giotto top

USE AND MAINTENANCE MANUAL

Giotto-Top®

GB-IST-GIOT-0507

(GB-IST-GIOT-0507) 2/30The Company BARDIANI VALVOLE reserves the right to modify its products at any time without prior notice.

1. Safety signs .......................................................................................................4 2. General safety precautions ................................................................................4 3. Operational overview for Giotto-Top® ................................................................5 4. Technical data ....................................................................................................6 5. Installation .........................................................................................................8 6. Troubleshooting .................................................................................................11 7. Pneumatic Connections .....................................................................................12 8. Electrical Connections .......................................................................................13 9. Maintenance ......................................................................................................22 10. Disassembly of Giotto-op® .................................................................................23 11. Assembly of Giotto-Top® ....................................................................................28 12. Parts list .............................................................................................................24 Warranty ............................................................................................................30 Disclaimer ..........................................................................................................30

Table of Contents

Foreword

This instruction manual is an integral part of the Giotto-Top® valve delivery.

• Always read it carefully before using the Giotto-Top® 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 specified. 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 modifications or updates without any further notice or obligations on the part of the manufacturer.


FAC-S

IMILE

Messrs.

STATEMENT OF CONFORMITY BY THE MANUFACTURERThe undersigned company BARDIANI VALVOLE S.P.A.

based in: Via G. di Vittorio, 50-52 - 43045 Fornovo Taro (PR) - Italiadeclares under its own responsibility that the valves

referred to your p.o.n° 1652 dtd. 23.06.2006 TYPE YEAR OF MANUFACTURE To wich this statement is connected, are in conformity with following rules ( it is obvious that the plant or the machinery where it will be included, is in conformity with one or following directives)

□ MACHINE DIRECTIVE 98/37/EEC And following amendments and integrations □ LOW VOLTAGE DIRECTIVE 72/23/EEC And following amendments and integrations

□ REGULATIONS 1935/2004 CE material to contact with product And following amendments and integrations

□ DIRECTIVE 97/23/EEC (PED) cat.I Mod.A And following amendments and integrations

□ DIRECTIVE 97/23/EEC (PED) Art.3 Paragr.3 And following amendments and integrations

□ ELECTROMAGNETIC COMPATIBILITY DIRECTIVE (EMC) 89/336/EEC And following amendments and integrations

Fornovo Taro,

LEGAL REPRESENTATIVEEMANUELA BARDIANI

Bardiani Valvole S.p.A. – I- 43045 Fornovo Taro (PR) – Via G.Di Vittorio 50/52 –Tel.+39 0525 400044 r.a. – Fax +39 0252 3408Http://www.bardiani.com - e-mail:[email protected] – Reg. Impr. Parma C.F. e I.V.A. n. 01511810341 – R.E.A. Parma n.159144Capitale Sociale € 1.186.800 I.V.


NOTA!

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 befollowed 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 personal 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.

ALWAYS connect air supply carefully and disconnect after use.

ALWAYS connect electrical supply carefully and disconnect after use.

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.

2. General Safety Precautions

1. Safety signs

We cannot be held responsible for correct installation, operation and maintenance!

LED


3. Operational overview for Giotto-Top®

The Giotto-Top® control unit was designed as a pneumatically controlled process valve.Depending on the initial configuration it is possible to fit Giotto-Top® with upto three solendoid valves to control the valve process and upto three induction sensors of which one is external to control valve position.

The solenoid valves are controlled via a PLC (Programmable Logic Controller) when they are activated compressed air operates the actuators. All solenoid valves are fitted with a manual operating switch.All the solenoid are fitted with a manual switch which allows opening and closing even without input.LED indicators keep you constantly informed of the solenoid valves status. The Giotto-Top® can be installed at any stage on any of our valves, and can be upgraded with more solenoid valves or sensors as needs require.

NOTE!

Pneumatic Connection

ElectricCircuit

Proximity or Microswitch

Wiring Connection

Solenoid valve support

Pneumatic Connection

ElectricCircuit

Proximity or Microswitch

Wiring Connection Solenoid valve support

Different electrical wires are available. Led shows if the solenoid valve is working or not.When LED is on, the solenoid is working

Solenoid valveTYPE1

Solenoid valveTYPE2


4. Technical data

Number of solenoid valves

Multi pole connections5,7,8-pole wiring for 24 V DC.Gland fitting PG11.

Connection Field busActuator sensor interface (ASI).

