Operating instructions (Translation)
Pressure relief valve BBV1, BBV2 up to 90
bar

Pressure relief valve BBV1, BBV2 up to 90 bar

BBV1, BBV2 up to 90 bar
Englisch2018-11-27

Table of Content
1 General4

1.1

About the documentation

4

1.2

Manufacturer´s address

4

1.3

Symbolism

5

2 Safety6

2.1

Intended use

62.2

Personnel qualification and training

6

2.3

Basic safety instructions

6

2.4

Basic hazards

7

3 Device description

8

3.1

Functional principle

8

3.2

Basic design9

4 Technical data

10

4.1

General information

10

4.2

Hydraulic specifications

10

4.3

Material data

11

4.4

Dimensions

11

4.5

Dimensions - Thread contour

12

4.6

Tightening torque for screw-in valve cartridge

12

5 Transport and storage

13

5.1

General13

5.2

Storage13

6 Installation

15

6.1

Safety instructions for installation

15

6.2

General16

6.3

Mechanical installation

16

6.3.1

Pressure relief valve

16

6.3.2

Mounting Connection lines

16

7 Operation start-up

17

7.1

Safety instructions for start-up

17

7.2

Pressure relief valve adjustment

18

7.3

Further operation start-up

19

8 Removal

20

8.1

Safety instructions for removal

20

8.2

General21

9 Maintenance

22

9.1

Safety instructions for maintenance

22

9.2

Maintenance work

23

9.3

Maintenance instructions

23

10

Repairs25

10.1

Safety instructions for repair

25

10.2

General26

10.3

Detecting and eliminating failures

27

Pressure relief valve BBV1, BBV2 up to 90 bar

1 General
1.1

About the documentation
These operating instructions describe the installation, operation and maintenanceof the following device:
Pressure relief valve BBV1, BBV2 up to 90 bar
The device is manufactured in different versions. Information about the version
concerned in the individual case can be found on the device's type plate.
These operating instructions are a component of the device and must be kept accessible for the personnel near the device at all times.
If you have any questions about these operating instructions, please contact the
manufacturer.

1.2

Manufacturer´s address
Brinkmann Pumpen
K. H. Brinkmann GmbH & Co. KG
Friedrichstraße 2DE 58791 Werdohl
Tel: +49 (0) 23 92 / 5006-0
Fax: +49 (0) 23 92 / 5006-180
E-mail: sales@brinkmannpumps.de
Web: www.brinkmannpumps.de4

BBV1, BBV2_EN 2018-11-27

Pressure relief valve BBV1, BBV2 up to 90 bar

1.3

Symbolism
DANGER
Identification of an immediate hazard, which would result in death or severe bodily injury if not avoided.

WARNING
Identification of a potential medium risk hazard, which would lead to death or severe bodily injury if not avoided.

CAUTION
Identification of a low risk hazard, which could lead to minor or medium bodily injury if not avoided.

NOTICE
Flagging of notices to prevent property damage.

Identification of basic safety instructions. Non-compliance can lead to hazards forpeople and the device.

Flagging of special user tips and other especially useful or important information.

BBV1, BBV2_EN 2018-11-27

5

Pressure relief valve BBV1, BBV2 up to 90 bar

2 Safety
2.1

Intended use
1.

The device has been designed for operation with fluid. Dry operation is not
permitted.

2.

The device may be operated in filled condition only.
The medium must be compatible with the materials used in the device. The
chemical competence is necessary for this. Be careful with ethylene oxide orother cathalytic or exothermic or self-decomposing materials. Please consult
the manufacturer in cases of doubt.

3.

The device may be operated only in usual industrial atmospheres. If there are
any aggressive substances in the air, always ask the manufacturer.

4.

Operation of the device is only permissible when complying with the operating
instructions and applicable documents.
Deviating operating conditions require the express approval of the manufacturer.

5.

2.2

In case of any use of the device not according to specification, any warranty isvoided.

Personnel qualification and training
The staff designated to assemble, operate and service the device must be properly
qualified. This can be through training or specific instruction. Personnel must be
familiar with the contents of this operating instructions.
Read the operating instructions thoroughly before use.

2.3

6

Basic safety instructions
1.

Comply with existing regulations on accident prevention and safety at work
along with any possible internal operator regulations.

2.

Pay attention to the greatest possible cleanliness.

3.

