Biffi Italia, a leading manufacturer of high-performance and reliable valve actuation systems, like the new 3000 series. Biffi is the absolute lead for ball and gate valves control through its electric actuators.

Featuring a wide range of torques from 30 to 1440 Nm and speeds up to 173 RPM, the Icon3000 possesses the versatility to slot into a myriad of industrial systems, yet exhibits the ruggedness necessary to survive in the most extreme environmental conditions. Rated for temperatures as low as -60°C, the actuator also offers certified painting solutions for the strongest protection against the most aggressive of environments. The actuator is compliant with a wide range of communication protocols, including Foundation Fieldbus, HART, Profibus DPV0, DPV1, and redundant DPV2, LonWorks and Modbus. Furthermore, the Icon3000 comes fully integrated with Biffi’s A-Manager software and the DCM2 Master Station, providing easy and smart configuration and diagnostics capabilities. Such programmable intelligence allows the end-user to achieve the level of control demanded by the target application. Equipped with a compact, dependable absolute encoder, which guarantees position detection, even if main and back-up battery power are lost, the actuator also comes with a new dot matrix OLED user interface display, capable of showing detailed information, such as icons and drawings – as well as being easy for the human eye to view in tough environments. A wide range of gears and couplings is available for combination, further increasing the actuator’s versatility to cover any application in the quarter or multi-turn arena.

The mechanical parts of these actuators are really robust. High-quality and specially-selected materials include an aluminum/low copper aluminum housing, cast-iron thrust bases, and cast-iron reduction gears (with bronze worm wheels where appropriate, to improve gear longevity and efficiency).

Simplified internal gear train is implemented as a single-stage reduction for transmission from motor to output shaft; extremely reliable, highly efficient, and easily maintainable.

Normally the actuator based on the order made, arrives assembled and configurated from the factory and also certified, including the battery which keep healthy the internal configuration (display on). Unfortunately, sometimes happens that the actuator remains in store for long periods before install it, with high risk that weather condition can contaminate the actuator with water or dust etc., and lost the actuator integrity. For this reason, we always suggest checking the actuator condition before install it. The following list are the main points which require to inspect (for all type of electrical actuators)

1. Always check the status of the O-ring seals

2. Check the oil level in the actuator and top up if necessary.

3. Put the batteries back into place (see paragraph 11.3, Maintenance - Lithium battery change).

4. Check the bushing housing and internal component (bearing etc)

I would like to highlight point 4 because in our opinion it is the most critical, especially if the actuator has been exposed to the weather condition for long periods before install it. For more details see figure below

Now if require, only in this context the bore can be machined in the stem nut to suit coupling requirements. The same procedure is also used for possible maintenance. Never machining the stem nut without removing it from housing. These are the classic mistakes that are made for these actuators. The dirty remains inside housing and then the internal bearing can damage and actuator will work with extra torque, consider also can burn due to metals overheating.

The actuator is lubricated for life, therefore under normal working conditions it is not necessary to replace or refill the oil. However it is recommended to check the oil level every 3-5 years using holes 1 or 2 depending on mounting position. The recommendations above is from BIFFi, based on our experience we recommend to check the oil level and lubrication of the thrust bearings every two years especially where the actuators are install outside and subject to weather conditions such as sandstorms, near the sea, extreme temperatures from winter to summer

How can see, from three figures above, the actuator is fitted with oil plugs (parts 1, 2), so that any assembly on the valve has at least one oil plug on the upper part of the housin and one on the lower part. A spherical head lubricator (part 3) is fitted on the coupling block for the proper greasing of the inside thrust or sliding bearings.

The actuator is supplied with oil and greased where necessary. This is very important to avoid any sedimental from external contaminate the bearing, or even if stem packing leak. This is can be a potential issue when actuator damage.

• Non-intrusive configurations
• User-friendly push-button panel for operation, setting and diagnostics
• Bluetooth™ wireless connectivity
• Watertight and explosionproof PDAs available
• Advanced maintenance data and alarm reports
• Valve condition monitoring
• Configurable 'data logger' function for maintenance and diagnostic programs in recorder or event modes
• Customized numeric and graphic displays with 8 language options
• Single enhanced terminal block
• Digital contactless torque and position sensing
• Advanced open bus communication protocols ( Lonworks,Profibus , Foundation Fieldbus,  Modbus, Hart
• 3-phase, direct current, and 1-phase variants
• Suitable for use in SIL 2 applications
• Torque output: From 30Nm to 1,440Nm
• Speed range: From 12RPM to 173RPM at 50/60 Hz
• Ambient temperature as low as -60°C (-76°F)

We know these types of actuators very well for over 27 years, since the first models on the market. Electrical actuators BIFFi are the leaders absolutely to operating Ball and gate valves for each size and torque.
Consider also that BIFFI Installation and Instruction manual (for all the models) is really very easy and intuitive. Consider also the software BIFFI which communicates laptops and actuators via Bluetooth is very simple to understand. All configuration and calibration can be done with no intrusive activity. The choice of a Biffi actuator for this type of valve mentioned above is really an excellent choice. Regarding the spare parts, all internal components are available, and straightforward to identify and order.

