Bardiani BBZK User manual

Instruction, Use and Maintenance Manual
MODULATING 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-BBZK-0721
BBZK - BBYK -
BBWK1
(Translation of the Original Instructions in the italian Language)

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EN-IST-BBZK-0721
MANUAL REVISION DATE

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EN-IST-BBZK-0721
INDEX
1 Safety,Warning and Mandatory Signs 5
1.1 Operator training 8
2 General safety warnings 9
2.1 General safety warnings 9
2.2 Safety Devices: 9
3 Technical data 10
4 Checking / Unpacking / Lifting 11
5 Installation 13
6 Operation 26
7 Troubleshooting 27
8 Cleaning 28
9 Disposal 29
10 Maintenance 30
10.1 General maintenance 30
10.2 Scheduled maintenance 31
10.3 Tools useful for Disassembly/Reassembly 32
10.4 Modulating valve BBZK - BBYK - BBWK1 33
10.5 Disassembly of the BBZK - BBYK - BBWK1 35
A Disassembly of the BBZK - BBYK 36
B Disassembly of the BBWK1 42
10.6 Assembly of the BBZK - BBYK - BBWK1 48
A Assembly of the BBZK - BBYK 49
B Assembly of the BBWK1 57
10.7 Modulating valve BBZK - BBYK Diverter 65
10.8 Disassembly of the BBZK - BBYK - Diverter 67
10.9 Assembly of the BBZK - BBYK Diverter 75
11 Annexes 87
12 2D diagram BBZK 88
13 2D diagram BBYK 89
14 2D diagram BBWK 90
15 2D diagram BBZK Diverter 91
16 2D diagram BBYK Diverter 92
17 Warranty 93
18 Recommendations 94

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EN-IST-BBZK-0721
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
of a specic manual is mandatory.
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.

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1 Safety,Warning and Mandatory Signs
EN-IST-BBZK-0721
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
Never touch the moving parts if the actuator is supplied
with compressed air
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-BBZK-0721
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-BBZK-0721
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 grease or similar
2APPLICATION
OF FOODSAFE
GREASE
Use FOODLUBE Multi-paste grease or similar
APPLICATION OF
MULTIPURPOSE
GREASE
Use AGIP GREASE MU EP 2 SE or similar
THREADLOCK
APPLICATION
Use SPEED BOND M500 threadlock or similar
AIR PRESSURE Refer To A table on page 10, Section Called " Pneumatic
actuator pressure range"
1
ASSEMBLY /
DISASSEMBLY
SEQUENCE
Sequence of assembly disassembly operations
OPTIONAL

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1 Safety,Warning and Mandatory Signs
EN-IST-BBZK-0721
1.1 Operator training
All persons who have to work on the valve must be qualified to carry out the relative
maintenance tasks. They must be informed as to the possible hazards involved and must
observe all the safety instructions set out in this manual. Allow expert personnel only to
work on the electrical components.

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2 General safety warnings
EN-IST-BBZK-0721
2 General safety warnings
2.1 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 risk
of fire unless otherwise stated by the manufacturer (in the case of valves certified in accordance with
Directive 2014/34/EU please refer to the ATEX Manual).
BARDIANI VALVOLE S.p.A. declines all liability for installation,
use or maintenance which fails to comply with the indications
provided in this manual!
2.2 Safety Devices:
(see the control unit manual)

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3 Technical data
EN-IST-BBZK-0721
3 Technical data
VALVE DATA
Maximum pressure 10 bar
Maximum seal pressure See catalogue
Pneumatic actuator pressure range
3 - 15 psi (0.21 - 1.05 bar)
6 - 18 psi (0.42 - 1.25 bar)
6 - 30 psi (0.42 - 2.07 bar)
9 - 32 psi (0.62 - 2.21 bar)
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, P.T.F.E. 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
Pneumatic actuator stroke 15 - 20 mm
VAPOUR BARRIER DATA
Connectors 1/8” BSP
Steam maximum temperature 130°C
Gaskets FKM
GASKET MATERIALS COMPATIBILITY
Product EPDM FKM HNBR MVQ
Temperature (applications with air) from -10 to 140°C from -10 to 200°C from -10 to 130°C from -70 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.
The end user is asked to carry out the acoustic emission tests once the valve has been installed in the destination
plant.
In the event of any doubt, please contact Bardiani Valvole S.p.A.

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4 Checking / Unpacking / Lifting
EN-IST-BBZK-0721
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. Based on the size
there are two different lifting procedures.
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.

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A B
4 Checking / Unpacking / Lifting
EN-IST-BBZK-0721
BBZK
Size
DN
Lifting method
10-25 A
40 A
50 A
65 A
80 B
100 B
125 B
150 B
Weight between 25 kg and
50 kg
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.

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5 Installation
EN-IST-BBZK-0721
5 Installation
Once valve installation has been completed, remove the eyebolts and put the Air connection back in
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.

