Bardiani GIOTTO TOP Specification sheet

Instruction, Use and Maintenance Manual
CONTROL UNITS
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
GB-IST-GIOT360-0816
GIOTTO TOP®

Instruction, Use and Maintenance Manual
GB-IST-GIOT360-0816
MANUAL REVISION DATE
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Instruction, Use and Maintenance Manual
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INDEX
1 Safety,Warning and Mandatory Signs 5
2 General safety warnings 6
3 Technical Data 7
4 Giotto Top®Installation 8
5 Giotto Top®Pneumatic connections 10
6 Giotto Top®Electrical connections 13
7 Giotto Top®Control unit 16
8 Giotto Top®Assembly / Disassembly 17
9 Troubleshooting 21
10 Maintenance and Cleaning 22
11 Ce Certificate 23
12 Warranty 24
13 Recommendations 25
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Instruction, Use and Maintenance Manual
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INTRODUCTION
This “Instruction, Use and Maintenance Manual” has been drawn up expressly for expert
technical personnel. Consequently any information which can easily be deducted from reading
the text and/or examining the illustrations and/or drawings provided herein shall not be the
object of further explanation.
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.
(Translation of the Original Instructions in the italian Language)
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Instruction, Use and Maintenance Manual
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1 Safety,Warning and Mandatory Signs
SIGNALS
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.
OBLIGATION
General
Special instructions must be followed to avoid injury to
persons.
PERSONAL
PERSONNEL
Dismantling/Assembling and maintenance operations
must be carried out by expert technicians only.
NOTE Follow the indicated note with care
ELECTRICAL
CONNECTION
Electrical connection to the control unit
ELECTRICAL
DISCONNECTION
Electrical disconnection from the control unit
PNEUMATIC
CONNECTION
Compressed air connection to the control unit
PNEUMATIC
DISCONNECTION
Compressed air disconnection from the control unit
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Instruction, Use and Maintenance Manual
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2 General safety warnings
The control unit has been designed to control the pneumatically controlled process valves manufactured
by Bardiani Valvole S.p.A.. It is possible to fit the Giotto Top® with a maximum of three solenoid valves
for controlling the process valve and up to a maximum of four inductive sensors, including an external
one for controlling the position.
For the electrical connections inside the control unit, there are three different configurations:
• LED terminal block: the LEDs indicate, in the presence of the relative inductive sensor, the status of
the valve: green light = valve open; yellow light = valve closed; white light = bottom or top lift activated.
• AS-i card: the LEDs indicate the status of the corresponding solenoid valve.
• 10-pole terminal block: no LEDs.
General warnings
• Always read the technical data carefully before machine installation, operation and maintenance.
• The Giotto Top®must always be installed, operated and maintained by authorized personnel. Said
personnel must know and understand both the unit and the contents of the manual.
• Take care over any separate parts of the Giotto Top®when removing it from its packaging.
• Always connect the air supply carefully and disconnect it after use.
• Always connect the power supply carefully and disconnect it after use.
• Never touch the moving parts in the Giotto Top®or valves.
• Always handle detergents with care.
Prohibited use
Use of the control unit is not envisaged:
• for any operations other than those for which it was designed.
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).
WARNING
The control unit contains circuits classified as LOW VOLTAGE LIMITED ENERGY CIRCUIT. For correct use
in North America dimension the protection circuits in accordance with Standard UL508A.
WARNING
ALWAYS make sure the electrical and pneumatic connections are NOT active when executing operations
on the Giotto Top® and that the power supply voltage is only 24 Vdc.
BARDIANI VALVOLE S.p.A. declines all liability for
installation, use or maintenance which fails to comply with
the indications provided in this manual!
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Instruction, Use and Maintenance Manual
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3 Technical Data
CONTROL UNIT TECHNICAL DATA
Weight from 0.55 Kg to 0.65 Kg depending on the configuration
Casing material PA66 + PA6-GF30 (glass fibre reinforced nylon)
Gaskets material NBR
Protection class IP67
Air supply and vent connections 1/8” BSP
Air line connections 6 mm / 1/4” (ON REQUEST)
Electrical connections 7-pole connector or M12 5- or 8-pole connector
Threaded fitting for cable gland PG11 or M20x1.5
Field bus connections Actuator Sensor interface (AS-i).