Wear suitable personal protection equipment.

4.

Do not remove, make illegible or obliterate type plates or other references on
the device.

5.

Do not make any technical changes on the device.

6.

Maintain and clean the device regularly.

7.

Use spare parts approved by the manufacturer only.

BBV1, BBV2_EN 2018-11-27

Pressure relief valve BBV1, BBV2 up to 90 bar

2.4

Basic hazards
DANGER
Hazardous fluids!
Danger of death when handling hazardous fluids.
1.

Comply with the safety data sheets and regulations on handling hazardous
fluids.

2.

Collect and dispose of hazardous fluids so that no hazards arise for peopleor the environment.

WARNING
Failure of load-carrying parts due to overload!
Danger of injury from flying parts.
Danger of injury from spurting fluids.
1.

Depressurise the device and all connection lines before doing any work.

2.

Securely prevent the restoration of pressure while working on the device.

WARNING
Failure of load-carrying parts due to overload!
Danger of injury from flying parts.
Danger of injury from spurting fluids.
1.

Use only connections and lines approved for the expected pressure range.

2.

Securely prevent exceeding the permissible pressure, e.g. by using pressure
relief valves or rupture discs.

3.

Design pipework so that no tensions, e.g. caused by changes in length due tofluctuations in temperature, are transmitted to the device.

WARNING
Failure of load-carrying parts due to overload!
Danger of injury from flying parts.
Danger of injury from spurting fluids.
1.

Consider the permissible pressure setting range of the valve.

2.

Check the pressure setting (the valve must not block).

BBV1, BBV2_EN 2018-11-27

7

Pressure relief valve BBV1, BBV2 up to 90 bar

3 Device description
3.1

Functional principle
Series BBV1, BBV2 up to 90 bar pressure relief valves are directly operated seatvalves for installation into pipelines or as screw-in valves. The valve is used as apressure safeguard in hydraulic systems up to 100 bar.

1.

Housing2.

Valve cone

3.

Valve seat4.

Threaded bush

5.

Compression
spring6.

Check nut

7.

Adjustment screw

8.

Protective cap

The valve cone is pressed by the compressed spring into the valve seat, whichblocks Pressure connection (P) from Tank connection (T). When the responsepressure is reached by adjusting with the setscrew, the valve cone releases thefluid flow to the tank connection.
The response pressure is set via setscrew. To accomblish, check nut has to beloosened and then retightened after adjustment.
The valve should preferably be mounted vertical, with the adjustment screw facing
down.
The flow direction is marked with an arrow on the unit housing. It is always implemented from the pressure port (P) to the tank connector (T).

8

BBV1, BBV2_EN 2018-11-27

Pressure relief valve BBV1, BBV2 up to 90 bar

3.2

Basic design

EBV1, 2

BBV1, 2

BBVH1, 2

10. Threaded bush

10. Housing

10. Threaded bush

20. Valve seat

20. EBV1, 2

20. Valve seat

30. Valve cone

50. Protection plug

30. Valve cone

40. Baffle

40. Baffle

50. Washer

50. Washer

60. Spring guide60. Spring guide70. Compression
spring70. Compression spring

80. Retaining ring

80 Retaining ring

90. Setscrew

90. Round-head screw

100. Protective cap

110. Union nut

110. Union nut

120. O-Ring

120. O-Ring

130. O-Ring

130. O-Ring

140. Hexagonal nut
150. Spacer sleeve160. Twist grip
170. Cover

3.3
BBV1, BBV2_EN 2018-11-27

9

Pressure relief valve BBV1, BBV2 up to 90 bar

4 Technical data
4.1

General information

General information BBV1, BBV2 up to 90 bar
DesignPoppet valve

Type of damping

Valve cone with damper

Fixing type

Screw-in valve
Pipeline valve

Connection type

G3/4

Mounting position

Any

Actuation typeMechanical setscrew / Twist grip

Filtering

Filter porosity: max. 20 µm for very hard particles 1.000 – 10.000 HV
max. 50 µm for hard particles 50 – 70 HRC
max. 60 µm for middle hard particles < 50 HRC
See the pollution classifications diagram in the screw pumps catalog

Permissible media

Oil and water based coolant according to the operating instructions in the screw
pumps catalog

4.2

Hydraulic specifications

Nominal size

10

Max. flow capacity

Qmax.

