Bardiani BBZS1 Specification sheet

Instruction, Use and Maintenance Manual
BY-PASS VALVE
Bardiani Valvole S.p.A.
via G. di Vittorio, 50/52 - 43045 Fornovo di Taro (PR) - Italy
tel. [phone] - fax [phone]
[email protected] - www.bardiani.com
EN-IST-BBZS1-0621
BBZS1- BBYS1
BBWS11
(Translation of the Original Instructions in the italian Language)

EN-IST-BBZS1-0621
MANUAL REVISION DATE
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INDEX
1 Safety,Warning and Mandatory Signs 5
1.1 Formazione dell'operatore 8
2 Sicurezza 9
2.1 Precauzioni Generali di Sicurezza 9
2.2 Dispositivi di sicurezza 9
3 Technical Data 10
4 Checking / Unpacking / Lifting 11
5 Installation 12
6 Operation 14
7 Troubleshooting 15
8 Cleaning 16
9 Disposal 17
10 Maintenance 18
10.1 General maintenance 18
10.2 Scheduled maintenance 19
10.3 Tools useful for Disassembly/Reassembly 20
10.4 Manual valve BBZS1 - BBYS1 21
10.5 Disassembly of the BBZS1 - BBYS1 - BBWS11 23
A Disassembly of the BBZS1 - BBYS1 24
B Disassembly of the BBWS11 32
10.6 Assembly of the BBZS1 - BBYS1 - BBWS11 37
A Assembly of the BBZS1 - BBYS1 39
B Assembly of the BBWS11 48
11 Annexes 54
12 2D diagram BBZS1 55
13 2D diagram BBYS1 56
14 2D diagram BBWS11 57
15 Warranty 58
16 Recommendations 59
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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
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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EN-IST-BBZS1-0621
1 Safety,Warning and Mandatory Signs
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
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.
1
ASSEMBLY /
DISASSEMBLY
SEQUENCE
Sequence of assembly disassembly operations
OPTIONAL
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EN-IST-BBZS1-0621
1 Safety,Warning and Mandatory Signs
1.1 Formazione dell'operatore
Tutte le persone che dovranno operare sulla valvola devono avere la qualifica per svolgere
le mansioni di manutenzione sulla valvola.
Devono essere informati sui possibili pericoli e devono osservare le istruzioni sulla
sicurezza riportate in questo manuale.
Consentire solo a personale qualificato di agire sui componenti elettrici.
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2 Sicurezza
2 Sicurezza
2.1 Precauzioni Generali di Sicurezza
Destinazione d’uso
Le valvole Bardiani sono destinate esclusivamente per la movimentazione di fluidi.
Usi non consentiti
Non è previsto utilizzare la valvola:
• per operazioni diverse da quelle descritte al paragrafo “Destinazione d’uso”;
• per la movimentazione di fluidi diversi da quelli previsti dal fabbricante e indicate nei dati tecnici della
valvola.
• per la movimentazioni di fluidi con pressioni diverse da quelle previste dal fabbricante e indicate nei
dati tecnici della valvola.
Limitazioni sull’utilizzo della valvola
E' vietato:
• utilizzare la valvola in una configurazione costruttiva diversa da quella prevista dal fabbricante.
• utilizzare la valvola in luoghi a rischio di esplosione e/o incendio, se non previsto dal fabbricante (in
caso di valvole certificate ai sensi della Direttiva 2014/34/UE fare riferimento al Manuale Atex);
• integrare altri sistemi e/o attrezzature non considerati dal fabbricante nel progetto esecutivo;
• utilizzare la valvola per uno scopo diverso da quelli previsti dal fabbricante.
ATTENZIONE
La macchina non può essere utilizzata all'interno di locali con atmosfera a rischio di esplosione o incendio
se non previsto dal fabbricante (in caso di valvole certificate ai sensi della Direttiva 2014/34/UE fare
riferimento al Manuale Atex).
BARDIANI VALVOLE S.p.A. declina qualsiasi responsabilità
per installazione, uso e manutenzione non conformi a quanto
previsto dal presente manuale!
2.2 Dispositivi di sicurezza
(vedi manuale unità di controllo)
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3 Technical Data
3 Technical Data
VALVE DATA
Maximum pressure PN10
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, 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
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
La valvola è conforme alla Direttiva PED 2014/68/UE, con speciale riferimento all’
Allegato III, Modulo A riguardante il Controllo di fabbricazione interno come indicato
nelle Procedure di Valutazione della Conformità.
Le valvole con DN uguale o inferiore al DN25 non sono comprese conformemente all’Articolo 4 paragrafo 3.
Le valvole destinate a gas, gas liquidi, gas disciolti sotto pressione, vapore e quei liquidi la cui tensione di vapore
alla temperatura massima ammissibile è superiore di 0,5 bar alla pressione atmosferica normale (1.013 mbar) sono
comprese entro i seguenti limiti:
- le valvole con DN da 32 a 100 (compresi) con fluidi del gruppo 1;
- le valvole con DN uguale o superiore al DN125 con fluidi del gruppo 2.
Si rimanda all'utilizzatore finale l'esecuzione delle prove di emissione acustica una volta avvenuta l'installazione
della valvola nello stabilimento di destinazione.
In caso di qualsiasi dubbio di qualsiasi tipo, contattare Bardiani Valvole S.p.A.
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4 Checking / Unpacking / Lifting
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. The handle in the DN15 - DN100
sizes is made from plastic (POM-C). 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.
DN10 and DN150
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
5 Installation
1. PNEUMATIC SUPPLY:
-Use expert personnel for installation/uninstallation operations.
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.
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5 Installation
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.
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6 Operation
6. MINIMUM MAINTENANCE CLEARANCES:
Make sure there is enough room around the valve for it to be
disassembled.
DN BBZS1
A (mm)
BBYS1
A (mm)
10-25 245 245
32-40 265 265
50 280 280
65 295 295
80 310 310
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.
6 Operation
1. PNEUMATIC SUPPLY:
-Use expert personnel for installation/uninstallation operations.
A = Valve opening
B = Valve closing
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A A
A B

EN-IST-BBZS1-0621
7 Troubleshooting
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
Operating conditions
Difficulty opening and closing
Incorrect valve body positioning.
Disassemble and correctly
reposition the valve body.
Disassemble and correctly
reposition the valve body
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8 Cleaning
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
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9 Disposal
9 Disposal
At the end of its service life, the device must be recycled in accordance with the legislation in force in the
country of valve use.
Any hazardous residues must be taken into consideration and adequately handled.
The valve is made of AISI 316L and AISI 304 stainless steel, elastomers (gaskets), plastic (control unit)
and electrical components (terminal boards, solenoid valves, sensors).
Adhere to the following steps before disconnecting the valve and refer to the heading "General
Maintenance".
-make sure the line on which the valve is installed in is not in use
-empty the line on which the valve is installed and clean if necessary
-disconnect the air supply if it is not required during dismantling
-disconnect the valve from the power supply
-remove the valve from the system
-move the valve in observance of the rules set out in the heading "Lifting"
-to dismantle the valve, refer to the heading "Disassembly"
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10 Maintenance
10Maintenance
10.1 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
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10 Maintenance
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.
3. SOSTITUZIONE PARTI USURATE DELLA VALVOLA:
Utilizzare sempre ricambi originali.
10.2 Scheduled 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
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10 Maintenance
Soft
10.3 Tools useful for Disassembly/Reassembly
TOOLS
20