Vibrations 1mm amplitude f=10..55Hz
Storage temperature -25..+70°C
Operating temperature -10...+50°C
Air supply Class 2,4,3 according to ISO 8573-1
SOLENOID VALVE APPLICATION CRITERIA
Single Acting Valves 1 Solenoid valve
Double Acting Valves (1 normally open and 1 normally closed), Mixproof and
Twin-Stop valves (2 normally closed)
2 Solenoid valves
Mixproof valves with air supply for opening, top and bottom lift (3 normally
closed)
3 Solenoid valves
SOLENOID VALVE TECHNICAL DATA
Electrical power supply 24 Vdc
Air pressure supply max. 7bar
min. 6bar
INDUCTIVE SENSOR TECHNICAL DATA
Electrical power supply 24 Vdc
In the event of any doubt, please contact Bardiani Valvole S.p.A.
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Instruction, Use and Maintenance Manual
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4 Giotto Top®Installation
WARNING
Always make sure that all wires are connected and securely fastened to the terminals and that the
solenoid valves, solenoid valves support, AS-i card and LED terminal block (when present) and any other
parts inside the Giotto Top ® are well assembled and secured.
WARNING
Always make sure that the electrical and pneumatic connections are disconnected when carrying out
operations on the Giotto Top®.
8
114b
114c
114d
25
22
1 2
3
26
4
114a

Instruction, Use and Maintenance Manual
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External inductive sensor installation
Pages 13-16
9
12
3
4
Ø 1,5 мм
Ø 12,5 мм
PG7
(M12x1,5)
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Instruction, Use and Maintenance Manual
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5 Giotto Top®Pneumatic connections
Compressed Air
inlet 1/8”
(BSP)
Connections
for air tting
1/8”
Air vent 1/8”
(BSP)
WARNING
Use only pipes with an external diameter of 6 mm.
Cut these pipes with a suitable cutter to avoid damaging the pipe which could lead to Giotto Top®
malfunctions.
Select a suitable length of pipe which allows the Giotto Top® to be removed without unscrewing the
anchoring.
10
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Instruction, Use and Maintenance Manual
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Valve with single acting actuator
Valve with double acting actuator
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Instruction, Use and Maintenance Manual
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Valve with single acting actuator with Twin Stop
Mixproof valve
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Instruction, Use and Maintenance Manual
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6 Giotto Top®Electrical connections
Solenoid valve 3
Solenoid valve 1
N.C.
Solenoid valve 1
1,2 PNP sensors with 1,2,3 normally closed solenoid valves and 7-pole connector
Sensor
VALVE
OPEN
Sensor
VALVE
CLOSED
Signal (Black)
0Vdc (Blue)
+24Vdc (Brown)
Signal (Black)
0Vdc (Blue)
+24Vdc (Brown)
Sensor
VALVE
OPEN
Sensor
VALVE
CLOSED
Signal (Black)
0Vdc (Blue)
+24Vdc (Brown)
Signal (Black)
0Vdc (Blue)
+24Vdc (Brown)
PIN
Connector
(7)
(6)
(4)
(3)
(2)
(1)
(5)
COLOR
Wire
(White)
(Blue)
(Brown)
(Purple)
(Black)
(Red)
(Gray)
Sensor signal
VALVE CLOSED
+24Vdc
Solenoid valves 0Vdc
PIN
Connector
(1)
(2)
(7)
(6)
(4)
(3)
(5)
COLOR
Wire
(Red)
(Black)
(Blue)
(White)
(Brown)
(Purple)
(Gray)
CLOSED VALVE Sensor signal
OPEN VALVE Sensor signal
0Vdc
+24Vdc Solenoid valves
+24Vdc Sensors
Solenoid valve 2
N.O.
