IMI STI BV User manual

BV - BIG VOLUME BOOSTER
INSTRUCTION MANUAL 2071

____________________________________________________________________________________
STI S.r.l. –Via Dei Caravaggi 15, 24040 Levate (BG) –ITALY www.imi-critical.com
Manual 2071, rev.07 02/2019 –BV
i
Date
Revision
Description
Compiled
Approved
19/02/2019
7
Changed Label
N.Mores
G.Alfieri
30/11/2017
6
Certificate Renewal
N.Mores
G.Alfieri
08/10/2014
5
Changed address
N.Zenoni
F.Tondolo
04/04/2014
4
Added information
N.Zenoni
F.Tondolo
STI S.r.l has taken every care in collecting and verifying the documentation contained in this Instruction
Manual. The information herein contained are reserved property of STI S.r.l.

____________________________________________________________________________________
STI S.r.l. –Via Dei Caravaggi 15, 24040 Levate (BG) –ITALY www.imi-critical.com
Manual 2071, rev.07 02/2019 –BV
ii
INDEX
1GENERAL INFORMATION .................................................................................................................. 1
1.1 GENERAL WARNINGS........................................................................................................................ 1
1.2 GENERALITIES.................................................................................................................................. 1
1.3 MANUFACTURER............................................................................................................................... 1
1.4 TERMS AND CONDITIONS................................................................................................................... 1
1.5 MANUFACTURER’S LIABILITY ............................................................................................................. 1
1.6 APPLICABLE STANDARDS AND DIRECTIVES ........................................................................................ 2
1.7 SYMBOLOGY USED........................................................................................................................... 2
2DEVICE DESCRIPTION ....................................................................................................................... 3
3TECHNICAL DATA............................................................................................................................... 4
4LABEL................................................................................................................................................... 4
5INSTALLATION .................................................................................................................................... 5
5.1 TRANSPORT ..................................................................................................................................... 5
5.2 RECEPTION...................................................................................................................................... 5
5.3 STORAGE......................................................................................................................................... 5
5.4 REQUIREMENTS OF STABILITY........................................................................................................... 5
5.5 DOCUMENTS AND DIMENSIONAL DRAWINGS........................................................................................ 5
5.6 INSTALLATION................................................................................................................................... 6
5.7 DISASSEMBLING ............................................................................................................................... 7
6OPERATION AND USE........................................................................................................................ 8
6.1 OPERATION DESCRIPTION ................................................................................................................. 8
6.2 INTENDED USE................................................................................................................................ 15
6.3 REASONABLY FORESEEABLE MISUSE ............................................................................................... 15
6.4 OPERATING LIMITS.......................................................................................................................... 15
6.5 RESIDUAL RISKS ............................................................................................................................ 16
7INSTRUCTIONS FOR THE OPERATOR........................................................................................... 16
8MAINTENANCE.................................................................................................................................. 17
8.1 PERIODIC INSPECTIONS .................................................................................................................. 17
8.2 SPECIAL MAINTENANCE................................................................................................................... 17
8.3 REPAIRS ........................................................................................................................................ 17
8.4 REASSEMBLING.............................................................................................................................. 17
8.5 MECHANISM LUBRICATION............................................................................................................... 17
9PARTS LIST GENERAL ASSEMBLY................................................................................................ 18
9.1 BV ASSEMBLY ................................................................................................................................ 18
10 TROUBLESHOOTING .................................................................................................................... 19
11 SPARE PARTS ............................................................................................................................... 19
12 DECOMMISSIONING...................................................................................................................... 20

____________________________________________________________________________________
STI S.r.l. –Via Dei Caravaggi 15, 24040 Levate (BG) –ITALY www.imi-critical.com
Manual 2071, rev.07 02/2019 –BV
iii