Type of application Number of solenoid valves

Single effect solenoid valve 1

Double effect solenoid valve (1 normally open and 1 normally closed), Mixproof valve and Twin-Stop with opening and upper lift

2

Mixproof valve with air supply for opening, upper and lower lift. 3

ALWAYS MAKE SURE that electrical power is disconnected while working on Giotto-Top® and that the supply is at all times 24 V DC.

Air supplyCompressed air, unlu-brificated, clean and

dry

Operating temperature -10...+50°C

Protection class IP 67


4. Technical data

Base-Cover Technical data

Solenoid valve Technical data

Proximity Switch Technical data

Microswitch Technical data

Weightfrom 0.55 Kg to 0.65 Kg according to the

configuration

Cover material PMMA (methacrylate) and PA6-GF30 (Nylon rienforced with GRP)

Seal material NBR

Protection class IP67

Air fittings 1/8” (BSP)

Air supply tube 6 mm

Electrical supply 24 V / DC

Air supply from 6 to 7 bar

For further information regarding individual compo-nents please consult the relevant manuals.

Electrical supply 24 V / DC


Electrical supply 24 V / DC PNP/NPN


192d 21c

TYPE1 TYPE2


1. Connect electrical power and air supply.

5. Installation

MAKE SURE that the electrical connections to Giotto-Top® aredisconnected while working on the valve and that it is only supplied with 24 V DC.

2. Check that the sensors are in the correct posi-tion, if not use the two screws on the double guide to regulate the hight.

3. For correct reading of the position by the sensors make sure that the maxi-mum distance between cam and proximity is 1,5mm.

4. Always make sure that all the wires are tightened well , that the solenoid valve, solenoid valve support, circuit board (192d, TYPE1), connector block (21c, TYPE2) and other internal parts of the Giotto-Top® are well anchored.

192d 21c

TYPE1 TYPE2


Installation of external proximity switch

4. Connect the external proximity in the slot provided and make sure its square.Make sure the distance to the cylinder shaft, is less than 1.5mm to ensure correct operation.

5. Installation

Installation of external proximity switch

1. Drill Giotto-Top® in the pre designa-ted area stamped in the cover.

2. Insert the glad and tighten the ring nut, insert the proximity’s and tighten the gland.

5. Installation

3a. TYPE1:Connect the wires of the external proximity to the connector block on the left (9 pole) on the circuit board (192d).Make sure that in the connector block on the right (8 pole) if the extrenal signal wire is connected.3b. TYPE2:Connect the wires of the external proximity to the connector block on the left (10 pole) on the circuit board (21c).Make sure that in the connector block on the right (10 pole) if the extrenal signal wire is connected.

192b

192

192d

192c

192e21h21i

Fig.1

192b

21g

TYPE1 TYPE2

192

192e

192d

192b

192

192e

21c


5. InstallationSolenoid valve Installation

In Giotto-Top® it is possible to have upto three solenoid valves and it is possible to alter the number of valves when necessary:

1. Remove the solenoid valve support (192b), the plug (192c)make a note of the postioning of the seals, and ‘O’ ring (192e), remove the air fitting plug (21g).

2. Fit the sealing ring (21h) and the air fitting (21i) using an appropriate tool such as a mallet and suitable sized tube as in figure 1.

3a. TYPE1Refit the solenoid valve support(192b), insert the circuit board (192d), fit the additional solenoid valve (192) make a note of the postioning of the seals and ‘O’ ring on the support (192e).3b TYPE2Refit the solenoid valve support(192b), insert the circuit board (21c), fit the additional solenoid valve (192) make a note of the postioning of the seals and ‘O’ ring on the support (192e).


6. Troubleshooting

MAKE SURE that the electrical connections to Giotto-Top® are discon-nected while working on the valve and that it is only supplied with 24 V DC.

PROBLEM POSSIBILE CAUSE POSSIBILE REMEDY

Air leak at solenoid valve support Missing seal or loose valve

jointCheck for seal and tighten

joint boltsAir leak from the safety valve

The LED does not light up

Damaged circuit boardChange the circuit board

LED damaged

Electrical connections incorrect

Check electrical connections to the valve at connector

block and tighten connector screws

The solenoid valve is not working

Damaged solenoid valve Change solenoid valve

Circuit board damaged Change circuit board

Incorrect air pressure Consult technical data sec-tion of the manual

Defective solenoid valve support

Change solenoid valve sup-port

Incorrect electrical connections

Check the electrical connec-tions and tighten connector

block screws

The proximity or micro-switches not working

Proximity or microswitches damaged

Change proximity or micro-switches

Incorrect electrical connec-tions

Check the connector block connections at the circuit board and tighten screws

TYPE1

TYPE2


7. Pneumatic Connections

Only use air tubing with a 6mm external diameter.Use a tube cutter to avoid crooked cuts and possible problems that could occur with Giotto-Top®.Cut tubes long enough to allow for disassembly of Giotto-Top® from its fixing point for maintenance work.

