of zone B of the same cam (previous figures). Lock the cam in
Roller Closing Cam
Roller Opening Cam
this position. Electrically bring the valve to a partially open position.
The cams for the setting of the limit switches operation have an A zone (for electrical signalling) and a Before any setting operation, it is necessary to unscrew the adjustable mechanical stops. Hold the lock nut and remove the mechanical stop protection by unscrewing it. B zone (for position-stopping); the cams must always come into contact with the roller, in zone A. The following indications are valid for valves closing clockwise. Electrically operate the valve in closing until the actuator automatically stops: check the valve disk position or the marks on the valve.
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Put the seal washer back in place and re-assemble the mechanical stop protection, both previously removed. Lock the protection cap. Electrically bring the valve to a partially open position.
The roller is operated by zone B of the cam (previous figures). Check that the roller arm pushes the screw and operates the swing lever; the stopping and the position signalling is obtained.
Electrical signalling of closed Electrically operate the valve in closing direction until the actuator automatically stops. Screw the closing mechanical stop until it reaches the end stroke. From here unscrew it by half a turn and lock it with the lock nut. Manually close the valve until it reaches the mechanical stop and check that the cam is still operating microswitch CT/P. 4.3) VALVE STOPPING ADJUSTMENT Repeat the adjustment if the contrary occurs. Check that limit switches CS1 and CS2 have actually been tripped. Electrically operate the valve until it comes to a nearly open position. Complete the valve opening manoeuvre manually making sure the desired position is reached. Swing Lever
ax Lm in. Lm
valve: the adjustment has already been carried out together with the positioning of the cam which causes the automatic stopping of the actuator.
IN OPENING BY POSITION LIMIT
Lock Screw
Zone B
Screw
Check the protrusion of the mechanical stop: Closing Cam _ for a stroke of 90 + 5 degrees, length L should be within the following values: Position of the cam when the actuator stops due to the Size L min L max intervention of the position limit switch. F 50 F100 F200 F400 F800 16 mm 22 mm 22 mm 25 mm 26 mm 24 mm 29 mm 29 mm 32 mm 39 mm Loosen the lock screw of the opening cam and rotate it until OT/P switch is operated by zone B of the cam (see previous figures). Lock the cam in this position. Roller
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To verify the correct setting, repeat the operations already described for closure setting, replacing the wording closed with the wording open and vice-versa, including the setting of the mechanical stops. Electrical signalling of open valve: the same applies as for Electrical signalling of closed valve substituting the wording CS1 with the wording OS1.
The value to be set can be read in percentage by means of the index on the graduated scale. To set the desired torque value, it is sufficient to manually operate the screw which will increase or decrease the rating value.
existing valve, the torque limiting device should be set at a percentage value equal to the ratio between the value recommended by the valve manufacturer and the actuator nominal torque. For example:
Important: in case of actuators with reduced nominal torque, where the max set (max setting torque) is lower than the range 100% value shown on the label, the index stroke is reduced by Biffi by means of a suitable spacer. The scale is
recommended value:
150 mKg
actuator nominal torque: 250 mKg percentage value to be set 150 = 60% 250
Electrical signalling: after the above procedures, the valve is set for stopping by torque in closing; it is now necessary to set the cams for electrical signalling. Bring the valve to a closed position.
4.4) VALVE STOPPING ADJUSTMENT BY TORQUE LIMITATION The torque limiting device can always operate during closing and opening strokes. The nominal output torque of the actuator is indicated on the name-plate of the control group; the setting of the torque is possible from 25% to 100% both in closing and in opening.
anyway always valid and refered to the range 100% value; for example: range 100% = 1,000 Nm max set = 800 Nm the index stroke is possible from 25% to 80% with index set at 80%, nominal torque = 800 Nm (max set value) with index set at 50%, nominal torque = 500 Nm (50% of the range 100% value).
For a correct adjustment of the Screw Graduated Scale Index Screw output torque, it is necessary to know the value of the torque required for closing or opening the valve: a slightly higher torque value has then to be set. Normally this operation is performed by the valve manufacturer while testing the motorized valve; the set value must be slightly higher than the value required by the valve to obtain perfect tightness. If no setting has been made or if the actuator has to be installed on an Electrically operate the valve in closing until the actuator automatically stops, by means of the torque limiting device. Loosen the lock screw of the closing cam and rotate it until switches CS1 and CS2 are operated by zone A of the cam (see previous figures). Lock the cam in this position. Electrically bring the valve to a partially open position.
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Verify that limit switches CS1 and CS2 have been operated by the cam and that they have actually been tripped.
Repeat the adjustment if the contrary occurs. Alternatively, taking into consideration a valve to be stopped by torque in opening, the above description is valid by replacing the term close with open and vice-versa, including the setting of the mechanical stops.
5.1) SETTING OF THE TRIP POINT OF CS, OS, IAS, IBS LIMIT SWITCHES Necessary equipment: a 2.5 mm hexagonal key. For particular service needs, in certain cases the setting of some switches must be slightly delayed in respect to the others.
Roller Arm Screw
Roller Zone A 0,5 to 1 mm Clearance
5 - Setting the Trip Point of the Auxiliary Limit Switches

