Bardiani BBZS5 Manual

OPERATING AND MAINTENANCE INSTRUCTIONS
By-pass settable pneumatic valve
BBZS5 - BBYS5
GB-IST-BBZS5-0312

(GB-IST-BBZS5-0312) 2/22
BARDIANI VALVOLE reserves the right to modify without notice its products, including products already ordered.
Table of Contents
1. Safety /Caution Signs .............................................................................................. 3
2. General Safety Precautions ..................................................................................... 3
3. Receiving/Unpacking/Storage.................................................................................. 4
4. Installation................................................................................................................ 5
5. Operation ................................................................................................................. 6
6. Troubleshooting ....................................................................................................... 6
7. Cleaning................................................................................................................... 7
8. General Maintenance............................................................................................... 8
9. Planned Maintenance .............................................................................................. 8
10. Spare parts order form............................................................................................. 9
11. Disassembly of the BBZS5 - BBYS5 valve............................................................. 10
Drawing BBZS5 - BBYS5......................................................................................... 14
14. Assembly of the BBZS5 - BBYS5 valve.................................................................. 17
13. Parts List .................................................................................................................. 20
14. Technical Data ......................................................................................................... 21
Warranty................................................................................................................... 22
Disclaimer ................................................................................................................ 22
Foreword
This instruction manual is an integral part of the valve delivery.
•To use the Atex valve model is obligatory to consult the appropriate manual.
• Always read it carefully before using the valve.
• Always keep it for future reference.
All rights are reserved. It is forbidden to reproduce or transit any part of the instruction manual by any means,
either electronic or mechanical, including photo copies, recording or any other memorisation or retrieval system
for purposes other than the exclusively personal use by the purchaser – without prior written permission by the
manufacturer.
This instruction manual is expressly intended for use by technicians. Therefore, some information which can easily
be inferred by reading the text and examining the illustrations and drawings has not been further specied. The
publisher is not responsible for any consequences of incorrect operations by the user.
The data and information in this instruction manual are subject to modications or updates without any further
notice or obligations on the part of the manufacturer.

BARDIANI VALVOLE reserves the right to modify without notice its products, including products already ordered. (GB-IST-BBZS1-0312)3/22
1. Safety/Caution Signs
2. General Safety Precautions
NOTE!
General WARNING sign, which indicates that special instructions MUST be
followed to avoid serious personal injuries.
General CAUTION sign, which indicates that special instructions MUST be
followed to avoid damage of equipment and environment.
Indicates IMPORTANT information, which improves the understanding of the
instructions.
ALWAYS read the technical data before installation, operation and maintenance.
ALWAYS use authorised personnel to install, operate and service the valve. The personal should
know the valve and the instruction manual thoroughly.
ONLY use the valve for the designed purpose.
ALWAYS handle heavy valves carefully and use lifting tools where necessary.
ALWAYS pay attention to possible loose valve parts when unpacking the delivery.
NEVER touch moving valve parts.
NEVER touch a hot valve.
ALWAYS handle cleaning agents carefully.
NEVER remove a valve from piping or disassemble it when the valve or piping are pressurised.
We cannot be held liable for incorrect installation,
operation and maintenance!

B
A
BBZS5 BBYS5
(GB-IST-BBZS5-0312) 4/22
BARDIANI VALVOLE reserves the right to modify without notice its products, including products already ordered.
3. Receiving/Unpacking/Storage
ATTENTION!
- Openings
Packing
material
Valve
safety
guards!
1. UNPACK AND CHECK VALVE
DELIVERY:
A. Complete valve.
B. Instruction Manual.
2. IDENTIFY VALVE TYPE SUPPLIED:
BBZS5: by pass settable pneumatic valve
BBYS5: by-pass settable pneumatic valve with steam barrier
3. LIFTING OF WEIGHY VALVES:
- Use lifting tool, if necessary.
- Fix the valve to lifting tool.
4. HANDLING OF LOOSE VALVE PARTS:
- Avoid falling loose valve parts
- Assemble and tighten loose valve parts.
5. PACKING MATERIAL:
- Inspect the interior of the valve.
- Remove material and dispose of
according to current directives.
6. INSPECTION/CLAIMS:
- Document/check for damage, missing
or wrong parts.
- Follow current claim procedures, if
necessary.
7.STORAGE /PROTECTION:
- Avoid dust, humidity, wet areas,
heat etc.
- Avoid vibration.
- Min.: - 10 °C
- Max.: + 50 °C