Exhausting port 1/8” (BSP)

Connections for 6mm tube Compressed air entry 1/8” (BSP)

Exhausting port 1/8” (BSP)

Connections for 6mm tubeCompressed air entry 1/8” (BSP)


8. Electrical Connections


When used correctly Giotto-Top® does not require special maintenance.In the event of maintenance being required this should be carried out by an authorised person making sure that all electrical connections are disconnected before conducting such work.

Before using cleaning products make sure that they are compatible with the materials found in Giotto-Top®, externally and internally.In the case of cleaning agents containing solvents, acids, or alkalines coming into contact accidentally with Giotto-Top® make sure that they are washed off immediatly with clean water.Extra attention should be given in areas where there are orifices or de-pressions where agents could collect or form pools.

During maintenance work or cleaning NEVER open the breather valve as this could cause damage to the installation or personnel.Every time the cover is opened make sure the various wires are re-po-sitioned as not to interfere with the movement of internal parts.

9. Maintenance

Should it be necessary to change components in Giotto-Top® consult Bardiani valvole S.p.A. for the purchase of parts and for guidance should you have any doubts regarding their installation or operation thus avoiding damage to the installation or persons.

22

21b

25

26

192d 21c

TYPE1 TYPE2


10. Disassembly of Giotto-Top®

2. Unscrew the cover (26), the cam (22) and two bolts (25) that fix the Giotto-Top to the cylinder.Remove seal (21b).

3. Disconnect the proximity switch, microswitches, and power supply wires to circuit board (192d TYPE1, 21c TYPE2). Use the maximum caution and be sure that power is not present during this process.

1. Disconnect electrical and air supply.

2721d

27d

27a

192b

TYPE1 TYPE2

192

192e

192d

192b

192

192e

21c

192c

192c

21c



5a. TYPE1Remove the solenoid valve support (192b), disassemble the solenoid valve (192) make a note of the postioning of the seals, and plug (192c) and ‘O’ ring on the support (192e), remove the circuit board (192d) and connector block (21c) if existing.5a. TYPE1Remove the solenoid valve support (192b), disassemble the solenoid valve (192) make a note of the postioning of the seals, and plug (192c) and ‘O’ ring on the support (192e), remove the circuit board (192d) and connector block (21c).

4. Unscrew the double guide (21d), the micro-proximity carriage (27d) and proximity (27a) or micro-switches (27) .

21f

21e

114a

21a

114c

21f

21e

114a

21a

114c


1. Insert the sealing ring (21a) in the lower part of the base, air fitting (21e) and breather plug (21f). Tighten the connector plug (114a) or sealing plug (114c).

6. Remove the sealing ring (21a) in the lower part of the base, air fitting (21e) breather plug (21f), Unscrew connector plug (114a) or sealing plug (114c).

11. Assembly of Giotto-Top®


192b

TYPE1 TYPE2

192

192e

192d

192b

192

192e

21c

192c

192c

21c

2721d

27d

27a


3. Tighten the double guide (21d), the micro-proximity carriage (27d) and the proximity (27a) or microswitches (27) .

2a. TYPE1Fit the solenoid valve support (192b), fit the solenoid valve (192) make a note of the postioning of the seals, and plug (192c) and ‘O’ ring on the support (192e), insert the circuit board (192d). and connector block (21c), if existing.2b TYPE2Fit the solenoid valve support (192b), fit the solenoid valve (192) make a note of the postioning of the seals, and plug (192c) and ‘O’ ring on the support (192e), insert the circuit board (192d) and connector block (21c).


22

21b

25

26

192d 21c

TYPE1 TYPE2



5. Tighten the two bolts (25) to fix Giotto-Top to the cylinder and the cam (22) .Insert the seal (21b) and tighten the upper cover (26). 6. Connect electrical power and air pressure.

4. Connect the proximity , microswitches , and power supply to the circuit board (192d TYPE1, 21c TYPE2). Use the maximum caution and be sure that power is not present during this process.


