Giotto TOP

USE AND MAINTENANCE MANUAL

Giotto-Top ®

GB-IST-GIOT-0507

Table of Contents 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.

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

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

Always read it carefully before using the Giotto-Top Giotto-Top ® valve.

•

Always keep it for future reference.

All rights are reserved. reserved. It is forbidden to reproduce or or transit any part of of the instruction manual manual by any any means, either electronic or mechanical, 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.

The Company BARDIANI VALVOLE VALVOLE reserves the right to modify its products at any time without prior notice.

(GB-IST-GIOT-0507) (GB-IST-GIOT-0507) 2/30

Table of Contents 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.

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

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

Always read it carefully before using the Giotto-Top Giotto-Top ® valve.

•

Always keep it for future reference.

All rights are reserved. reserved. It is forbidden to reproduce or or transit any part of of the instruction manual manual by any any means, either electronic or mechanical, 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.

The Company BARDIANI VALVOLE VALVOLE reserves the right to modify its products at any time without prior notice.

(GB-IST-GIOT-0507) (GB-IST-GIOT-0507) 2/30

Messrs. STATEMENT OF CONFORMITY BY THE MANUFACTURER The undersigned company BARDIANI VALVOLE S.P.A. based in: Via G. di Vittorio, 50-52 - 43045 Fornovo Taro (PR) - Italia declares under its own responsibility that the valves referred to your p.o.n° 1652 dtd. 23.06.2006

E L I M I S C A F 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 DIRECTIVE 98/37/EEC 98/37/EEC And following amendments and integrations integratio ns

□ LOW VOLTAGE VOLTAGE DIRECTIVE DIRECTIV E 72/23/EEC And following amendments and integrations integratio ns

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

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

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

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

Fornovo Taro,

LEGAL REPRESENTATIVE REPRESENTATIVE

EMANUELA 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 3408 Http://www.bardiani.com - e-mail:[email protected] – Reg. Impr. Parma C.F. e I.V.A. n. 01511810341 – R.E.A. Parma n.159144 Capitale Sociale € 1.186.800 I.V. The Company BARDIANI VALVOLE VALVOLE reserves the right to modify its products at any time without prior notice. (GB-IST-GIOT-0507) (GB-IST-GIOT-0507) 3/30

1.

Safety signs

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 be followed to avoid damage of equipment and environment.

NOTA!

2.

Indicates IMPORTANT information, which improves the understanding of the instructions.

General Safety Precautions 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.

We cannot be held responsible for correct installation, operation and maintenance! The Company BARDIANI VALVOLE reserves the right to modify its products at any time without prior notice.

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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. LED

Proximity or Microswitch

Electric Circuit

Solenoid valve TYPE1

Wiring Connection

Pneumatic Connection

Proximity or Microswitch Solenoid valve support Electric Circuit

Solenoid valve TYPE2

Pneumatic Connection

Solenoid valve support

Wiring Connection

Different electrical wires are available. Led shows if the solenoid valve is working or not. When LED is on, the solenoid is working 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 NOTE! 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. The Company BARDIANI VALVOLE reserves the right to modify its products at any time without prior notice.

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4.

Technical data

Number of solenoid valves

Number of solenoid valves

Type of application 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

Multi pole connections 5,7,8-pole wiring for 24 V DC. Gland fitting PG11. Connection Field bus Actuator sensor interface (ASI).

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 supply

Operating temperature Protection class

The Company BARDIANI VALVOLE reserves the right to modify its products at any time without prior notice.

Compressed air, unlubrificated, clean and dry -10...+50°C IP 67

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4.

Technical data Base-Cover Technical data from 0.55 Kg to 0.65 Kg according to the configuration

Weight

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

Solenoid valve Technical data Electrical supply Air supply

24 V / DC from 6 to 7 bar

For further information regarding individual components please consult the relevant manuals. Proximity Switch Technical data Electrical supply

24 V / DC PNP/NPN

For further information regarding individual components please consult the relevant manuals.

