omal automation 375 User manual

EN - 1
OMAL S.p.A.
Headquarters: Via Ponte Nuovo, 11 - 25050 Rodengo Saiano (BS) Italy • Production Site: Via Brognolo, 12 - 25050 Passirano (BS) Italy
Ph. [phone] • Fax [phone] • [email protected] • www.omal.it
Rif. UMA0082W - 10/19
ITENDEFRES
INSTRUCTION MANUAL
BUTTERFLY VALVES
ITEM 375 - 376 -377 , 385 - 386 - 387

EN - 2
OMAL S.p.A.
Headquarters: Via Ponte Nuovo, 11 - 25050 Rodengo Saiano (BS) Italy • Production Site: Via Brognolo, 12 - 25050 Passirano (BS) Italy
Ph. [phone] • Fax [phone] • [email protected] • www.omal.it
Rif. UMA0082W - 10/19
ITENDEFRES
INSTRUCTION MANUAL
BUTTERFLY VALVES
ITEM 375 - 376 -377 , 385 - 386 - 387
INDEX:
Pag.
1. GENERAL FEATURES 3
2. WORKING CONDISTIONS 3
3. OPERATING INFORMATION 4
4. SAFETY INFORMATION 5
5. INSTALLATION INSTRUCTION 6
6. MATERIALIAL AND THEIR DURABILITY 7
7. MAINTENANCE 7
8. VERSIONI SPECIALI 9
9. STORAGE 9
10. TROUBLE SHOOTING 10
11. DISPOSAL OF PRODUCTS AT THE END OF LIFE 11
12. DECLARATION CONFORMITY 11
Environmentally friendly: Environmentally friendly: under the green leaf icon you can nd the
instructions for a correct and environmentally friendly handling of the product.
All data and features in this manual may be changed at any time and with no notice for the implementation of technical improvements.
Therefore they can not be considered as binding for the delivery.
FOREWORD
The present User’s Installation and Maintenance Manual has been edited in conformity with:
-2014/68/EU Directive “Pressure equipment” PED
-2006/42/EC Directive “Machinery” MD
-2014/34/EU Directive “Equipment and protection systems designated to be used in potentially explosive atmospheres” ATEX
The following standards/technical specications also apply:
-UNI CEN/TS 764-6 Pressure equipment Part 6: Operating instructions structure and contents.
It’s up to the reader to nd his own product, and the correct operating conditions, possibly referring to the attached drawings.
Below you will nd the safety instructions, the minimum information for storage / warehousing, the installation, the commissioning, the
maintenance and the instructions for disposal of products at the end of their life.
The company disclaims any liability for damage caused by improper use, even if partial, in respect to the information contained in
this manual.

EN - 3
OMAL S.p.A.
Headquarters: Via Ponte Nuovo, 11 - 25050 Rodengo Saiano (BS) Italy • Production Site: Via Brognolo, 12 - 25050 Passirano (BS) Italy
Ph. [phone] • Fax [phone] • [email protected] • www.omal.it
Rif. UMA0082W - 10/19
ITENDEFRES
INSTRUCTION MANUAL
BUTTERFLY VALVES
ITEM 375 - 376 -377 , 385 - 386 - 387
1. GENERAL FEATURES
OMAL buttery valves, available in wafer or lug version from DN 40 to DN 600 (lug DN 300), are designed and manufactured to be
used in most applications in all industrial elds.
- General requirements in accordance with UNI EN593
- Face to face as per EN 558 series 20
- Tightness at 16 bar or 10 bar according to EN 12266-1 rate A
- Integral sealing (with liner vulcanized on hard ring) which avoids any contact between uid and valve body.
- Sealing design allowing perfect adherence to the valve body and perfect tightness to the anges, without additional parts.
- Clamping between anges does not inuence the torque of the valve.
- Lapped disc edges that allows better tightness, reduced torque and low wear of the liner.
- Bushes to support the shaft.
- Coupling between stem and disc with two shafts (better Kv) carried out with no additional ttings (e.g. screws, bolts, pins, etc.) to
avoid any risk of corrosion and breaking.
- Valve neck with top work as per EN ISO 5211 for easy connections with all different types of actuators.
- All components properly treated against corrosion.
2. WORKING CONDITIONS
2.1 Fluids
Valves are designed and tested to be used with all uids belonging to Group 1, as per 2014/68/EU either liquid or gaseous.
The operator or the Engineering company in charge of the project will be responsible for the selection of the valve materials che-
mically and physically compatible with the intercepted uid. To the best of their abilities OMAL technical staff will be pleased to help
customers select the best product for a specic application. However the operator or the Engineering company will be responsible
for the nal selection.
2.2 Working pressure
The Omal buttery valves are designed for a continuous use at: PN 16 bar from DN 40 to DN 300, PN 10 bar from DN 350 to DN
600. The Maximum Working pressure must be equal to PN valve.
2.3 Working temperature
The buttery valves type 375 - 376 - 377 - 385 - 386 - 387 series (A 536 spheroidal cast iron body) are designed and tested for a
continuous use keeping the PN value unchanged throughout the whole range of temperatures. Below the maximum and minimum
working temperatures for seal material:
NBR: - 23°C + 82°C
EPDM: - 25°C + 135°C
FKM: - 10°C + 190°C
WARNING
Elastomer working temperatures are to be considered as approximate temperatures with inert uids. A slight chemical sensitivity of
the elastomers to the intercepted uids can dramatically reduce the working temperature range.
2.4 Lubrication
The buttery valves are factory lubricated for the standard working condition life. During maintenance and reassembling, check that
the lubricant to be used is suitable for contact with the seal material, with the uid intercepted and with the operating conditions.
2.5 External protection
OMAL buttery valves are suitable for indoor and outdoor installation. The cast-iron body is external protected from corrosion by
160÷200 microns of epoxy painting. The shaft and the disc are in stainless steel or protected by the corrosion
This normally allows to satisfy applications where a protection class C3 is required according to ISO 12944-6
2.6 Marking and classication
The following information are marked on the buttery valves body and / or with an additional label:
• Manufacturer’s brand and name
• Nominal Size
• Nominal pressure
• Heat number