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A
B
B
A
7
9
10
8
6
- 4-20 mA
+ 4-20 mA
5 Installation
EN-IST-BBZK-0721
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 = Pneumatic power supply
B = Air discharge
Check the correct feed pressure on the valve head
2. CONNECTIONS
Actuator
Air In (6 bar)
NO
NC

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5 Installation
EN-IST-BBZK-0721
3. CORRECT VALVE STEM ADJUSTMENT
DN
PNEUMATIC ACTUATOR
NC NO
T200
3-15psi
T200
6-30psi
T275
3-15psi
T275
9-32psi
T360
3-15psi
T360
9-32psi
T200
6-18psi
T275
3-15psi
T360
3-15psi
L
3,2 32 32 32 32 32 32 28 28 28
4,7 32 32 32 32 32 32 28 28 28
6,3 32 32 32 32 32 32 28 28 28
9,5 32 32 32 32 32 32 28 28 28
12,7 32 32 32 32 32 32 28 28 28
19 32 32 32 32 32 32 28 28 28
25 30 30 30 30 30 32 34 30 -
32 36 36 35 35 - - - 35 35
40 36 36 35 35 35 - 36 35 35
50 35 35 36 36 35 35 - 35 35
2"1/2 - - 24 24 24 24 - 24 24
65 - - 24 24 24 28 - 24 24
3" - - 31 31 30 30 - 31 30
80 - - 31 31 30 30 - 31 30
100 - - 36 36 36 36 - 37 37

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5 Installation
EN-IST-BBZK-0721
4. CORRECT PNEUMATIC ACTUATOR STEM ADJUSTMENT
DN
PNEUMATIC ACTUATOR
NC NO
T200
3-15psi
T200
6-30psi
T275
3-15psi
T275
9-32psi
T360
3-15psi
T360
9-32psi
T200
6-18psi
T275
3-15psi
T360
3-15psi
L
3,2 66 66 66 66 66 66 47 47 47
4,7 66 66 66 66 66 66 47 47 47
6,3 66 66 66 66 66 66 47 47 47
9,5 66 66 66 66 66 66 47 47 47
12,7 66 66 66 66 66 66 47 47 47
19 66 66 66 66 66 66 47 47 47
25 64 64 64 64 66 66 41 45 -
32 63 63 68 68 64 - - 40 39
40 63 63 71 68 64 - 40 40 39
50 63 63 68 68 64 64 - 40 40
2"1/2 - - 66 66 68 68 - 39 39
65 - - 66 66 68 68 - 38 38
3" - - 67 67 66 66 - 39 39
80 - - 67 67 66 66 - 39 39
100 - - 64 64 64 64 - 39 39

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5 Installation
EN-IST-BBZK-0721
DN
PNEUMATIC ACTUATOR
NC NO
T200
3-15psi
T200
6-30psi
T275
3-15psi
T275
9-32psi
T360
3-15psi
T360
9-32psi
T200
6-18psi
T275
3-15psi
T360
3-15psi
L
3,2 125 120 120 120 120 120 136 136 136
4,7 120 120 120 120 120 120 136 136 136
6,3 125 120 120 120 120 120 136 136 136
9,5 120 120 120 120 120 120 136 136 136
12,7 120 120 120 120 120 120 136 136 136
19 120 120 120 120 120 120 136 136 136
25 115 120 120 120 120 120 136 136 -
32 115 115 115 115 - - - 122 122
40 115 115 115 115 115 - - 122 122
50 115 115 115 115 115 115 - 122 122
2"1/2 - - 115 115 115 115 - 122 122
65 - - 115 115 115 115 - 122 122
3" - - 115 115 115 115 - 122 122
80 - - 115 115 115 115 - 122 122
100 - - 115 115 115 115 - 122 122
5. CORRECT SIEMENS POSITIONER FASTENING

18
noini
2 8.8p
sdir
7
fall
1
2
5 Installation
EN-IST-BBZK-0721
6. SIEMENS POSITIONER SELF-CALIBRATION
This procedure must be carried out each time the positioner is installed.
Turn on the electrical and pneumatic power supply to the positioner
Press and hold to enter programming mode
If a NA head is being used, proceed to next step, otherwise skip to point
(4)
Press to reach parameter 7 (SDIR).
Press to set it to FALL

19
vdir
38
fall
ycls
39
up do
3
4
5
4 inita
n o
5 Installation
EN-IST-BBZK-0721
Press to reach parameter 38 (YDIR).
Press to set it to FALL
Press to reach parameter 39 (YCLS).
Press to set it to uP do
Press to go back to parameter 4 (INITA).

20
4
p 53.7
d O U
5
6
7
4 inita
s
5 Installation
EN-IST-BBZK-0721
Press and hold until self-calibration commences
If the positioner stops with the message
Move the ring nut indicated in the figure using a screwdriver