Necessary equipment: a 3 mm hexagonal key.
Position of the cam when the actuator stops by the intervention of the torque limiting device: the roller is operated by zone A of the cam. Check that a 0.5 to 1 mm clearance is left between the roller arm and the screw. However, the tripping of each pair of switches is adjustable at any point along the valve stroke. The auxiliary switch group, in the standard version, consists of two pairs of switches: IAS1 and IAS2; IBS1 and IBS2. Each pair is actuated by a single cam, therefore the tripping of each pair of switches is simultaneous. With a 2.5 mm hexagonal key adjust the screw of the blade springs operating the switches (detail 1): by turning clockwise the adjustment screw a delayed tripping is obtained, by turning it anticlockwise an advanced tripping is obtained.
1
Caution: do not rotate the adjustment screw more than 3 turns Screw the closing mechanical stop until it reaches the end stroke. From here unscrew it by half a turn and lock it with the lock nut. The tripping of each pair of switches is Check the protrusion of the mechanical stop, as previously described in this chapter. obtained by having the corresponding cam act on the relevant actuating lever. from its rest position to avoid damages to the lever. The checking of the trip settings is made by comparing the tripping point difference by means of two ohmmeters connected to the two concerned switches.
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CHAPTER 4 Setting of the Dial Position Local Indicator
2 - Adjustment of the Opening Indication

Automatically bring the valve in completely open position. Turn the higher indicator disk (transparent) until the OPEN indication is vertical heading downwards. During this last operation be careful not to displace the lower disk. Assemble the cover of the switches box without fixing it, and check that the CLOSED indication on the indicator disk coincide exactly with the arrow on the cover. Correct any possible differences, as previously described.
INDEX
1) Adjustment of the closing indication 2) Adjustment of the opening indication
1 - Adjustment of the Closing Indication
Bring the valve to closed position. Remove the cover of the switches box.
Assemble the cover of the switches box without fixing it and check that the OPEN indication on the indicator disk coincide exactly with the arrow on the cover. Correct any possible differences, as previously described. Turn the lower indicator disk (white) until the CLOSED indication is vertical heading downwards. Fix the switches box cover making sure that the O-ring is in its place.
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CHAPTER 5 Setting of the Resistive-Type Position Transmitter
Without disconnecting the ohmmeter, operate the actuator, bring the valve to the automatic opening position and take note of the transmitter resistance value in this position.
Subtract from this value the resistance value previously set at closed valve position: the resistance range value thus obtained (referred to the actual valve stroke), is to be used for the correct adjustment of the equipment controlled by the transmitter.
If necessary, in order to optimize the output value from the transmitter, it is possible to change the reduction ratio of the gearing that drives the transmitter.
Legenda: 1: Transmitter 2: Transmitter arm 3: Transmitter pinion 4: Multigear wheel 5: Current position transmitter
The position transmitter is supplied with the full scale value required in the order. The value of the actual resistance transmitted according to the valve stroke can vary from 75% to 100% of the nominal full scale value; the correct operation of the equipments driven by the potentiometer is however ensured by the adjustable devices on all equipment controlled by the transmitter. Electrically operate the valve in closing direction until the actuator automatically stops. Connect an ohmmeter to the terminals which link the zero and the transmitter slider. Note: the indication of the transmitter total resistance is stamped on its enclosure. Lift the transmitter arm and rotate the transmitter slide adjustment shaft until the ohmmeter indicates a value corresponding to about 5% of the transmitter full scale value. Loosen the locking screw of the transmitter arm.
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Caution: The arm is loaded by an internal spring that will return to its rest position as soon as the locking screw is loosened. This small spring device assures that the transmitter pinion is always well engaged with the multigear wheel, thus obtaining reduced gear back-lash and easier adjustment.
transmitter pinion to the desired multigear wheel: the larger gear expands the range of the output value and the smaller gear reduces it. Insert the hexagonal key into the arm locking screw, rotate the bush by approximately half a turn and fix the bush in this position.
Repeat the previous operations to check the new output values. Slide the transmitter arm on the supporting bar and engage the
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CHAPTER 6 Seal Application to the Electrical Enclosures