Solenoid valve 2
CLOSED VALVE Sensor signal
OPEN VALVE Sensor signal
0Vdc
+24Vdc Solenoid valve 1
+24Vdc Solenoid valve 2
+24Vdc Solenoid valve 3
+24Vdc Sensors
Solenoid valve 3
+24Vdc
Solenoid valve 1 0Vdc
+24Vdc
Solenoid valve 2
+24Vdc
Solenoid valve 3 Sensor signal
VALVE OPEN
+24Vdc
Sensors
Sensor signal
VALVE CLOSED
Sensor signal
VALVE OPEN
+24Vdc
Sensors
1,2 PNP sensors with 1 normally closed solenoid valves and 5-pole connector
Sensor
VALVE
OPEN
Sensor
VALVE
CLOSED
Solenoid valve
Signal (Black)
0Vdc (Blue)
+24Vdc (Brown)
Signal (Black)
0Vdc (Blue)
+24Vdc (Brown)
+24Vdc
Solenoid valve
0Vdc
Sensor signal
VALVE CLOSED
Sensor signal
VALVE OPEN
+24Vdc
Sensors
PIN
Connector
(2)
(4)
(3)
(5)
(1)
COLOR
Wire
(White)
(Black)
(Blue)
(Gray)
(Brown)
Sensor
VALVE
OPEN
Sensor
VALVE
CLOSED
Signal (Black)
0Vdc (Blue)
+24Vdc (Brown)
Signal (Black)
0Vdc (Blue)
+24Vdc (Brown)
+24Vdc
Solenoid valves
0Vdc
Sensor signal
VALVE CLOSED
Sensor signal
VALVE OPEN
PIN
Connector
(2)
(4)
(3)
(5)
(1)
COLOR
Wire
(White)
(Black)
(Blue)
(Gray)
(Brown)
+24Vdc
Sensors
CLOSED VALVE Sensor signal
OPEN VALVE Sensor signal
0Vdc
+24Vdc Solenoid valve
+24Vdc Sensors
Solenoid valve 1
N.C. Solenoid valve 2
N.O.
CLOSED VALVE Sensor signal
OPEN VALVE Sensor signal
0Vdc
+24Vdc Solenoid valves
+24Vdc Sensors
1,2 PNP sensors with 2 solenoid valves (1 N.C. and 1 N.O.) for double acting 7-pole connector
1,2 PNP sensors with 2 solenoid valves (1 N.C. and 1 N.O.) for double acting 5-pole connector
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Instruction, Use and Maintenance Manual
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Solenoid valve 1
Solenoid valve 1
1,2,3 PNP sensors with 1,2,3 normally closed solenoid valves and 8-pole connector
1,2,3 PNP sensors with 1,2,3 normally closed solenoid valves and 8-pole connector
Sensor
VALVE
OPEN
Sensor
VALVE
CLOSED
Signal (Black)
0Vdc (Blue)
+24Vdc (Brown)
Signal (Black)
0Vdc (Blue)
+24Vdc (Brown)
Sensor
VALVE
OPEN
Sensor
VALVE
CLOSED
Signal (Black)
0Vdc (Blue)
+24Vdc (Brown)
Signal (Black)
0Vdc (Blue)
+24Vdc (Brown)
Signal (Black)
0Vdc (Blue)
+24Vdc (Brown)
PIN
Connector
(8)
(1)
(6)
(7)
(5)
(3)
(4)
(2)
COLOR
Wire
(Red)
(White)
(Pink)
(Blue)
(Gray)
(Green)
(Yellow)
(Brown)
External Sensor signal
UPPER LIFT
PIN
Connector
(8)
(1)
(6)
(7)
(5)
(3)
(4)
(2)
COLOR
Wire
(Red)
(White)
(Pink)
(Blue)
(Gray)
(Green)
(Yellow)
(Brown)
LOWER LIFT Sensor signal
CLOSED VALVE Sensor signal
OPEN VALVE Sensor signal
0Vdc
+24Vdc Solenoid valve 1
+24Vdc Solenoid valve 2
+24Vdc Solenoid valve 3
+24Vdc Sensors
Solenoid valve 2
Solenoid valve 2
UPPER LIFT Sensor signal
CLOSED VALVE Sensor signal
