Bardiani BYAW3 Specification sheet

Instruction, Use and Maintenance Manual
MIXPROOF 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-BZAW3-0123
BZAW3
BYAW3
BWAW3
(Translation of the Original Instructions)

2EN-IST-BZAW3-0123
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 Electrical device 9
3 Technical data 10
4 Checking / Unpacking / Lifting 11
5 Installation 13
6 Operation 16
7 Troubleshooting 17
8 Cleaning 18
9 Disposal 20
10 Maintenance 21
10.1 General maintenance 21
10.2 Scheduled maintenance 22
10.3 Tools useful for Disassembly/Reassembly 23
10.4 Mixproof Valve BZAW3 24
10.5 Disassembly of the BZAW3 - BWAW3 26
A Disassembly of the BZAW3 28
B Disassembly of the BWAW3 40
10.6 Assembly of the BZAW3 47
A Assembly of the BZAW3 51
B Assembly of the BWAW3 59
10.7 Mixproof Valve BZAW3 Diverter 65
10.8 Disassembly of the BZAW3 Diverter 68
10.9 Assembly of the BZAW3 Diverter 85
A Assembly of the BZAW3 Diverter 89
B Assembly of the BZAW3 PTFE diverter 96
11 Annexes 103
12 2D diagram BZAW3 104
13 2D Diagram BYAW3 105
14 2D Diagram BWAW3 106
15 2D diagram BZAW3 M8 107
16 2D diagram BYAW3 M8 108
17 2D diagram BZAW3 Diverter 109
18 2D Diagram BYAW3 Diverter Steam Barrier 110
19 2D Diagram BZAW3 M8 Diverter (PTFE) 111

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MANUAL REVISION DATE
20 Warranty 112
21 Recommendations 113

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FOREWORD
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.

5
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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

6EN-IST-BZAW3-0123
1 Safety,Warning and Mandatory Signs
MANDATORY SIGNS (FOR THE OPERATOR IN CHARGE OF MECHANICAL MAINTENANCE
AND THE OPERATOR IN CHARGE OF ASSEMBLY/DISASSEMBLY)
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
PRESS Use of a press

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1 Safety,Warning and Mandatory Signs
OPERATING SIGNS
Pictogram Description Notes
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
PLUG INSERTION Insertion of the plug in the three-way connector when air is
connected to the valve.
DO NOT CONNECT
AIR
Don't connect compressed air
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
MULTI-PURPOSE
GREASE
Use AGIP GREASE MU EP 2 SE or similar
THREADLOCK
APPLICATION
Use SPEED BOND M500 threadlock or similar
1
ASSEMBLY /
DISASSEMBLY
SEQUENCE
Sequence of assembly disassembly operations
OPTIONAL

8EN-IST-BZAW3-0123
1 Safety,Warning and Mandatory Signs
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
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 and indicated in the valve's
technical data.
• 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 Electrical device
(see the control unit manual)

10 EN-IST-BZAW3-0123
3 Technical data
3 Technical data
VALVE DATA
Maximum pressure 10 bar
Maximum seal pressure See catalogue
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 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 (266°F)
Gaskets material FKM
PNEUMATIC ACTUATOR DATA
Connectors 1/8” BSP
Pipe dimensions 6 mm external diameter, 4 mm internal diameter
Air pressure from 6 bar (87 psi) to 8 bar (116 psi)
Air quality Class 2, 4, 3 ISO8573-1
External material AISI 304L (1.4307)
Seals NBR
Noise levels 76 dB
Electrical supply See Giotto Top
GASKET MATERIALS COMPATIBILITY
Product EPDM FKM HNBR
Temperature (applications with air) from -10°C to +140°C from -10°C to +200°C from -10°C to +130°C
Caustic soda 2% 60°C 30°C To be checked
Nitric Acid 2% 60°C 80°C To be checked
Saturated steam 125°C Suitable To be checked Suitable
Greases Unsuitable Suitable Suitable
Alcohols Suitable Unsuitable 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
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.

12
A
B B
EN-IST-BZAW3-0123
4 Checking / Unpacking / Lifting
CAUTION!
The figures above are used purely to represent the methods and procedures for hoisting the valves.
Handle the device according to the regulations in force in the country of use.
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.
3. VALVE LIFTING:
Take care as to the type of valve you are handling. Based on the size
there are 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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5 Installation
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");
-Check the power supply to the control unit is correct (consult the
relative instruction manual).
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.

14
A A A
B
C
EN-IST-BZAW3-0123
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.
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 (with the control unit installed).
BZAW3
Valve
dimension
(DN)
A (mm) B (mm) C (mm)
25 225 130 60
40 225 150 60
50 285 155 60
65 300 155 60
80 315 155 60
100 330 155 60
125 350 250 60
150 350 250 60
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
7.PREPARING THE VALVE FOR INSTALLATION:
To move the valve (dn125-dn150), first screw in the eye bolts.
Once valve installation has been completed, remove the eyebolts and put the screws back in.

16
A
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6 Operation
6 Operation
1. VALVE INSPECTION BEFORE OPERATION:
-Supply air to the actuator;
-Power the valve (via the control unit);
-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.

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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
Too many commands active
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
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
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
8 Cleaning

19
A
B C
A
EN-IST-BZAW3-0123
8 Cleaning
2. INTERMEDIATE CHAMBER CLEANING
Close the valve.
Clean and sterilize the intermediate chamber and the
body of the auxiliary valves.
A=Product
B=CIP/ Steam inlet
C=CIP / Steam outlet
Open the valve
Clean the valve body and remove any leakage residues
from the auxiliary valves.
A=CIP
Operations to be performed:
ALWAYS read the technical data indicated in Chapter 3
ALWAYS release the compressed air after use
NEVER touch the assembly or the actuator pin when the cylinder is connected to the compressed
air supply.
NEVER touch the piping when using hot products or during sterilization procedures.
ALWAYS handle caustic soda and acid with great care.
ALWAYS keep the cleaning pressure below the product pressure.
NEVER deform the auxiliary valve outlet pipe.

20 EN-IST-BZAW3-0123
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"