Microswitch Technical data Electrical supply

24 V / DC

For further information regarding individual components please consult the relevant manuals.


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5.

Installation

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

1. Connect electrical power and air supply.

TYPE1

TYPE2 192d

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

21c

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.

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


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5.

Installation

Installation of external proximity switch

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

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

TYPE1

TYPE2 192d

21c

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.

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. The Company BARDIANI VALVOLE reserves the right to modify its products at any time without prior notice.

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5.

Installation

Solenoid 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:

192d 192b

192

Fig.1

192c 192e

21i

21h

21g

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.

192d

21c

192

192 192b 192b 192e 192e

TYPE1

TYPE2

3a. TYPE1 Refit 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 TYPE2 Refit 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). The Company BARDIANI VALVOLE reserves the right to modify its products at any time without prior notice.

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6.

Troubleshooting PROBLEM

Air leak at solenoid valve support Air leak from the safety valve

POSSIBILE CAUSE

Missing seal or loose valve joint

POSSIBILE REMEDY

Check for seal and tighten joint bolts

Damaged circuit board Change the circuit board LED damaged The LED does not light up

The solenoid valve is not working

The proximity or microswitches not working

Electrical connections incorrect

Check electrical connections to the valve at connector block and tighten connector screws

Damaged solenoid valve

Change solenoid valve

Circuit board damaged

Change circuit board

Incorrect air pressure

Consult technical data section of the manual

Defective solenoid valve support

Change solenoid valve support

Incorrect electrical connections

Check the electrical connections and tighten connector block screws

Proximity or microswitches damaged

Change proximity or microswitches

Incorrect electrical connections

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

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


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7.

Pneumatic Connections TYPE1

Exhausting port

Connections for 6mm tube

Compressed air entry 1/8” (BSP)

1/8” (BSP)

TYPE2

Compressed air entry 1/8” (BSP)

Connections for 6mm tube

Exhausting port 1/8” (BSP)

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. The Company BARDIANI VALVOLE reserves the right to modify its products at any time without prior notice.

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8.

Electrical Connections


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8.



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8.



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8.



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8.



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8.



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8.



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8.



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8.



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9.

Maintenance

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 depressions 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-positioned as not to interfere with the movement of internal parts.

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.


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10.

Disassembly of Giotto-Top®

26

22

25

21b

1. Disconnect electrical and air supply.

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

TYPE1

TYPE2 192d

21c

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. The Company BARDIANI VALVOLE reserves the right to modify its products at any time without prior notice.

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10.

Disassembly of Giotto-Top® 27d

27 21d

27a

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

21c 192d

21c

192

192

192b 192b

192e

192e 192c 192c

TYPE1

TYPE2

5a. TYPE1 Remove 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. TYPE1 Remove 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). The Company BARDIANI VALVOLE reserves the right to modify its products at any time without prior notice.

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10.

Disassembly of Giotto-Top®

114a

114c

21f

21a

21e

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®

114a

114c

21f

21e

21a

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). The Company BARDIANI VALVOLE reserves the right to modify its products at any time without prior notice.

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11.

Assembly of Giotto-Top® 21c 192d

192

21c

192

192b 192e

192b 192e

192c 192c

TYPE1

TYPE2

2a. TYPE1 Fit 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 TYPE2 Fit 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).

27d

27

21d

27a

3. Tighten the double guide (21d), the micro-proximity carriage (27d) and the proximity (27a) or microswitches (27) . The Company BARDIANI VALVOLE reserves the right to modify its products at any time without prior notice.

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Assembly of Giotto-Top®

11.

TYPE1

TYPE2 192d

21c

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.

26

25

22

21b

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). The Company BARDIANI VALVOLE reserves the right to modify its products at any time without prior notice.

6. Connect electrical power and air pressure. (GB-IST-GIOT-0507) 27/30

12.

Part list


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12.

Parts 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


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Giotto TOP

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