EN - 4
OMAL S.p.A.
Headquarters: Via Ponte Nuovo, 11 - 25050 Rodengo Saiano (BS) Italy • Production Site: Via Brognolo, 12 - 25050 Passirano (BS) Italy
Ph. [phone] • Fax [phone] • [email protected] • www.omal.it
Rif. UMA0082W - 10/19
ITENDEFRES
INSTRUCTION MANUAL
BUTTERFLY VALVES
ITEM 375 - 376 -377 , 385 - 386 - 387
• Address of the manufacturer
• Model / Product Code
• Min./max. Temperature
• Production date
• Materials (body, disc and seal)
• CE marking according to Directive 2014/68/EU
3. OPERATING INFORMATION
The buttery valves can be supplied bare shaft, provided with a lever for manual operation or equipped with an electric or pneumatic
actuator.
3.1 Handle-operated
If a valve is provided with a handle, the handle will have to be assembled in such a way that, viewed from above, it will have to be
turned clockwise to close the valve and counterclockwise to open it. With a closed valve, the handle needs to be in its normal position
with respect to the pipeline while with an open valve it needs to be parallel to the pipeline. The handle needs to be stopped (and even
locked) in ten different positions angularly equidistant from one another all along the valve stroke.
3.2 Automated valve
The automated valves can be used in a lot of applications where it is necessary also to guarantee full control, efciency and duration
in service. The connection between valve and actuator can be of three types:
A) DIRECT MOUNTING
B) MOUNTING PLATE CONNECTION
C) BRACKET & JOINT CONNECTION
A B C

