Bardiani Valvole BBZS5 Specification sheet

Instruction, Use and Maintenance Manual
ADJUSTABLE PNEUMATIC
BY-PASS VALVE
Bardiani Valvole S.p.A.
via G. di Vittorio, 50/52 - 43045 Fornovo di Taro (PR) - Italy
tel. +39 0525 - Fax [phone]
[email protected] - www.bardiani.com
EN-IST-BBZS5-0420
BBZS5 - BBYS5 -
BBWS51

EN-IST-BBZS5-0420
MANUAL REVISION DATE
2

EN-IST-BBZS5-0420
INDEX
1 Safety,Warning and Mandatory Signs 5
2 General safety warnings 8
3 Technical Data 9
4 Checking / Unpacking / Lifting 10
5 Installation 11
6 Operation 13
7 Troubleshooting 14
8 Cleaning 15
9 General maintenance 16
10 Scheduled maintenance 18
11 Tools useful for Disassembly/Reassembly 19
12 Calibratable pneumatic by-pass valve BBZS5 - BBYS5 - BBWS51 20
13 Disassembly of the BBZS5 - BBYS5 - BBWS51 22
A Disassembly of the BBZS5 - BBYS5 23
B Disassembly of the BBWS51 28
13.1Disassembly of the cil.83 31
14 Assembly of the BBZS5 - BBYS5 - BBWS51 33
14.1Assembly of the cil.83 34
A Assembly of the BBZS5 - BBYS5 38
B Assembly of the BBWS51 44
15 Annexes 47
16 2D diagram BBZS5 48
17 2D diagram BBYS5 49
18 2D diagram BBWS51 50
19 Warranty 51
20 Recommendations 52
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EN-IST-BBZS5-0420
INTRODUCTION
This “Instruction, Use and Maintenance Manual” has been prepared to provide guidance and
recommendations to assist qualified skilled technicians in the understanding, running and
maintenance orf the Products supplied.
It forms an integral part of the Products supplied and must be read prior to any installation,
operation and/or maintenance of all types of valves provided.
This manual must be saved for future reference and be kept readily available at the unit.
WithregardstotheuseofvalvescompliantwithEUDirective2014/34/UE(ATEX),consultation

The essential characteristics of all types of valves described herein being consistent, the
Manufacturer reserves the right to alter and or complement and or update at any time and with
no obligation to notify so in writing, the data and or information relevant to the use of the valves
described in this "Instruction, Use and Maintenance Manual".
A constantly updated version of this "Instruction, Use and Maintenance Manual" is available
at the Manufacturer's website www.bardianivalvole.it.
Under no circumstance shall the Manufacturer be held liable for consequences resulting
from failure and or improper use of the instructions contained in this Manual and relating to
the installation, operating, maintenance and storage of the products.
All rights reserved.
Full or part reproduction, transfer and or recording of any part of this "Instruction, Use and
Maintenance Manual" by all means, whether it be electronic, on hard copy, mechanical or any
other means or recording or reuse is strictly prohibited without the prior written consent of the
Manufacturer and for any use other than that of the Buyer.
(Translation of the Original Instructions in the italian Language)
4