12. Part list


21 base 26 cover

21a sealing ring 27 microswitch

21b sealing ring 27a proximity

21c connector block 27d micro-proximity carriage

21d double guide 114a connector male

21e air fitting 114c wiring connection

21f breather plug 192 solenoid valve

21g Bush plug 192b support solenoid

21h sealing ring 192c stopper solenoid closing

21i Bush air connection 192d electric circuit

22 cam 192e ‘O’ ring

25 bolts

12. Parts List

BARDIANI VALVOLE S.P.A. - Via G. di Vittorio 50/52 43045 - FORNOVO TARO - PR - Tel.: +390525/400044 - Fax.: +390525/3408


1. All the statements, indications and technical data listed in this document are based on technical tests carried out by Bardiani Valvole S.p.A.. However accurate and reliable, such tests do not reflect all possible circumstances under which the products may be used.

It is therefore advisable that the Buyer should always ascertain the suitability of the product in its application. The Buyer will be entirely liable for all risks and damages incurred by said products.

Bardiani Valvole S.p.A. are not liable for any accident, loss or damage incurred, whether they be directly or indirectly caused by the use or misuse of the products.

No further guarantees other than those stated in this document shall be granted.2. All our customers are advised to consult our technicians as well as our offices who will supply all information

pertaining the technical characteristics of our products.3. The pictures contained in this document are intended to be general representations. They are not to be intended

either legally binding or detailed representations of our products.4. The data and statements listed in this document only refer to our standard products. They do not apply in any

case to any tailor-made products that might have been purchased by the customers.5. Bardiani Valvole S.p.A. are not liable for any defects or faults resulting from the incorrect installation of their

products. Such installation is to be carried out in full compliance with the instructions contained in the “Manual of Instructions for the Use and Maintenance of the Product”. Bardiani Valvole S.p.A. are not liable for any defects or faults resulting from the incorrect use of their products.

6. Bardiani Valvole S.p.A. are not liable for any defects or faults resulting from the incorrect transportation and/or incorrect storage and/or incorrect maintenance of their products.

7. Bardiani Valvole S.p.A. cannot accept any liability for any faults or damages deriving from mishandling of the products and/or interventions carried out by unqualified personnel. No liability is accepted for damages caused by hits, dents, carelessness, negligence or any other any acts that cannot be considered as construction faults or faults related to the materials used in production.

1. CONTRACTUAL WARRANTIES AND LIABILITY1.1 Bardiani Valvole S.p.A. warrant that their products are free from defects in design, material and workmanship. Bardiani Valvole

S.p.A. shall be liable should any such defects be found within 12 (twelve) months from the date of delivery of the products.1.2 Any claim regarding defects and/or faults found in the products shall be notified in full and in writing to Bardiani Valvole

S.p.A. within 8 (eight) days from the date they were found. Adequate documentation shall be provided as evidence of said defects at the time the claim is filed.

2. LIMITATION IN LIABILITY2.1 Without prejudice to any statutory right of the Buyer, Bardiani Valvole S.p.A. shall be under no liability in respect of electric

components or elastomers that are part of their products.2.2 The Seller shall be under no liability in respect of defects/faults specified in the following points: - defects and/or faults arising from failure to follow the instructions contained in the “Manual of Instruction for the Use and

Maintenance of the Product” as to the use and storage of the products by the Buyer; - defects and/or faults arising from fair wear and tear of the products or their parts or their components; - defects and/or faults arising from repairs or interventions of the goods carried out by unauthorized or unqualified staff; - defects and/or faults arising from misuse, accidents, negligence and abnormal working conditions caused by the Buyer.3. WARRANTY3.1 Bardiani Valvole S.p.A. shall, at their discretion, repair or replace the products that are acknowledged to be defective.3.2 Should repair or replacement of the product or of its components occur, the parts returned shall become the property of

Bardiani Valvole S.p.A. The relevant freight costs involved in the return of the goods or their components shall be entirely met by Bardiani Valvole S.p.A..

3.3 Under no circumstance shall Bardiani Valvole S.p.A. be liable to indemnify immaterial or indirect damages such as damages or consequential loss, whether loss of profit, loss of business, loss of business opportunities, loss of time, loss of goodwill and damage to corporate image, etc.

3.4 The performance of repair or replacement under the above warranty shall not entail any extension of the warranty period of 12 (twelve months), such term being unconditional.

3.5 No distributor, agent or staff to Bardiani Valvole S.p.A. is entitled to make any amendment, extension or addition to the above warranty.

DISCLAIMER

WARRANTY

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