A safety seal can be applied to the limit switch enclosure to prevent the removal of the cover by non-authorized personnel.
Drill a hole on the housing (max dia.= 2 mm), passing through the M6 threaded hole of the enclosure cover.
Attention: When drilling the hole, be careful not to damage the threads of the M6 hole.
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CHAPTER 7 Lubrication
The actuator is supplied filled with oil and greased where necessary.
ACTUATOR SIZE
OIL QUANTITY (lt) 1.8 1.8 1.8 3.3 3.3
INDEX
1) Lubrication inspection 2) Lubrication tables 3) Comparison table of approved lubricant substitutes
F 50 F100 F200 F400 F800
1 - Lubrication Inspection
In normal working conditions, the lubricating oil has practically an indefinite lifespan. In case it is necessary to top up to the max. oil level, the same type of lubricant should be used.
2 - Lubrication Tables
AMBIENT TEMPERATURE AND LUBRICANT TYPES: Ambient Temperature from -30C to +85C Ambient Temperature from -60C to +65C
OIL: ISO viscosity grade Viscosity: 2 Engler (at 50C) cSt (at 40C) The actuator is fitted with oil plugs (parts 1 and 2), so that for any assembly on the valve at least one oil plug is located on the upper part of the housing and one on the lower part. GREASE: ISO viscosity grade X1 (EP1) 18-22E 135-165 cSt VG 150
OIL: ISO viscosity grade Viscosity: Engler (at 50C) cSt (at 40C) 5.5-6.7E 41.4-50.5 cSt VG 46
GREASE: FUCHS FN20
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3 - Comparison Table of Approved Lubricant Substitutes
AMBIENT TEMPERATURE AND LUBRICANT TYPES: Ambient temperature: from -30C to +85C Ambient Temperature: from -60C to +65C
OIL MANUFACTURER ISO viscosity grade VG 150
OIL MANUFACTURER ISO viscosity grade VG 46
AGIP AMOCO BP CHEVRON ELF ESSO GULF IP MOBIL SHELL TEXACO TOTAL
BLASIA 150 PERMAGEAR EP LUBRICANT 150 ENERGOL GR-XP 150 NL GEAR COMPOUNG 150 REDUCTELF SP 150 SPARTAN EP 150 EP LUBRICANT HP 150 IP MELLANA OIL 150 MOBILGEAR 629 OMALA OIL 150 MEROPA LUBRICANT 150 CARTER EP 150
SHELL SYNECO
HD75W/90 WINTER PLUS
GREASE MANUFACTURER ISO viscosity grade X1 (EP1)
GREASE MANUFACTURER
AGIP BP ELF ESSO
GR MU/EP1 LTX 1 EPEXA 1 BEACON EP1
AGIP TEXACO
FN 20/00 LOW TEMPERATURE GREASE EP
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CHAPTER 8 Maintenance
1.2) check the external part of the actuator, to verify possible damages (breakages of the handwheel, of the glass of the local position indicator); restore the
1.6) if the actuator operation is not frequent, periodically carry out electrical and manual operations (only if allowed by the working conditions of the plant).
INDEX
1) Standard maintenance 2) Special maintenance
actuator to its original condition;
1.3) re-paint the areas where the paint might have come off (after removing all rust), especially if the actuator is installed in chemically aggressive or saline environments;
2 - Special Maintenance
Approx. every 3 years, according to the scheduled maintenance of the plant where the actuator operates, it is necessary: - to check the electrical enclosures and all components therein;
1 - Standard Maintenance
QTC actuators should not require maintenance, even after long periods of operation in the most unfavourable conditions.
1.4) check that the nuts and bolts fixing the actuator to the valve are tightly secured; if necessary, re-tighten with a dynamometric key (for the tightening torque see installation, chapt. 2);
- to replace the O-rings; - to replace the oil if the actuator operates in severe working conditions either due to frequency of operation or high temperature conditions.
They are designed to perform more operations than actually requested on any type of plant.
It is however advisable to check the actuator periodically by the following simple procedures:
1.5) for a particularly severe actuator service, the standard maintenance operations must be carried out more frequently, as shown by the standard maintenance card of the plant where the actuator operates;
1.1) check that there is no oil leakage from the housing, due to accidental damage; the oil level should be approx 20 mm. from the top of the housing;
BIFFC-0040-EN-9603
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CHAPTER 9 Trouble-shooting
2 - The Motor Cannot Unseat the Valve