OPEN VALVE Sensor signal
0Vdc
+24Vdc Solenoid valve 1
+24Vdc Solenoid valve 2
+24Vdc Solenoid valve 3
+24Vdc Sensors
Solenoid valve 3
+24Vdc
Solenoid valve 1
0Vdc
Sensor signal
VALVE OPEN
+24Vdc
Solenoid valve 3
+24Vdc
Sensors
Sensor signal
VALVE CLOSED
Sensor signal
VALVE OPEN
+24Vdc
Sensors
1,2,3,4 PNP sensors with 1,2,3 normally closed solenoid valves
Sensor
VALVE
OPEN
Sensor
VALVE
CLOSED
Solenoid valve 1
Signal (Black)
0Vdc (Blue)
+24Vdc (Brown)
Signal (Black)
0Vdc (Blue)
+24Vdc (Brown)
Signal (Black)
0Vdc (Blue)
+24Vdc (Brown)
1,2 PNP sensors with 2 solenoid valves (1 N.C. and 1 N.O.) for double acting
signal (black)
Sensor
UPPER LIFT
(external)
+24Vdc (brown)
0Vdc (Blue)
+24Vdc
Solenoid valve 2
Sensor signal
VALVE CLOSED
+24Vdc
Solenoid valve 1
Sensor
LOWER LIFT
+24Vdc
Solenoid valve 2
+24Vdc
Solenoid valve 3
Sensor signal
LOWER LIFT
Solenoid valve 3
signal (black)
Sensor
UPPER LIFT
(external)
+24Vdc (brown)
0Vdc (Blue)
Sensor
LOWER LIFT
Solenoid valve 2
Solenoid valve 3
UPPER LIFT Sensor signal
LOWER LIFT Sensor signal
CLOSED VALVE Sensor signal
OPEN VALVE Sensor signal
0Vdc
+24Vdc Solenoid valve 1
+24Vdc Solenoid valve 2
+24Vdc Solenoid valve 3
+24Vdc Sensors
Sensor
VALVE
OPEN
Sensor
VALVE
CLOSED
Solenoid valve 1
Signal (Black)
0Vdc (Blue)
+24Vdc (Brown)
Signal (Black)
0Vdc (Blue)
+24Vdc (Brown)
Solenoid valve 2
UPPER LIFT Sensor signal
LOWER LIFT Sensor signal
CLOSED VALVE Sensor signal
OPEN VALVE Sensor signal
0Vdc
+24Vdc Solenoid valves
+24Vdc Sensors
0Vdc
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Instruction, Use and Maintenance Manual
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AS-i 360° Board 1,2,3,4 PNP sensors with 1,2,3 normally closed solenoid valves
Sensor
VALVE
OPEN (DI0)
Sensor
VALVE
CLOSED (DI1)
Sensor
LOWER LIFT
(DI3)
Signal (Black)
0Vdc (Blue)
+24Vdc (Brown)
Signal (Black)
0Vdc (Blue)
+24Vdc (Brown)
Signal (Black)
0Vdc (Blue)
+24Vdc (Brown)
Solenoid valve 1
(DO0)
Solenoid valve 2
(DO1)
Solenoid valve 3
(DO2)
AS-i Network
Signal (Black)
0Vdc (Blue)
+24Vdc (Brown)
AS-i - (Blue)
AS-i + (Brown)
Sensor
UPPER
LIFT (DI2)
AS-i 360° Board 1,2 PNP sensors with 2 solenoid valves (1 N.C. and 1
N.O.) for double acting
Sensor
VALVE
OPEN (DI0)
Sensor
VALVE
CLOSED (DI1)
Sensor
LOWER LIFT
(DI3)
Signal (Black)
0Vdc (Blue)
+24Vdc (Brown)
Signal (Black)
0Vdc (Blue)
+24Vdc (Brown)
Signal (Black)
0Vdc (Blue)
+24Vdc (Brown)
Solenoid valve 1
(DO0)
Solenoid valve 2
(DO1)
AS-i Network
Signal (Black)
0Vdc (Blue)
+24Vdc (Brown)
AS-i - (Blue)
AS-i + (Brown)
Sensor
UPPER
LIFT (DI2)
1,2,3 normally closed solenoid valves and 7-pole connector
+24Vdc Solenoid valve 3