____________________________________________________________________________________
STI S.r.l. –Via Dei Caravaggi 15, 24040 Levate (BG) –ITALY www.imi-critical.com
Manual 2071, rev.07 02/2019 –BV
1
1 GENERAL INFORMATION
1.1 General Warnings
Important
This Instruction Manual is an integral part of the machine, it should be carefully
read before carrying out any operation and it should be kept for future references.
The operators shall adopt the safety precautions required by the country where
the product is installed.
This Instruction Manual is realized in accordance with the Directive 2006/42/CE.
1.2 Generalities
STI S.r.l. accessory are conceived, manufactured and controlled according to the Quality Control System in
compliance with EN ISO 9001 International Standard.
1.3 Manufacturer
With respect to Machinery Directive 2006/42/EC, the Manufacturer of the described BV Big Volume Booster
is STI S.r.l. as specified on the label.
STI S.r.l. Via Dei Caravaggi 15
24040 Levate (BG) Italy
Tel. [phone]
Fax [phone]
[e-mail]
1.4 Terms and conditions
STI S.r.l. guarantees each single product to be free from defects and to conform to current goods
specifications. The warranty period is one year from the date of installation by the first user, or eighteen
months from the date of shipment to the first user, whichever occurs first.
The warranty does not cover special products or components not covered by warranty in their turn by
subcontractors. No warranty is given for products which have been subject to improper storage, improper
installation, misuse, corrosion, or which have been modified or repaired by unauthorised personnel: it is not
advisable that customer or end users modify the device characteristics.
1.5 Manufacturer’s Liability
STI S.r.l. declines all liability in the event of:
- use of the BV in contravention of local safety at work legislation;
- incorrect installation, disregard or incorrect application of the instructions provided on the BV label and
in this manual;
- modifications without STI’s authorisation;
- work done on the unit by unqualified or unsuitable persons.

____________________________________________________________________________________
STI S.r.l. –Via Dei Caravaggi 15, 24040 Levate (BG) –ITALY www.imi-critical.com
Manual 2071, rev.07 02/2019 –BV
2
1.6 Applicable Standards and Directives
-EN ISO 12100:2010
Safety of machinery - General principles for design;
-IEC 61508:2010
Functional Safety of Electrical/Electronic/Programmable Electronic Safety-
related Systems;
-2006/42/EC
Machinery Directive;
-2014/68/UE
Pressure Equipments Directive (PED);
-2014/34/UE
Equipments used in potentially explosive atmospheres (ATEX).
1.7 Symbology Used
1.7.1 Signs of warning
Be careful where these symbols are shown, they indicate a potentially hazardous situation and they
warn that if the steps are not properly performed, MAY RESULT CAUSING serious injury, death or
long-term risks to the health of exposed persons.
1.7.2 Sings of obligation
General
obligation (with
the possible
supplementary
signboard)
Must wear
protective
clothing.
Obligation to
wear
protective
footwear.
Is required to
wear a helmet.
Is required to
protect the
eyes.
Obligation to
protect your
hearing.
GENERAL DANGER
DANGER POWER SUPPLY
CRUSHING HAZARD

____________________________________________________________________________________
STI S.r.l. –Via Dei Caravaggi 15, 24040 Levate (BG) –ITALY www.imi-critical.com
Manual 2071, rev.07 02/2019 –BV
3
2 DEVICE DESCRIPTION
The Big Volume Booster BV is a flow amplifier that allows to reduce the working time of an actuator by
increasing the air mass flow to the cylinder or by reducing the air mass flow from the same cylinder. Designed
to meet high control applications, STI series BV relay produces a high volume boosting action. The volume
booster contains an integral stabilizing bypass valve (or valve shutter) controlled by a screwdriver adjustment
in the body: opening this valve improves the stability of the positioner/volume booster/actuator.
Figure 1 –Big Volume Booster BV
BYPASS VALVE or
VALVE SHUTTER