[l/min]60

Nominal pressure

pN

bar

100

Pressure setting range

p min

bar

10

pmax

bar

90

Outlet pressurepR maxbar

10

Fluid temperatureϑm min.

°C-20

ϑm max°C150

ϑu min.

°C-20

ϑu max.

°C

60

νmin

mm2/s

1

νmax

mm2/s

600

Ambient temperature

Viscosity

10

BBV1, BBV2_EN 2018-11-27

Pressure relief valve BBV1, BBV2 up to 90 bar

4.4

Material data

Component

Material

Housing

EN-GJS-400-18LT

Threaded bush

Steel

Compression spring

Spring steel

Sealing material

FKM

Interior parts

Steel, heat-treated

Other materials

Steel

Union nut

Steel, Polyamid

Twist grip

Plastic

4.5

Dimensions

Dimensions
A
45

B
min

max.

68

80.5

G

H

J

K

L

M

N

Z

G3/4

36

1

45

41.5

M35x1.5

100.5

77.5

All dimensions in mm

BBV1, BBV2_EN 2018-11-27

11Pressure relief valve BBV1, BBV2 up to 90 bar

4.6

Dimensions - Thread contour
A=

Drain

Z=

Inflow selectable

Dimension for fixing type

BBV1, 2

D1

D2H9

D4H9

D5
max.

D6

L1

L2
max.

L3

L4

L5

L6

W

M35x1.5

32

31.9

12

20

22

25

35

52

80

41

15°

All dimensions in mm

4.7 Tightening torque for screw-in valve cartridge
Nominal size
Tightening torque MA (max.)

12

10
80 Nm

BBV1, BBV2_EN 2018-11-27

Pressure relief valve BBV1, BBV2 up to 90 bar

5 Transport and storage
5.1

5.2

General●After receipt, check the device for transport damages.

●

If transport damage is noticed, report this immediately to the manufacturer
and the carrier. The device must then be replaced or repaired.

●Dispose of packing material and used parts in accordance with the local stipulations.

Storage
The device's function is tested in the plant with mineral hydraulic oil. Then all connections are closed. The remaining residual oil preserves the interior parts for up to
6 months.
Metallic exposed exterior parts are protected against corrosion by suitable conservation measures, also up to 6 months.
In case of storage, a dry, dust-free and low-vibration environment is to be ensured.
The device is to be protected against influences from weather, moisture and strong
fluctuations of temperature. The recommended storage conditions are to be adhered to.
Below the permissible ambient temperature ϑu elastomer seals lose their elasticity
and mechanical loading capacity, since the glass transition temperature is fallen
below. This procedure is reversible. A force action on the device is to be avoided incase of storage below the permissible ambient temperature ϑu.
When storing for a long period of time (> 6 months), treat all surfaces at risk ofcorrosion again with suitable preserving agents.
If high air humidity or aggressive atmospheres are expected, take additional corrosion-preventing measures.
Storage in corrosion protection bags (VCI) maximum of 6 months.

NOTICE
Corrosion/chemical impact
Improper storage can render the device useless.
1.

Protect endangered surfaces by means of suitable conservation measures.

2.

Comply with recommended storage conditions.

BBV1, BBV2_EN 2018-11-27

13

Pressure relief valve BBV1, BBV2 up to 90 bar

Recommended storage conditions

14

1.

Storage temperature: 5 °C - 25 °C

2.

Relative air humidity: < 70 %3.

Protect elastomer parts from light, especially direct sunlight.

4.

Protect elastomer parts from oxygen and ozone.

5.

Comply with maximum storage times of elastomeric parts:○

5 Years: AU (Polyurethane rubber)○

7 Years: NBR, HNBR, CR○

10 Years: EPM, EPDM, FEP/PTFE, FEPM, FKM, FFKM, VMQ,
FVMQ

BBV1, BBV2_EN 2018-11-27

Pressure relief valve BBV1, BBV2 up to 90 bar

6 Installation
6.1

Safety instructions for installation
DANGER
Hazardous fluids!
Danger of death when handling hazardous fluids.
1.

Comply with the safety data sheets and regulations on handling hazardous
fluids.

2.

Collect and dispose of hazardous fluids so that no hazards arise for peopleor the environment.

WARNING
Failure of load-carrying parts due to overload!
Danger of injury from flying parts.
Danger of injury from spurting fluids.
1.