2.1) Try to unseat the valve by means of manual operation.
4 - The Actuator Works Electrically without Operating the Valve

4.1) Check that the valve is working in manual operation; if not, it is necessary to check the manual control area, or the kinematic chain from the motor to the drive sleeve.
INDEX
2.2) After unseating it, try to make the 1) The actuator does not work electrically 2) The motor cannot unseat the valve 3) The motor is very hot and does not start 4) The actuator works electrically without operating the valve 5) Excessive torque for the valve operation; the motor overheats during operation 6) Incorrect valve seating 7) Jammed valve in closed position 8) The actuator does not stop in fully open or closed position actuator work electrically.
3 - The Motor Is very Hot and Does not Start

3.1) Wait until the motor cools down and the normally closed contact of the thermal switch automatically resets.
5 - Excessive Torque for the Valve Operation; the Motor Overheats during Operation
5.1) Valve packing too tight: loosen the gland bolt nuts. 5.2) Ensure that there are no axial forces on the valve stem by leaving adequate axial clearance between the stem and the drive bush. 5.3) Check that the internal valve trim or the reducer gears are well lubricated and not damaged.
3.2) When the motor is cold, check the continuity of the terminals connected to the thermal switch.
3.3) Check that the number of operations per hour and their duration is suitable for the actuator
1 - The Actuator Does not Work Electrically

1.1) Check the supply or control voltage values and compare them with the data shown on the name-plate of the motor and actuator.
service (S2 or S4, see motor name-plate or test certificate attached to the actuator).
6 - Incorrect Valve Seating

6.1) Valves which are stopped by the intervention of the torque limit switch in closing: increase the output torque of the actuator by adjusting the torque limit switch.
3.4) Check that the valve operating time does not exceed the original operating time.
1.2) Check the wiring diagram and the continuity of the power and control connections. 3.5) ALWAYS check the cause of abnormal overheating.
6.2) Valves which are stopped by the intervention of the position limit switches in closing: check that the valve reaches its seat position; then re-adjust the setting of the limit switches.
1.3) Check the continuity of the motor phases.
1.4) If there is a phase discriminator, reverse two phases of the supply line.
22
BIFFC-0040-EN-9603

6.3) The internal trims of the valve may be damaged.
7 - Jammed Valve in Closed Position

7.1) Check that the opening electrical signal corresponds to the rotation of the actuator in the opening operation. 7.2) Try to move the valve from the jammed condition by the manual operation.
8 - The Actuator Does not Stop in Fully Open or Closed Position

8.1) Check the exact position of the limit switch cams.
8.4) Check that the control cables are connected to the torque and position limit switches (CT/P and OT/P) as shown on the wiring diagram.
8.2) Make sure that the operating cams are securely fixed to their shaft.
8.5) Check the functioning of the kinematic chain operating the torque/position limit switches (CT/P and OT/P).
8.3) Check the correct electrical operation of the torque/position limit switch (CT/P and OT/P).
BIFFC-0040-EN-9603
23