____________________________________________________________________________________
STI S.r.l. –Via Dei Caravaggi 15, 24040 Levate (BG) –ITALY www.imi-critical.com
Manual 2071, rev.07 02/2019 –BV
4
3 TECHNICAL DATA
Technical features
Model
Type A
Type B
Housing material
Aluminum
Stainless steel
Size
1”
1”
Feeding connections
Plug-in - 1”NPTF
Plug-in - 1”NPTF
Outlet connections
Plug-in
Plug-in
Signal connection
½” NPTF
½” NPTF
Extreme Operating
Temperature Range
-60/+100 °C
-60/+100 °C
Design pressure
12 bar
12 bar
Operating pressure range
See label
See label
Expected lifetime
20 years
20 years
4 LABEL
The label fastened on the BV contains the main operating conditions. The supply can be instrument air or
natural gas. It is forbidden to modify the information and the marks without previous written authorization by
STI S.r.l.
Figure 2 –label

____________________________________________________________________________________
STI S.r.l. –Via Dei Caravaggi 15, 24040 Levate (BG) –ITALY www.imi-critical.com
Manual 2071, rev.07 02/2019 –BV
5
5 INSTALLATION
Important
Not performing the following procedures will invalidate the product guarantee.
5.1 Transport
Important
The lifting and handling should be made by qualified staff and in compliance with
the laws and provisions in force.
5.2 Reception
- Check that the model corresponds with that of order confirmation.
- Check that the BV was not damaged during transportation: if necessary renovate the painting according
to the specification reported on the order confirmation.
5.3 Storage
Big Volume Boosters leave the factory in perfect condition. Performances of each unit are guaranteed by
tests and data reported on a specific Test Report. In order to maintain these characteristics until the BV is
installed on site, proper attention must be observed for preservation during the storage period.
If the BV needs storage, before installation follow these steps:
- place it on a wood surface pallet or on metallic support, so that they are not in direct contact with the
ground, or packed with appropriate covering;
- make sure that plastic plugs are present on the pneumatic connections (if present).
If the storage is long-term or outdoor:
- keep the BV protected from direct weather conditions;
- replace plastic plugs of pneumatic connections (if any) with metal plugs that guarantee perfect tightness.
5.4 Requirements of Stability
Concerning the requirement of stability during installation and disassembling it‘s possible to refer to the next
chapters 5.6 and 5.7.
5.5 Documents and dimensional drawings
Pneumatic diagrams, wiring diagrams and dimensional drawings are furnished with document accompanying
the actuator.

____________________________________________________________________________________
STI S.r.l. –Via Dei Caravaggi 15, 24040 Levate (BG) –ITALY www.imi-critical.com
Manual 2071, rev.07 02/2019 –BV
6
5.6 Installation
Warning
Before proceeding with any installation, the following instructions must be
respected:
- Always wear protective clothing, gloves, and eyewear to prevent personal
injury;
- Check with your process or safety engineer for any additional measures that
must be taken to protect against process media.
5.6.1 Checks to be performed before installation
- Check that the coupling dimensions meet the specified coupling dimensions.
- Prepare the necessary tools for the assembly and setting of the unit.
- Check that the outer surface of the BV is free from dust and dirt.
- Clean the BV surfaces and remove anything that might prevent a perfect adherence.
5.6.2 Assembling of the BV
Threading
Material
Tightening torque [Nm]
M8
8.8
25
A4-70
20
5.6.3 Pneumatic connections
Warning
Check that the values of pneumatic supply available are compatible with those
reported on the identification plate of the BV. Use pipes and connections
appropriate as for type, rating, material and dimensions. The connection should be
made by qualified staff.
-Properly deburr the ends of rigid pipes.
-Properly clean the interior of pipes sending through them plenty of the supply fluid used in the
system.
-Mould and fasten the connection pipes so that no irregular strains at entries or loosening of
threaded connections occur.
-Use pipe sealant sparingly and only on male threads. A non-hardening sealant is strongly
recommended.
-Make the connections according to the operating diagram.
-Check the absence of leakages from pneumatic connections. If necessary, tighten the nuts of the
pipe-fittings.