BBZS5 BBYS5
A A
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4. Installation
Manual
Valve
1. AVOID VALVE OVERLOADING AND COMPENSATE FOR:
- Vibration
- Thermal expansion
2. CORRECT FLOW DIRECTION:
- If possible, have ow against valve closing direction to
avoid or minimise water hammer.
3. VALVE CONNECTIONS/UNIONS:
- Ensure tight connections between valve and piping.
- Remember gaskets and t correctly.
- Tighten unions rmly and carefully.
4. WELDING VALVE BODY INTO PIPING:
- Remove inner valve parts.
- Weld body carefully into piping.
- Assemble valve.
- See assembly instructions.
5. INSTALLING VALVE INTO PIPING:
- Ensure sufcient clearance for valve disassembly.
VALVE SIZE BBZS5
A (mm)
BBYS5
A (mm)
DN10-25 270 270
DN32-40 295 295
DN50 310 310
DN65 330 330
DN80 350 350
DN100 370 370

BBZS5 BBYS5
(GB-IST-BBZS5-0312) 6/22
BARDIANI VALVOLE reserves the right to modify without notice its products, including products already ordered.
5. Operation
2. HOT VALVE/PIPING
- Never touch hot valve or piping, if possible.
- Alternatively use protective gloves.
RISK of scalding
Problem Possible cause Possible remedy
External leakage
Worn out gasket Replace gasket
Internal leakage withh closed
valve, caused by normal wear
External leakage
Too high pressure
Replace with gasket of different elastomer type
Too high temperature
Internal leakage with closed valve
occurring earlier than normal wear
Aggressive uids
Modify operation conditions
Too many active control
Difcult opening and closing
Incorrect elastomer type of ga-
skets Replace with gasket of different elastomer type
Incorrect positioning of actuator Assemble actuator correctly
Incorrect operation of actuator Change from normally open (NO) to normally
closed (NC) or vice versa
Dirt in actuator Check and service actuator
Incorrect positioning of valve body Disassemble and reposition valve body
6. Troubleshooting
1. TROUBLESHOOTING VALVE:
Always study operation and maintenance
instructions carefully before troubleshooting.
2. REPLACING WORN VALVE PARTS:
- See page 9 for spare parts ordering.
Check and
replace gaskets!
Corrosion risk of
stainless steel!
1. ONLY USE VALVE FOR DESIGNED PURPOSE
BBZS5: by pass settable pneumatic valve
BBYS5: by-pass settable pneumatic valve with steam barrier

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RISK of scalding
Risk of
corrosion
stainless steel
1. CLEANING VALVE WITH CLEANING AGENTS:
- Use authorised personnel to clean the valve.
- Observe concentrations of cleaning agents.
- Follow instructions of cleaning agent suppliers.
- Always use protective goggles and gloves
2. HOT VALVE/PIPING:
- Never touch hot valve or piping, if possible.
- Alternatively use protective gloves
3. HANDLING OF CLEANING AGENTS:
- Dose cleaning agents regularly to avoid excessive
concentration.
- Always rinse carefully with clean water after cleaning.
- Check compatibility of valve materials.
Risk of
damaging the
elastomers
7. Cleaning
Example of suggested CIP
Step Temperature °C Cip product
First rinsing Atmosphere Water without chlorine or
chlorids
Washing 70° Soda (NaOH) at 1%
Intermediate washing Atmosphere Water without chlorine or
chlorids
Washing 70° Nitric acid (HNO3) at 0,5%
Final rinsing Atmosphere Water without chlorine or
chlorids
Recommended claning speed = 2 m/s

(GB-IST-BBZS5-0312) 8/22
BARDIANI VALVOLE reserves the right to modify without notice its products, including products already ordered.
8. General Maintenance
9. Planned Maintenance
3. CLEANING OF DEPOSITS
- Wash and clean all valve parts thoroughly before disassembly and
assembly!
- Pay attention to possible deposits of cleaning agents and other ag-
gressive uids!
- Always use protective goggles and gloves, if necessary.
Wash and
clean!
4. REPLACING WORN VALVE
PARTS:
- Always use original pare parts.
- See page 9 for spare parts ordering.
Planned maintenance Valve gaskets
Preventive Replace after 12 months
In case of leak Replace at the end of the day
Periodical
Check for proper operation and make sure
there are no leaks
Record all actions
1. PRESSURISED VALVE/PIPING:
- Always release uid pressure from valve and piping
before disassembling the valve.
2. HOT VALVE/PIPING:
- Never touch hot valve or piping, if possible.
- Alternatively use protective gloves.
RISK of scalding

BARDIANI VALVOLE reserves the right to modify without notice its products, including products already ordered. (GB-IST-BBZS1-0312)9/22
10. Spare Parts Ordering Form
NOTE!
Please copy this page, ll it out and fax it to below address.
To:
BARDIANI VALVOLES S.P.A. – Ufcio Ricambi
Fax: [phone]
From:
Valve type:
Serial number:
Month/year of purchase:
Shipping instructions:
Quantity: Position No.:
Description:
Quantity: Position No.:
Description:
Quantity: Position No.:
Description:
Quantity: Position No.:
Description:
Quantity: Position No.:
Description:

33
1
2
14
14
28
2
24 24
120
50
157
156
9
45
168
47
57
47
168
33
50
45
35
(GB-IST-BBZS5-0312) 10/22
BARDIANI VALVOLE reserves the right to modify without notice its products, including products already ordered.
2. Remove clamp (33) and body (1).
1. Fix the guide bushing (17)
through 2 screw M6x10 and sup-
ply air to tting (24).
3. Release air pressure to air tting
(24).
Air
Air
Air
24
Air
2
Counterhold!
9
14
35
34
7
8
6
157
156
120
138
1
33
14
28
Air
24
Air
2
Counterhold!
9
14
35
34
7
8
6
157
156
120
138
1
33
14
28
6. P.T.F.E. SHUTTER:
Unscrew shutter nut (28) and remove
shutter ring (14).
5. Remove shutter ring (14) to
the shutter (2).4. Unscrew shutter (2).
7. Reassemble in sequence, the
pivot (11), the spring (31), the adju-
sting sleeve (5) and the cap (26) in
to the part assembly part(15).
11. Disassembly of the BBZS5 - BBYS5
8. BBYS5. Remove the clamp (33)
between steam barrier (45) and
assembly (35). Remove the cap (50).
9. BBYS5. Remove seal rings (47,
57) and bushing (168) from steam
barrier (45).

35
34
277
17
276
157
50
156
9
207
77
Air
24
Air
2
Counterhold!
9
14
35
34
7
8
6
157
156
120
138
1
33
14
28
9
31
67
87
16
18
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11. Remove screws (34) and assembly (35).
10. Remove seal rings (156 and 157) from cap (50).
11. Disassembly of the BBZS5 - BBYS5
12. Remove screws M6x10 and guide bushing from the cylinder
(17) with a suitable tool. Remove seal rings (277 e 276).
13. Unscrew the socket screw (77) and re-
move from the cylinder (9) the nut (207).
14. Unscrew from the cylinder (9) il tampone (18), pay attention to the preload of the spring and then remove
the spring (31) and the upper piston (67). Remove the seal rings (87,16).

209
11
209
12
4
11
13
256
11
13
9
18
20
20
9
18
9
67
256
(GB-IST-BBZS5-0312) 12/22
BARDIANI VALVOLE reserves the right to modify without notice its products, including products already ordered.
11. Disassembly of the BBZS5 - BBYS5
18. CYLINDER 108-134:
Remove elastic thread (20) by rotating plug (18) until the end part of
the elastic thread is visible through cylinder slot (9). Pull out completely
the end part by a pointed tool.
COUNTERHOLD!
15. Remove the Snap ring (256)
and the pivot (13-11), to cylinder
(9).
16. Unscrew the nut (209)
counterholding the pivot (11)
with an allen wrench.
17. Unscrew the nut (209) from the piston
(11-13). Remove the seal rings (4,12).
20. CYLINDER 108-134:
Using a press with a plug specially made for the operation (A) preload the spring on
the piston upper (67) and remove the seeger (256).
This operation must be carried out with great care by a
specialised person.
19. CYLINDER 108-134:
Remove plug (18) to the cilinder (9).

256
87
67
31
11
9
97
4
12
13
11
209
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11. Disassembly of the BBZS5 - BBYS5
21. CYLINDER 108-134:
Gradually reduce the press force exer
cised by the device (A) on the spring
(31),Remove the plate (67), seal rings (87) and
spring (31). Remove the lower seeger (256). 22. CYLINDER 108-134:
Remove from the cylinder (9) the pivot (11).
COUNTERHOLD!
23. CYLINDER 108-134:
Unscrew the nut (209) from the pivot-piston(11-13) counterhold the pivot with an allen wrench. Remove the seal
rings(12,4) and the guide bushing (97) from the piston (13).

(GB-IST-BBZS5-0312) 14/22
BARDIANI VALVOLE reserves the right to modify without notice its products, including products already ordered.
11. Disassembly of the BBZS5 - BBYS5
BBZS5 cyl.83
P.T.F.E. SHUTTER

BARDIANI VALVOLE reserves the right to modify without notice its products, including products already ordered. (GB-IST-BBZS1-0312)15/22
P.T.F.E. SHUTTER
BBYS5
11. Disassembly of the BBZS5 - BBYS5

(GB-IST-BBZS5-0312) 16/22
BARDIANI VALVOLE reserves the right to modify without notice its products, including products already ordered.
P.T.F.E. SHUTTER
BBZS5 cyl. 108-134
11. Disassembly of the BBZS5 - BBYS5