CHAPTER 10 Recommended Spare Parts and Sectional Drawings INDEX

1) Commissioning spare parts kits 2) Recommended spare parts for two-years operation
1 - Commissioning Spare Parts Kits
2 - Recommended Spare Parts for Two-Years Operation

Please refer to the marked-up part list items on the attached sectional drawings.
Size
Code
F 50 F100 F200 F400 F800
SPF050/001 SPF100/001 SPF200/001 SPF400/001 SPF800/001 Important: for any order of spare parts, the serial number of the actuator must be specified.
QTC#F50 through F800

ITEM 3 24 30 42 42.1 42.2 42.3 42.4 42.5 57 58 59 60 61 62 63 64 65 66 67 68 69 70 70.1 70.2 70.3 70.4 70.5 70.6 71 72 73 74 Q.ty 1 2 1 1 10 1 1 86 1 1 1 1 1 1 1 1 1 1 2 2 1 1 1 1 2 4 1 1 1 1 1 1 1 DESCRIPTION O-Ring Screw Bearing Terminal Board Screw Wiring connection label Terminal Board Cover Screw O-Ring Wiring Loom Holder Connector Support Electric Motor O-Ring Motor Gasket Circlip Housing O-Ring Worm Gear Cover Screw Washer Bearing Support Bearing Worm Gear Group Key Thrust Bearing Thrust Shoe Worm Gear Spring Bearing Ring Nut Circlip Circlip Gear Motor Pinion MATERIAL NBR Carbon Steel Carbon Steel
table 1
RECOMENDED SPARE PARTS
Stainless Steel Plastic Aluminium Stainless Steel NBR
Carbon Steel
NBR Fiber Carbon Steel Aluminium NBR Aluminium Carbon Steel Carbon Steel Carbon Steel Carbon Steel
Carbon Steel Carbon Steel Carbon Steel Alloy Steel Alloy Steel Alloy Steel Carbon Steel Carbon Steel Alloy Steel Alloy Steel
24
BIFFC-0040-EN-9603

table 1
24 3
63 64 65 66 - 67 68 69 70 30
42 57 58 59 60 61 62
71
72
73 74
70.1 70.4
70.2 - 70.3
70.2 - 70.3 42.1
70.5
70.6
42.2 42.3 42.4 42.5
BIFFC-0040-EN-9603
25


ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 37.1 37.2 37.3 37.4 37.5 37.6 37.7 38 39 40 40.1 40.2 40.3 40.4 40.5 41 Q.ty 1 1 2 1 1 1 1 1 1 2 1 2 2 4 4 1 2 1 1 1 1 4 1 6 6 1 1 1 1 1 3 2 8 8 1 8 1 1 3 3 3 3 3 1 1 1 1 3 3 3 6 1 2 DESCRIPTION Dial Indicator Group Additional Control Group O-Ring Control Group O-Ring Bearing Worm Wheel Worm Wheel Support Manual Drive Wheel Worm Wheel Sliding Washer Internal Gear Mechanical stop protection Nut Seal Washer Pin Coupling Block Mechanical Stops O-Ring Insert Shoulder Ring Insert Control Group Cover Screw Heater Screw Washer Torque Transmission Device O-Ring Circlip Position Transmission Shaft Bearing Screw O-Ring Nut Washer Oil Plug Stud Bolt 2nd Epicycloidal Stage Group Planet Wheel Shoulder Plate Screw Washer Planet Wheel Pin 2nd Stage Planet Wheel 2nd Stage Bush Planet Wheel Bush 2nd Stage Support Plate Coupling Block Bush 1st Epicycloidal Stage Group Bush Planet Wheel Pin 1st Stage Planet Wheel 1st Stage Circlip Pinion 2nd Stage Washer MATERIAL
table 2
NBR