1 Safety,Warning and Mandatory Signs
EN-IST-BBZS5-0420
1 Safety,Warning and Mandatory Signs
WARNING SIGNS
Pictogram Description Notes
WARNING
General
This tells the person in question that the operation
described involves (when not performed in accordance
with the relative safety regulations) the risk of personal
injury.
WARNING
Hand crushing
Exercise caution in executing the procedure
Hand crushing hazard
WARNING
Heavy loads
Exercise caution in executing the procedure
Heavy suspended loads.
WARNING
Severe burns
Heat emission hazard Very hot surface, risk of severe
burns
WARNING
Risk of explosions
Take Care, risk of explosions
MANDATORY SIGNS (FOR THE OPERATOR IN CHARGE OF ASSEMBLY/DISASSEMBLY)
Pictogram Description Notes
OBLIGATION
General
Special instructions must be followed to avoid injury to
persons.
PROTECTIVE GLOVES Safety gloves must be available for handling objects
which could cause hand injuries.
HARD HAT A hard hat must be worn during machine lifting
operations to protect against hazards generated by
suspended loads.
FOOTWEAR Use safety footwear to protect against the risks of
falling objects during operations to transport the
machine.
SUITABLE CLOTHING Suitable clothing such as overalls. It is strictly
prohibited to wear clothes with large flapping sleeves
and/or other loose items which could easily get caught
up in machine parts.
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1 Safety,Warning and Mandatory Signs
EN-IST-BBZS5-0420
MANDATORY SIGNS (FOR THE OPERATOR IN CHARGE OF MECHANICAL MAINTENANCE)
Pictogram Description Notes
OBLIGATION
General
Special instructions must be followed to avoid injury to
persons.
PROTECTIVE GLOVES Protective gloves must be available for handling
objects which could cause hand injuries or when there
is the possibility of coming into contact with harmful
substances..
HARD HAT Hard hats must be available when lifting heavy parts.
FOOTWEAR Use safety footwear to protect against injuries caused
by falling objects during maintenance operations
(particularly when dismantling parts).
SUITABLE CLOTHING Suitable clothing such as overalls. It is strictly
prohibited to wear clothes with large flapping sleeves
and/or other loose items which could easily get caught
up in machine parts.
SAFETY GLASSES Protective glasses must be available when there is the
possibility of contact which harmful substances which
could cause eye injuries.
OPERATING SIGNS
Pictogram Description Notes
SKILLED
PERSONNEL
Dismantling/Assembling and maintenance operations must be
carried out by expert technicians only.
NOTE Follow the indicated note with care
ENVIRONMENTAL
NOTE
Follow the regulations in force in the country of used
governing waste disposal.
CLAMP Use of a clamp
CLAMP WITH SOFT
JAWS
Use of a clamp with jaws made from soft material
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1 Safety,Warning and Mandatory Signs
EN-IST-BBZS5-0420
OPERATING SIGNS
Pictogram Description Notes
PRESS Use of a press
PRESS
(release)
Use of a press Gradual release of the pressure force
ELECTRICAL
CONNECTION
Electrical connection to the control unit (consult the relative
instruction manual).
ELECTRICAL
DISCONNECTION
Electrical disconnection from the control unit (consult the
relative instruction manual).
PNEUMATIC
CONNECTION
Connection of the air to the valve.
PNEUMATIC
DISCONNECTION
Disconnection of the air from the valve
1APPLICATION OF
FOODSAFE
GREASE
Use FOODLUBE HI-TEMP 2 15254 grease or similar
2APPLICATION
OF FOODSAFE
GREASE
Use FOODLUBE Multi-paste 15756 grease or similar
APPLICATION OF
MULTIPURPOSE
GREASE
Use AGIP GREASE MU EP 2 SE 463754 or similar
THREADLOCK
APPLICATION
Use SPEED BOND M500 threadlock or similar
OPTIONAL
7

2 General safety warnings
EN-IST-BBZS5-0420
2 General safety warnings
Intended use
Bardiani valves have been designed exclusively for moving fluids.
Prohibited use
The valve must not be used:
• for any operations different to those described under the heading “Intended Use”,
• for handling fluids different to the type specified by the manufacturer;
• for moving fluids at different pressures to those envisaged by the manufacturer and indicated in the
valve's technical data.
Limitations on valve use
It is forbidden to:
• use the valve in a construction configuration different to the one envisaged by the manufacturer.
• use the valve where there is a risk of explosion and/or fire, unless envisaged by the manufacturer (if
the valves are certified in accordance with Directive 2014/34/EU, please refer to the ATEX Manual)-;
• integrate other systems and/or equipment which were not considered by the manufacturer during the
executive design phase,
• use the valve for purposes other than those specifically envisaged by the manufacturer.
WARNING
The machine may not he used inside premises where there is a potentially explosive atmosphere or

with Directive 2014/34/EU please refer to the ATEX Manual).
BARDIANIVALVOLES.p.A.declinesallliabilityforinstallation,
use or maintenance which fails to comply with the indications
provided in this manual!
8