+24Vdc Solenoid valve 2
+24Vdc Solenoid valve 1
0Vdc
+24Vdc Sensors
HIGH Sensor signal
LOW Sensor signal
PIN
Connector
(1)
(2)
(3)
(4)
(5)
(6)
(7)
COLOR
Wire
(Red)
(Black)
(Purple)
(Brown)
(Gray)
(White)
(Blue)
Sensor signal
LOW
+24Vdc
Sensors
+24Vdc
Solenoid valve 1
+24Vdc
Solenoid valve 2
+24Vdc
Solenoid valve 3
Sensor signal
HIGH
0Vdc
+24Vdc Solenoid valve 3 (Red)
+24Vdc Solenoid valve 2 (Red)
+24Vdc Solenoid valve 1 (Red)
0Vdc Solenoid valve 3 (Black)
0Vdc Solenoid valve 2 (Black)
0Vdc Solenoid valve 1 (Black)
0Vdc Sensor HIGH (Blue)
0Vdc Sensor LOW (Blue)
+24Vdc Sensor HIGH (Brown)
+24Vdc Sensor LOW (Brown)
HIGH Sensor signal (Black)
LOW Sensor signal (Black)
+24Vdc
Sensors
+24Vdc Solenoid valve
0Vdc
+24Vdc Sensors
HIGH Sensor signal
LOW Sensor signal
PIN
Connector
(5)
(3)
(1)
(4)
(2)
COLOR
Wire
(Gray)
(Blue)
(Brown)
(Black)
(White)
1,2,3 normally closed solenoid valves and 5-pole connector
Sensor signal
LOW
Sensor signal
HIGH
0Vdc
+24Vdc
Solenoid valve
+24Vdc Solenoid valve (Red)
0Vdc Solenoid valve (Black)
0Vdc Sensor HIGH (Blue)
0Vdc Sensor LOW (Blue)
+24Vdc Sensor HIGH (Brown)
+24Vdc Sensor LOW (Brown)
HIGH Sensor signal (Black)
LOW Sensor signal (Black)
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Instruction, Use and Maintenance Manual
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7 Giotto Top®Control unit
NO. DESCRIPTION
21 Base
21a Sealing ring
21b Sealing ring
21d Double guide
21e Vent plug
21f Air coupling
21g Air coupling
21i Cap
21k Terminal block with support
22 Cam
25 Screw
26 Bardiani case
27a Sensor
27d Micro-size inductive sensors holder slide
114a Sleeve for cable gland
114b 7-pole connector
114c 5-pole connector
114d 8-pole connector
192 Solenoid valve
192b Solenoid valve support
192c Cap
192d Solenoid valve board
192e Sealing ring
283 AS-i board
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Instruction, Use and Maintenance Manual
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8 Giotto Top®Assembly / Disassembly
17
21d
27d 27a
21
21e
21i
21g
21f
114b
114a 114c
114d
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Instruction, Use and Maintenance Manual
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Solenoid valve sequence
NC NC NO NO NO NO
18
TYPE 8
NC NC NA NCNC NC
192
x 4
192
x 5
192b
192e
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Instruction, Use and Maintenance Manual
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Solenoid valve sequence
NC NC NO NC NC NC
19
TYPE 5
NC NC NA NCNC NC
192
x 2
x 5
192e
192b
192
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20
TYPE B - TYPE S
21k
21
21k
21
21k
21
21b
21a
21