NBR Carbon Steel Aluminium-Bronze Aluminium Carbon Steel Carbon Steel Carbon Steel Carbon Steel Carbon Steel Steel+rubber Carbon Steel Cast Ductile Iron Alloy Steel NBR Carbon Steel Carbon Steel
Carbon Steel
Carbon Steel Carbon Steel Brass NBR Stainless Steel Brass Carbon Steel Carbon Steel NBR Carbon Steel Carbon Steel Carbon Steel Alloy Steel
Carbon Steel Carbon Steel Carbon Steel Alloy Steel Alloy Steel Steel+Bronze+Teflon Cast Ductile Iron Carbon Steel Bronze
Steel+Bronze+Teflon Alloy Steel Alloy Steel Carbon Steel Alloy Steel Nylon
26
BIFFC-0040-EN-9603

table 2
21 22 23
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 37.1 37.2 37.3 37.4 37.5 37.6 37.7 40.2 40.1
24 25 26 27 28 29 30 31 32 32 33 34 35 36 37 38 39 24 25 40 41
40.3 40.4 40.5
BIFFC-0040-EN-9603
27

QTC#F800
ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 37.1 37.2 37.3 37.4 37.5 37.6 37.7 38 39 40 40.1 40.2 40.3 40.4 40.5 41 76 76.1 76.2 76.3 76.4 76.5 77 78 79 80 81 82 Q.ty 1 1 2 1 1 1 1 1 1 2 1 2 2 4 4 1 2 1 1 1 1 4 1 6 6 1 1 1 1 1 3 2 8 8 1 8 1 1 3 3 3 3 3 1 1 1 1 3 3 3 6 1 2 1 3 3 3 6 1 1 1 4 8 8 2 DESCRIPTION Dial Indicator Group Additional Control Group O-Ring Control Group O-Ring Bearing Worm Wheel Worm Wheel Support Manual Drive Wheel Worm Wheel Sliding Washer Internal Gear Mechanical stop protection Nut Seal Washer Pin Coupling Block Mechanical Stops O-Ring Insert Shoulder Ring Insert Control Group Cover Screw Heater Screw Washer Torque Transmission Device O-Ring Circlip Position Transmission Shaft Bearing Screw O-Ring Nut Washer Oil Plug Stud Bolt 3rd Epicycloidal Stage Group Planet Wheel Shoulder Plate Screw Washer Planet Wheel Pin 3rd Stage Planet Wheel 3rd Stage Bush Planet Wheel Bush 3rd Stage Support Plate Coupling Block Bush 1st Epicycloidal Stage Group Bush Planet Wheel Pin 1st Stage Planet Wheel 1st Stage Circlip Pinion 2nd Stage Washer 2nd Epicycloidal Stage Group Bush Planet Wheel Pin 2nd Stage Planet Wheel 2nd Stage Circlip Pinion 3rd Stage Flange Internal Gear 3rd Stage Pin Screw Washer O-Ring MATERIAL
table 4
NBR

NBR Carbon Steel Aluminium-Bronze Aluminium Carbon Steel Carbon Steel Carbon Steel Carbon Steel Carbon Steel Steel+rubber Carbon Steel Cast Ductile Iron Alloy Steel NBR Carbon Steel Carbon Steel
Carbon Steel
Carbon Steel Carbon Steel Brass NBR Stainless Steel Brass Carbon Steel Carbon Steel NBR Carbon Steel Carbon Steel Carbon Steel Alloy Steel
Carbon Steel Carbon Steel Carbon Steel Alloy Steel Alloy Steel Steel+Bronze+Teflon Cast Ductile Iron Carbon Steel Bronze
Steel+Bronze+Teflon Alloy Steel Alloy Steel Carbon Steel Alloy Steel Nylon
Steel+Bronze+Teflon Alloy Steel Alloy Steel Carbon Steel Alloy Steel Cast Ductile Iron Carbon Steel Carbon Steel Carbon Steel Steel+rubber NBR
BIFFC-0040-EN-9603
30

QTC#F800
1 2 3 4 5 6 7 8 9 10 11 76 77 78 79 12 13 14 15 16 17 18 19 20 37 39 38 40 41 30 31 24 25 32 80 81 82 33 34 35 36 21 22 23 24 25 26 27 28 29
table 4
40.1 37.1 37.2 37.3 37.4 37.5 37.6 37.7 76.2 76.1 40.2
40.3 40.4 40.5
76.3 76.4 76.5
BIFFC-0040-EN-9603
31