EN - 5
OMAL S.p.A.
Headquarters: Via Ponte Nuovo, 11 - 25050 Rodengo Saiano (BS) Italy • Production Site: Via Brognolo, 12 - 25050 Passirano (BS) Italy
Ph. [phone] • Fax [phone] • [email protected] • www.omal.it
Rif. UMA0082W - 10/19
ITENDEFRES
INSTRUCTION MANUAL
BUTTERFLY VALVES
ITEM 375 - 376 -377 , 385 - 386 - 387
A) DIRECT MOUNTING
Valve actuator direct mounting is the best solution to avoid plays between valve stem and actuator drive shaft. For a direct mounting
you should have the same standard ange connection on valve and actuator as well as the valve stem dimensions that t perfectly
with the actuator drive. Before installation please verify that the actuator and valve ange ISO connections are the same size; verify
that the valve stem size and shape is suitable for direct mounting, if necessary use a drive reduction. Fit the valve stem into the actua-
tor drive shaft connection, and bolt together the two ISO anges.
B) MOUNTING PLATE CONNECTION
In case direct mounting is not possible cause of little differences in actuator/valve anges or drives sizes, mounting plates adapters
with suitable anges dimensions allows an easy connection living a sufcient space for the valve/actuator drive adapter.
C) BRACKET & JOINT CONNECTION
Wherever for technical reason the plant installation requires a distance between actuator and valve, or the valve ange and/or stem
are not standard, and in any case, where the valve/actuator connection could not be possible, a bracket and joint is the right answer.
The Bracket is a steel bridge that allows to connect the valve with is own ange connection in one side and with the suitable actuator
connection into the opposite side, living a space in between for a steel joint connection.
The joint allows a drive connection between the actuator and the valve stem indispensable in case of stem key drive and at head.
Chose the suitable ange bracket and the required joint connections to x the actuator onto the valve very tight without any plays.
OMAL actuator with its draining channels system on the ange connection pattern is especially designed for valve direct mounting.
This system allows to drop away any possible ow coming from the valve stem that with valve/actuator direct mounting could damage
the actuator.
Coppia di serraggio delle viti
SIZE TORQUE Nm
M5 5-6
M6 10-11
M8 20-23
M10 45-50
M12 80-85
3.2.1 Cycle time
The cycle time depends on the operating device put on the valve. Please read the instructions about the installed actuator. The inter-
face between valve and actuator complies with ISO 5211
3.2.2 Valve stroke
the construction type of the valve (centric drive) guarantees the seal a few degrees before complete closure, depending on the size.
The actuated valves are adjusted during assembly to limit the actuator closing to 87 ° - 88 °, an angle that allows the valve seal to
the nominal pressures, avoiding unnecessary increase of the drive torques. Increasing the run up to 90 °, provide a long life of the
product in service
The stroke adjustment up to 90 °, allows the recovery of the wear of the gaskets greatly increasing the life of the product.
For the assembly of valves with actuators and actuator stroke adjustment refer to the specic documentation available on the website:
www.omal.it
4. SAFETY INFORMATION
• When you receive a product, make sure it is in perfect conditions. Do not install a product which comes in a damaged box
especially if it shows signs of damage.
• While the valve is being installed, make sure that the pipeline and the working environment are perfectly clean. The presen-
ce of dirt and particles can seriously affect the tightness of the valve. If you use a sealing product, either tape or paste, make sure that
it will not end up in the valve body or in the sealing areas.
• If an aggressive or dangerous uid ows through the valve, make sure the material the valve is made of is compatible with
the uid. If you have any doubt, please contact OMAL technical staff who will carefully evaluate the chemical compatibility of the uid
with the valve.

EN - 6
OMAL S.p.A.
Headquarters: Via Ponte Nuovo, 11 - 25050 Rodengo Saiano (BS) Italy • Production Site: Via Brognolo, 12 - 25050 Passirano (BS) Italy
Ph. [phone] • Fax [phone] • [email protected] • www.omal.it
Rif. UMA0082W - 10/19
ITENDEFRES
INSTRUCTION MANUAL
BUTTERFLY VALVES
ITEM 375 - 376 -377 , 385 - 386 - 387
• A valve is a safe product provided that it is properly installed between anges on a plant. If you want to test a valve at the
bench, especially a pneumatically operated one, make sure there are protections enough to prevent objects and parts of your body
to get caught between the buttery and the valve body. Please remember that a valve closes in less than a second and with
enough energy to damage itself and a careless operator.
• Before installing a valve, make sure that the operating temperature and pressure are compatible with the parameters stated
by the manufacturer.
• If a valve is used as an END OF LINE valve, please remember that it has not been tested for that specic function. For an
END OF LINE application, please note that the valve PN corresponds to 60% of the PN stated for an installation in a pipeline.
• Never try to disassemble a valve or any of its parts when there is uid in the pipeline regardless of the pressure
• Never remove the valve shafts when there is pressure in the pipeline as the buttery could be swallowed by the uid under
pressure in the pipeline
5. INSTALLATION
While carrying out the risk assessment for this kind of product as per 2014/68/EU - PED it was impossible to fully evaluate the risks
related to trafc, wind, earthquakes etc as every evaluation was strictly related to the type of application and installation.
The owner of the plant will have to carry out this evaluation, where necessary, along with the risk assesment for the plant itself.
OMAL buttery valves are very easy to install and if you follow some basic installation procedures, the product will perform at its best.
• never try to force a valve between anges which are not open enough to allow the insertion of the valve as you might seriou-
sly damage the sealing areas on the anges (g. 1)
• while you insert the valve between the anges and you subsequently block them, the disc must be kept in an half-open
position without exceeding the valve edges (g. 2)
• support the buttery by means of two tie-rods which, going through the holes on the anges and the slots on the valve body,
will allow a rst generic centering between the anges. Slightly close the 4 tie-rods (opposite to one another) until the valve is slightly
xed and then center the valve body carefully with respect to the pipeline anges (a mistake of +- 1mm on a DN 50 and proportionally
of +-5mm on a DN 300 is more than acceptable).
Close the 4 tie-rods until the valve is fully blocked, open the buttery completely (g 3) and then insert and close all other bolts requi-
red by the anges.
The valve is not particularly sensitive to the torque generated by closing the bolts on the anges. Please apply the torque stated in
the relevant standard also considering the material of bolting.