11
9
209
11
12
4
13
256
11
13
9
Air
24
Air
2
Counterhold!
9
14
35
34
7
8
6
157
156
120
138
1
33
14
28
9
31
67
87
16
18 97
4
12
13
11
87
31
67
256
9
209
13
BARDIANI VALVOLE reserves the right to modify without notice its products, including products already ordered. (GB-IST-BBZS1-0312)17/22
6. CYLINDER 108-134:
Put the pivot (11) into the cylinder (9).
1. Insert to the piston (13) the
seal ring (4 and 12).
3. Insert into the cylinder (9) the pivot
piston (11-13) and the seeger (256).
COUNTERHOLD!
COUNTERHOLD!
2. Assemble the piston (13) on
the pivot (11)and screw the nut
(209) counterholding the pivot
(11) with an allen wrench.
4. Assemble the seal ring (87) on the upper piston (67).Insert into
the cylinder (9) the spring (31) and the upper piston (87). Assmbly
the seal ring (16) on the stopper (18) and paying attention to the
preload of the spring, screw the stopper (18) on the cylinder (9).
5. CYLINDER 108-134:
Insert the seal rings (4,12) and the guide
bushing (97) on the piston (13), block the
piston with the nut (209) on the pivot (11),
counterholding the pivot with an allen wrench.
7. CYLINDER 108-134:
Assembly on the cylinder (9) the seeger (256) and insert the
spring (31). Assembly on the upper piston (67)the seal ring
(87) and insert them inside the cylinder (9).
12. Assembly of the BBZS5 - BBYS5

67
256
18
20
20
9
18
9
35
34
120
50
157
156
9
277
17
276
9
9
(GB-IST-BBZS5-0312) 18/22
BARDIANI VALVOLE reserves the right to modify without notice its products, including products already ordered.
*Lubricate elastomers with a product suitable for food contact
13. Insert seal rings (156 e
157)* and guide bushing (120)*
into the cap (50). Fit the cap on
the cylinder (9).
12. Fit assembly (35) to
cylinder (9) with screws
(34).
11. Insert seal rings (276 and 277) on the guide bushing
(17) and assembly them on the cylinder (9)
10. CYLINDER 108-134:
Position the retaining ring (20) in the plug (18)
through the cylinder slot (9). Rotate the plug until it
is completely inserted.
8. CYLINDER 108-134:
Insert the upper seeger (256) making sure it is
correctly seated.
Remove with caution the pressure
excerted on the upper piston (67).
14. Assembly of the BBZS5 - BBYS5
9. CYLINDER 108-134:
Insert the plug (18) to the cilinder (9).

2
24
2
14
14
14
28
24
33
1
35
33
50
45
35
157
50
156
45
168
47
57
47
168
BARDIANI VALVOLE reserves the right to modify without notice its products, including products already ordered. (GB-IST-BBZS1-0312)19/22
20. Release air pressure to air tting (24).
22. Assemble body (1) and part
assembly (35) with clamp (33).
21. Supply air to tting (24).
Air
24
Air
2
Counterhold!
9
14
35
34
7
8
6
157
156
120
138
1
33
14
28
19. Screw shutter (2)
into cylinder pivot (9).
*Lubricate elastomers with a product suitable for food contact
17. Pre-heat shutter ring (14*) to approx. 80°C to
make it softer and insert it in shutter slot (2). Insert
the ring in a crosswise manner using a plastic cylin-
drical tool.
18. PTFE SHUTTER:
Assemble the P.T.F.E. seal
ring (14) on the shutter (2)
and the shutter nut (28).
14. Assembly of the BBZS5 - BBYS5
Air Air
16. BBYS5. Insert steam barrier (45)
into the assembly (35) with clamp (33)
and the cap (50).
15. BBYS5. Insert seal rings
(47, 57)* and bushing (168)
into steam barrier (45).
14. BBYS5. Insert seal rings (156, 157)*
into the cap (50).
Air
24
Air
2
Counterhold!
9
14
35
34
7
8
6
157
156
120
138
1
33
14
28

(GB-IST-BBZS5-0312) 20/22
BARDIANI VALVOLE reserves the right to modify without notice its products, including products already ordered.
13. Spare Parts List
N° Description N° Description
1 Lower body 156 Seal ring
2 Shutter 157 Seal ring
4 Seal ring 168 Guide bushing
9 Cylinder 207 Nut
10 Guide bushing 209 Nut
11 Pivot 256 Snap ring
12 Seal ring 274 Seal ring
13 Piston 275 Seal ring
14 Seal ring
16 Snap ring
18 Stopper
24 Air tting
28 Shutter nut
31 Spring
33 Clamp
34 Socket screw
35 Part assembling
40 Plug
45 Steam barrier
47 Seal ring
50 Cap
57 Seal ring
67 Piston upper
77 Socket screw
97 Guide bushing
120 Guide bushing