The internal gearbox of the actuator is very robust, in fact, does not require any additional maintenance. In some cases happen that actuators get stuck due to blocking the body valve (with 100% torque), then to return operable the valve for production issue (temporary), many technicians try to apply additional force to the handwheel, so, this is the classic case that gearbox of the actuator can get damage. BIFFI already calculated the max torque and does not require any other torque from the handwheel, or better you can operate the handwheel by hand only and not apply additional force on it like installing a lever, in this case, the gearbox will break easily (Our recommendations are always to check periodically the gearbox oil tank level and the operability of the clutch lever).
Another thing we would like to highlight is the clutch lever to activate the handwheel on the actuator, this lever should be checked periodically if the internal spring on it working properly. Sometimes it happens that the internal spring of lever gets damaged or accumulates dirt and cannot return to the neutral position, then as soon the electrical motor runs, simultaneously with it will rotate the handwheel itself. This is dangerous for the personnel working around it. Sometimes it also happens that the clutch is not engaged 100% and then the gear teeth can break easily (very expensive)

Another feature added is closed-loop control. Closed-loop control takes the on-off/bang-bang control or PID control methodologies that are typically used in a PLC or discrete PID controller and incorporates them into the range. Multi-turn non-modulating IQ3 Pro actuators use a setpoint positioning method known as “bang-bang”, while part-turn IQT3 Pro and IQ3M Pro actuators use the PID closed-loop control method.

The IQ3 Pro range valve actuators are robust, flexible, and reliable. They have a double-sealed enclosure, ‘non-intrusive’ commissioning, and predictive maintenance capabilities using the in-built data loggers. Control and commissioning can be done via a Rotork app, Bluetooth® Setting Tool Pro, or local control knobs. Data logs can be downloaded to the app, then exported to Insight 2 or sent via Rotork’s cloud-based intelligent asset management (iAM) system.

The functionality and reliability is available for valves of virtually every size and description, including multi-turn, part-turn, linear, isolating and modulating, with watertight and hazardous area approvals to all internationally recognised standards.

Below the list which you need to make a perfect order

• Torque & Power Supply Feature - 50-60Hz AC or DC
• Class according to EN15714-2
• Duty type
• Standard remote controls
• Actuator Drive Couplings
• Actuator Feature (Part-turn, Multi-Turn, High Speed, etc
• Fail-Safe Action Interlock Control
• Actuator with lithium battery
• Auxiliary relays Control Monitor Relay
• Graphic display and LED’s color

BIFFI actuators are equipped with 'intelligent asset management' which means they use data loggers, such as the ICON 2000/3000. Pratically, collect all data on from vibration, temperature and torque to the number of starts and whether the unit has lost power. This enables engineers to assess the health of an actuator and make recommendations around maintenance. Based on our experience they are great actuators.

All this information can be download thrudht program BIFFI (Bluetooth) between laptop and actuator, or even with a smartphone. All this is really wonderful because all activity will be no intrunsive, this is very convenient, especially in Hazardous areas.

Normally the internal torque of actuators are configured with 40% only (factory setting). During its operation, it may require to increase its torque due to dirty inside body valve and require more power to operate it (till 70% is normal)

This is possible, but in our opinion, the engineers must inform the responsible area that has changed (increased) due to stem packing issue (or body valve). This is a warning that the next opportunity require to inspect the stem or body valve. The torque can be also set to 100% (maximum) but if the valve gets stuck with 100% of torque there is no other choice except to open the body valve.

Based on the manual BIFFI, the actuator will operate satisfactorily in any position. When mounted upside down, the end of the stem cover tube should be drilled Ø5 mm to avoid build up of service fluid or rainwater. In our opinion, upside down is not recommended precisely because of the fact that water or dust can enter inside the actuator.

We always suggest where it's possible to install the actuators in the position like in the 3 figures above