3 Technical Data
EN-IST-BBZS5-0420
3 Technical Data
VALVE DATA
Maximum pressure 10 bar
Minimum pressure Vacuum
Storage temperature from -10°C to 25°C
Material in contact with the product AISI 316L (1.4404). Check the resistance to corrosion in
relation to products and detergents
Gasket material in contact with the
product
EPDM, FKM, HNBR, PTFE. and other gaskets on request.
Check compatibility with products and detergents
Surface finish in contact with the
product
Ra 0.8 µm. Other finishes available on request
VAPOUR BARRIER DATA
Connectors 1/8” BSP
Steam maximum temperature 130°C
Gaskets material FKM
PNEUMATIC ACTUATOR DATA
Connectors 1/8" (BSP) for 6x4mm pipe
Air pressure From 6 bar to 8 bar
Material AISI 340L
Gaskets material NBR
GASKET MATERIALS COMPATIBILITY
Product EPDM FKM HNBR MVQ
Temperature (applications with air) from -10°C to
+140°C
from -10°C to
+200°C
from -10°C to
+130°C
from -70°C to
+230°C
Caustic soda 2% 60°C 30°C To be checked Unsuitable
Nitric Acid 2% 60°C 80°C To be checked Unsuitable
Saturated steam 125°C Suitable To be
checked
Suitable Unsuitable
Greases Unsuitable Suitable Suitable Unsuitable
Alcohols Suitable Unsuitable Suitable Suitable
The valve complies with PED 2014/68/EU directive, with special reference to Annex III, Module A,
concerning internal manufacturing checks as indicated in the Conformity Assessment Procedures.
Valves with DN equal or smaller than DN25 are not included in compliance with Article 4, paragraph 3.
Valves designed for use with gases, liquefied gases, gases dissolved under pressure, vapours and also those liquids
whose vapour pressure at the maximum allowable temperature is greater than 0,5 bar above normal atmospheric
pressure (1 013 mbar) are included within the following limits:
- valves with DN between DN32 and DN100 (included) with group 1 fluids;
- valves with DN125 or bigger with group 2 fluids.
In the event of any doubt, please contact Bardiani Valvole S.p.A.
9

4 Checking / Unpacking / Lifting
EN-IST-BBZS5-0420
4 Checking / Unpacking / Lifting
1. CHECK:
-Check the valve show no signs of damage caused during transport
and that it corresponds with the order;
-Check the inside of the valve.
2. UNPACKING:
The valve packaging is made up of cardboard, wood and plastic.
The valve is mainly made up of metal materials. The gaskets are
usually made from elastomers. Disposal must be in compliance with
local legislation.
3. VALVE LIFTING:
Take care as to the type of valve you are handling.
CAUTION!
Before lifting the valve, make sure there are no disassembled or
separate valve parts which could fall off causing injury to persons
and damage to the valve.
Weight up to 25 kg
CAUTION!
The figures above are used purely to represent the methods and procedures for hoisting the valves.
Bardiani Valvole S.p.A. declines all liability for any damage to things and/or injuries to persons caused
by improper and/or incorrect hoisting of the valve.
10

5 Installation
EN-IST-BBZS5-0420
5 Installation
1. ELECTRICAL AND PNEUMATIC ENERGY SUPPLY
-Use expert personnel for installation/uninstallation operations;
-Check that the air pressure and quality are correct (see
"Technical Data");
A = Upward movement of the valve member
2. REDUCING THE STRESS TO WHICH THE VALVE IS SUBJECTED:
-Vibrations;
-Thermal expansion of the piping;
-Excessive welding;
-Overload.
CAUTION!
The seal seats may become deformed or cause valve malfunctioning.
3. CORRECT DIRECTION OF FLOW:
Flow in the opposite direction to valve closure minimizes water
hammer.
CAUTION!
Bardiani Valvole S.p.A. declines all liability for any damage to things
and/or injuries to persons caused by any failure to correctly follow the
installation procedures.
11
A

5 Installation
EN-IST-BBZS5-0420
4. VALVE CONNECTIONS/CONNECTORS:
If the valve is fitted with connectors, you may proceed with installation.
Correctly insert the gaskets and tighten the connectors.
5. WELDING THE VALVE BODY ONTO PIPING:
Remove the body from the rest of the valve before proceeding with
welding operations. Please refer to the following pages in this manual.
CAUTION!
Hand crushing hazard. During operation there is a risk of crushing
inside the valve body in the area between the actuator and the valve
body.
6. MINIMUM MAINTENANCE CLEARANCES:
Make sure there is enough room around the valve for it to be
disassembled.
DN BBZS5
A (mm)
BBYS5
A (mm)
10-25 245 245
32-40 265 265
50 280 280
65 290 290
80 300 300
100 330 330
CAUTION!
Bardiani Valvole S.p.A. declines all liability for any damage to things
and/or injuries to persons caused by any failure to correctly follow the
installation procedures.
12
A A

6 Operation
EN-IST-BBZS5-0420
6 Operation
1. VALVE INSPECTION BEFORE OPERATION:
-Supply air to the actuator:
-Open and close the valve several times;
-Check that the valve works correctly and accurately.
A = Upward movement of the valve member
CAUTION!
Hand crushing hazard. During operation there is a risk of crushing
inside the valve body in the area between the actuator and the valve
body.
13
A