ITEM 22 35 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 Q.ty 8 1 1 2 2 4 1 1 1 1 4 1 1 1 1 1 1 DESCRIPTION Screw Oil Plug Terminal Board Group Bush Thrust Bearing Thrust Shoe Manual Drive Worm Gear Name Plates Group 1st Epicycloidal Stage Pinion Manual Drive Flange Screw Key Handwheel Screw Handwheel Spacer Seal Ring O-Ring MATERIAL Carbon Steel Carbon Steel
table 3
Steel+Bronze+Teflon Carbon Steel Carbon Steel Carbon Steel
Alloy Steel Aluminium Carbon Steel Carbon Steel
Alloy Steel Nylon NBR NBR
28
BIFFC-0040-EN-9603

table 3
47 48 44 - 45 43 49 50 51 42 22 43 44 - 45 46 35 52 53 54 55 56 22
BIFFC-0040-EN-9603
29
Local Sales Organizations:
BIFFI ITALIA s.r.l. - Loc. Caselle S. Pietro - 29017 Fiorenzuola dArda - Piacenza - ITALY - Tel. (0523) 944411 - Fax (0523) 941885 - Telex 530107 - 531447
BIFFC-0040-EN-9603
A. C./Grafiche Malvezzi/2.000/05.96
QTC-IM-E Rev. 2

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QTC Series Electric Actuator

instruction and operating manual

INSTRUCTION AND OPERATING MANUAL

Contents may change without notice.

QTC Series Electric Actuator

DETAILED INDEX CHAPTER 1, page 3 Storage and Pre-Installation

CHAPTER 8, page 21 Maintenance

CHAPTER 4, page 15 Setting of the Local Position Dial Indicator

CHAPTER 9, page 22 Trouble Shooting

CHAPTER 2, page 5 Installation

CHAPTER 5, page 16 Setting of the Resistive-Type Position Transmitter

CHAPTER 6, page 18 Seal Application to the Electrical Enclosures

CHAPTER 7, page 19 CHAPTER 3, page 9 Setting of Electrical Cam Control Group

CHAPTER 10, page 24 Recommended Spare Parts and Sectional Drawings

Contents may change without notice.

QTC Series Electric Actuator

CHAPTER 1 Storage and Pre-Installation INDEX

1 - Tests to be Carried Out on Receipt of the Actuator

Contents may change without notice.

QTC Series Electric Actuator

3 - Checks to be Performed Before Installation

2.3) LONG PERIOD STORAGE (more than one year):

Contents may change without notice.

QTC Series Electric Actuator

1 - Identification of the Main Parts

QTC Series Electric Actuator

2 - Bush: Disassembly from the Actuator

4 - Mounting of the Actuator onto the Valve

2.1) PREPARATION OF THE BUSH

Lift the actuator with slings suitable for its weight.

Size F 50 F100 F200 F400 F800

QTC Series Electric Actuator

5 - Removal of the Electrical Enclosures Covers

QTC Series Electric Actuator

8 - Instructions for the Explosion-Proof Enclosures

Contents may change without notice.

QTC Series Electric Actuator

CHAPTER 3 Setting of Electrical Cam Control Group INDEX

1 - Electrical Cam Control Group

OT/P OS1 OS2

2 - Checking the Setting of Motorized Valves

QTC Series Electric Actuator

Contents may change without notice.

QTC Series Electric Actuator

4 - Torque and Position Setting

Remove the seal washer.

Roller Closing Cam

Roller Opening Cam

this position. Electrically bring the valve to a partially open position.

Contents may change without notice.

QTC Series Electric Actuator

IN OPENING BY POSITION LIMIT

Contents may change without notice.

QTC Series Electric Actuator

Contents may change without notice.

QTC Series Electric Actuator

Roller Arm Screw

Roller Zone A 0,5 to 1 mm Clearance

5 - Setting the Trip Point of the Auxiliary Limit Switches

Contents may change without notice.

QTC Series Electric Actuator

CHAPTER 4 Setting of the Dial Position Local Indicator

2 - Adjustment of the Opening Indication

1 - Adjustment of the Closing Indication