EN - 7
OMAL S.p.A.
Headquarters: Via Ponte Nuovo, 11 - 25050 Rodengo Saiano (BS) Italy • Production Site: Via Brognolo, 12 - 25050 Passirano (BS) Italy
Ph. [phone] • Fax [phone] • [email protected] • www.omal.it
Rif. UMA0082W - 10/19
ITENDEFRES
INSTRUCTION MANUAL
BUTTERFLY VALVES
ITEM 375 - 376 -377 , 385 - 386 - 387
6. MATERIALS AND THEIR DURABILITY
To ensure the full reliability of the valve, it is recommended to carry out at least once a year, a check of the efciency level of the
plant, changing all the worn-out parts promptly where leakage or straining occur, both inside the pipeline and towards the outside of
the valve. The life time of the consumable parts can be summarized as follows. Spare parts kits are available for valves maintenan-
ce.
DN 40÷80 100 125 150 200 250 300 350 400 450 500 600
Num. of cycles 100.000 90.000 90.000 80.000 70.000 60.000 50.000 45.000 40.000 35.000 30.000 20.000
7. MAINTENANCE
The product maintenance must be done by trained and qualied people with proper tools, we recommend checking the correct
replacement performing a tightness and functional tested on the valves.
- Remove the spring pins with a punch (9) or the shaft retention anges, in the case of measures of more than ND 300.
- Remove the upper (4) and lower (5) shafts. For measures of more than ND 300, the lower shaft is not prevalent and can be remo-
ved using an M16 bolt.
- Remove the disc (2). The operation is facilitated by rotating the disk 15° from the closed position.
- Remove the main seal (3) noting that in the ange are, it has two different diameters; obviously, it must be extracted by pushing
on the smaller diameter. It is recommended to use a hydraulic press with thrust plate diameter of 15 mm more than the valve ND.
- Check that the o-rings (6), also came out with the main seal; if not, remove them from the valve body.
- Remove the upper bushing (7)
- The bushings (8) are not normally replaced during maintenance. Should it be necessary to remove them, contact our technical
department for instructions.
- Place the o-rings (6) and (10) in their seats after thorough greasing.
- Insert the main seal (3) into the valve body, aligning the shaft holes as well as possible with the corresponding holes in the body.
- Insert the disc (2), aligning the shaft holes as well as possible with the corresponding holes in the seal. Keep the disc rotated at
15°.
- insert the upper bushing (7)
- Reposition the shafts in their relative seats, until the groove of the rod reaches the same level as the pin hole (up to ND 300 only).
During insertion, there may be a slight resistance due to the slight misalignment of the components; use moderate force to insert
the shafts; where necessary re-check the alignment of the components. Pay attention to the groove on the head of the upper shaft,
which must be exactly in line with the buttery valve position. Insert the pins or assemble the shaft holder anges.
- Always run a valve seal test before recommissioning the system.

EN - 8
OMAL S.p.A.
Headquarters: Via Ponte Nuovo, 11 - 25050 Rodengo Saiano (BS) Italy • Production Site: Via Brognolo, 12 - 25050 Passirano (BS) Italy
Ph. [phone] • Fax [phone] • [email protected] • www.omal.it
Rif. UMA0082W - 10/19
ITENDEFRES
INSTRUCTION MANUAL
BUTTERFLY VALVES
ITEM 375 - 376 -377 , 385 - 386 - 387
*
*
DN 350 ÷ DN 600
1 Body
2 Disc
3* Liner
4Upper shaft
5Lower shaft
6* Lower O-ring
7* Upper bush
8* Shaft bush
9* Elastic pin
10* Shaft O-ring
* Spare parts kit (KGF)
8
4
7
6
5
6
9
2
9
3
1
8
10
6
LUG BODY