7 Troubleshooting
EN-IST-BBZS5-0420
7 Troubleshooting
PROBLEM POSSIBLE CAUSE POSSIBLE SOLUTION
External leak
Worn gasket Replace the seal
Leaks inside the closed valve
caused by normal wear
External leak Excessive pressure Replace with a gasket of a
different type of elastomer
Excessive temperature
Premature leaks inside the
closed valve
Aggressive fluids Modify the operating conditions
Too many commands active
Difficulty opening and closing
Difficulty opening and closing
Incorrect type of elastomer used
for the gaskets
Replace with a gasket of a
different type of elastomer
Incorrect positioning of the
actuator Install the actuator correctly
Incorrect operation of the
actuator
Change from normally open
(NO) to normally closed (NC) or
vice versa
Impurities in the actuator Actuator inspection and
maintenance
Incorrect valve body positioning Disassemble and correctly
reposition the valve body
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8 Cleaning
EN-IST-BBZS5-0420
8 Cleaning
1. VALVE CLEANING WITH DETERGENTS:
The system in which the valve is installed must be cleaned by expert
personnel in observance of the following:
-Abide by the indicated detergent concentration values;
-Observe the instructions provided by the detergent manufacturer.
-Always wear protective safety glasses and gloves.
IMPORTANT!
-Accurately dose detergents to avoid excessive concentration;
-Always rinse thoroughly with clean water after washing.
-Check compatibility of valve materials.
CAUTION!
Burns hazard. The valves and piping may be very hot. Wear protective
gloves
WARNING
After installing a new or serviced valve, perform an internal washing
cycle before using the piping for food liquids. If it there has been any
welding work, passivation treatment must be carried out.
EXAMPLE OF INTERNAL WASHING CYCLE (CIP)
Phases Temperature °C Washing product
Initial rinse Environment Chlorine- and chloride-free
water
Washing 70 °C Caustic soda (NaOH) at 1%
Intermediate rinse Environment Chlorine- and chloride-free
water
Washing 70 °C Nitric acid (HNO3) at 0.5%
End rinse Environment Chlorine- and chloride-free
water
Recommended washing product velocity = 2m/s
Risk of
stainless steel
corrosion
Risk of damage
elastomers
15

9 General maintenance
EN-IST-BBZS5-0420
9 General maintenance
1. MAINTENANCE PRECAUTIONS
Maintenance operations must be carried out by expert technicians
only.
CAUTION!
Maintenance operations must be carried out with the line stopped
and all utilities (electricity, compressed air) disconnected.
CAUTION!
Always discharge the fluid pressure in the valve and piping before
disassembling the valve.
CAUTION!
Burns hazard. The valves and piping may be very hot. Wear protective
gloves
16

9 General maintenance
EN-IST-BBZS5-0420
2. CLEANING AWAY DEPOSITS:
-Thoroughly wash and clean all the valve parts before disassembly;
-Pay attention to any possible detergent or other aggressive fluid
deposits (see "Cleaning");
-Always use protective safety glasses and gloves when required.
CAUTION!
Hand crushing hazard. During operation there is a risk of crushing
inside the valve body in the area between the actuator and the valve
body.
3. REPLACEMENT OF WORN VALVE PARTS:
Always use original spare parts
17

10 Scheduled maintenance
EN-IST-BBZS5-0420
10Scheduled maintenance
SCHEDULED MAINTENANCE VALVE GASKETS
Preventive Replace after 12 months
In the event of leaks Replace at the end of the day
Periodical Check correct operation and that there are no leaks
Record the actions carried out
18

11 Tools useful for Disassembly/Reassembly
EN-IST-BBZS5-0420
11Tools useful for Disassembly/Reassembly
TOOLS
Soft
19

1 2 Calibratablepneumaticby-passvalveBBZS5-BBYS5-BBWS51
EN-IST-BBZS5-0420
12Calibratable pneumatic by-pass valve BBZS5 -
BBYS5 - BBWS51
NO. DESCRIPTION
1 Lower body
2 Shutter
4 Sealing ring
9 Cylinder
10 Bush
11 Pin
12 Sealing ring
13 Piston
14 Sealing ring
16 Sealing ring
18 Buffer
23 Pin
24 Air connector
28 Valve member nut
31 Spring
33 Clamp
34 Screw
35 Assembly
40 Cap
45 Steam barrier
47 Sealing ring
50 Gasket holder disc
57 Sealing ring
67 Upper piston
77 Nut
87 Sealing ring
120 Bush
128 Membrane
156 Sealing ring
157 Sealing ring
168 Bush
207 Nut
209 Nut
238 Diaphragm nut
256 Metallic wire
274 Sealing ring
275 Sealing ring
286 Air connector
20