EN - 9
OMAL S.p.A.
Headquarters: Via Ponte Nuovo, 11 - 25050 Rodengo Saiano (BS) Italy • Production Site: Via Brognolo, 12 - 25050 Passirano (BS) Italy
Ph. [phone] • Fax [phone] • [email protected] • www.omal.it
Rif. UMA0082W - 10/19
ITENDEFRES
INSTRUCTION MANUAL
BUTTERFLY VALVES
ITEM 375 - 376 -377 , 385 - 386 - 387
WARNING
To make sure there is no pressure in the pipeline, before servicing a valve. If a dangerous or aggressive uid ows through the pipe-
line, always wash the pipeline as suggested by the manufacturer. Always wear suitable protections while you open the connections
between valve and pipeline.
As products change and evolve in time, please order and use original spare parts only (as per specic instructions accompanying
each product). When you place an order, always mention the product code and the production date stamped on the valve and you will
get the latest possible version of the spare part you need. If you have any doubt, please contact OMAL technical staff who will help
you keep the product as efcient as possible.
8. SPECIAL VERSION
The buttery valves, suitable for use in potentially explosive atmospheres in compliance with the requirements of Directive 2014/34 /
EU, is available on request by applying an antistatic device which keeps the valve body, stem and disc in continuity and serves as a
grounding point.
The buttery valves in compliance with the Atex Directive are suitable for being applied on equipments belonging to GROUP II Category
2, suitable for zones 1 & 2 GAS and 21 & 22 DUST.
9. STORAGE
Choose clean sites for storage, not excessively humid and with temperatures between –10 and +60°C. If the products are to be stored
for long periods of time, it is best not to remove them from their protective packaging. Keep the valves in the package during storage.
If the valves are not packaged, must be protected the ends in order to avoid liquid or other to penetrate during storage and thus damage
the disc or the seals.
If the valves are to be stored for long periods of time, then they should be inspected periodically: check in particular the possible presen-
ce of rust, oxidation, paint nicks or even partial unscrewing of the closures. It is also recommended to perform a complete dry cycle of
opening and closing of the valve.
The seals are subject to aging and lose of their characteristics: for this reason, after storage periods of more than two years, it is recom-
mended to check the functionality and the seals before mounting the valve in the line.
Protect the seals from sun light (UV rays cause seal aging).

EN - 10
OMAL S.p.A.
Headquarters: Via Ponte Nuovo, 11 - 25050 Rodengo Saiano (BS) Italy • Production Site: Via Brognolo, 12 - 25050 Passirano (BS) Italy
Ph. [phone] • Fax [phone] • [email protected] • www.omal.it
Rif. UMA0082W - 10/19
ITENDEFRES
INSTRUCTION MANUAL
BUTTERFLY VALVES
ITEM 375 - 376 -377 , 385 - 386 - 387
10. TROUBLE SHOOTING
POTENTIAL EFFECTS OF FAILURE POTENTIAL FAILURE MODE SOLUTIONS
Valve leakage
Incomplete closing of the disc Check the maneuvering system
/ Contact OMAL
Liner worn Replace worn parts as per instruction
manual
Chemical incompatibility with valve con-
struction materials (gasket and / or lens) Contact OMAL
Disc worn
Check the chemical compatibility between
the media and the construction materials
/ Contact OMAL
Leakage from Upper or Lower Shaft Damage on the stem seat or disc liner
Replace worn parts as per instruction
manual
Check the chemical compatibility between
the media and the construction materials
/ Contact OMAL
Damage on body Contact OMAL
Valve blocked
Driving system fault
Contact OMAL
Disc / stem gripping
Stem break
Actuator- valve connection’s break
Increased maneuvering time / shoo-
ting motion
Disc / stem gripping Contact OMAL
Liner hardening
Check the chemical incompatibility with
valve construction materials.
/Contact OMAL
Partial actuator gripping Contact OMAL
Inadequate rotation angle
Actuator cannot perform the maneuver Check actuator dimensioning and verify
that actuator uid pressure is equal to or
greater than nominal pressure on plate
Insufcient air supply to produce the
required torque
Mechanical stop (if present) not properly
adjusted Adjust the stroke limiters
Stem gripping Contact OMAL
Possible presence of blocked foreign body Remove the valve and check its operation
on the bench
Incorrect fIxing between actuator outlet
hole and valve stem
Check for proper connecting kit between
valve and actuator