Depressurise the device and all connection lines before doing any work.

2.

Securely prevent the restoration of pressure while working on the device.

WARNING
Failure of load-carrying parts due to overload!
Danger of injury from flying parts.
Danger of injury from spurting fluids.
1.

Use only connections and lines approved for the expected pressure range.

2.

Securely prevent exceeding the permissible pressure, e.g. by using pressure
relief valves or rupture discs.

3.

Design pipework so that no tensions, e.g. caused by changes in length due tofluctuations in temperature, are transmitted to the device.

BBV1, BBV2_EN 2018-11-27

15

Pressure relief valve BBV1, BBV2 up to 90 bar

6.2

General●Check the device for transport damage and dirt.

●

Check the device for freedom of movement.

●

Remove existing preservatives.

●○

Use only those cleaning agents that are compatible with the materials
used in the device.

○

Do not use cleaning wool.

Compare the environmental and ambient conditions at the place of installation
to the permissible conditions.
○

Expose the device only to small vibrations, see IEC 60034-14.

○

Secure sufficient access for maintenance and repair.

6.3

Mechanical installation

6.3.1

Pressure relief valve

6.3.2

●

Install the device preferably vertical with the pressure adjustment screw facing
down.

●

Take measures against accidental touching of hot surfaces (> 60 °C).

Mounting Connection lines
Position of the device connections: See chapter 3 “Device description”●

16

Clean all lines.
○

Do not use cleaning wool.

○

Pickle and flush welded pipes.

●

Remove the protective plugs.

●

Mount the lines.
○

Comply with the manufacturer's information.

○

Do not use any sealing materials such as hemp, Teflon tape or putty.

BBV1, BBV2_EN 2018-11-27

Pressure relief valve BBV1, BBV2 up to 90 bar

7 Operation start-up
7.1

Safety instructions for start-up
DANGER
Hazardous fluids!
Danger of death when handling hazardous fluids.
1.

Comply with the safety data sheets and regulations on handling hazardous
fluids.

2.

Collect and dispose of hazardous fluids so that no hazards arise for peopleor the environment.

WARNING
Failure of load-carrying parts due to overload!
Danger of injury from flying parts.
Danger of injury from spurting fluids.
1.

Consider the permissible pressure setting range of the valve.

2.

Check the pressure setting (the valve must not block).

CAUTION
Hot surfaces!
Burn injury to skin if touched.
1.

BBV1, BBV2_EN 2018-11-27

Wear protective gloves at temperatures ≥48°C.

17

Pressure relief valve BBV1, BBV2 up to 90 bar

7.2

Pressure relief valve adjustment
The response pressure of the device is factory set to the mean value of each pressure stage. If applicable, the pressure setting must be adapted during commissioning.
Pressure setting for actuation type: A (non-adjustable)
1. Flange nut with sealing
2. Adjustment screw
3. Protective cap

Pressure setting●

Remove the protective cap●

Unscrew flange nut●

Set the response pressure using the adjusting screw○

clockwise - Higher response pressure○counterclockwise - Lower response pressure●

Tighten flange nut (MA = 23 Nm)●

Put on the protective cap

Pressure setting for actuation type: B (Rotary knob)
1. Flange nut with sealing
2. Twist grip

Pressure setting●

Unscrew flange nut●

Set the response pressure with the adjusting screw

●
18

○

clockwise - Higher response pressure○counterclockwise - Lower response pressure

Tighten flange nut (MA = 23 Nm)
BBV1, BBV2_EN 2018-11-27

Pressure relief valve BBV1, BBV2 up to 90 bar

When the flange nut is loosened, slight leakage may occure during pressure adjustment. Once the flange nut is fastened again, the complete tightness of thevalve is guaranteed.
The pressure relief valve can only work flawlessly if all chambers in the valve arefilled with hydraulic fluid. If the mounting position is disadvantageous, air pockets in
the interior can lead to vibration noises.

7.3

Further operation start-up●

Open existing shut-off elements upstream and downstream of the device.

●

Vent the system at the highest possible point.

●

Check the operating data such as:○

Response pressure○

System pressure (as close as possible to device)○

Fluid temperature (as close as possible to device)

○

...

●

Check the device for leaks.

●

Check all threaded connections for leaks and retighten if necessary.

Existing venting and drain plugs must always be closed during operation according to specification.

BBV1, BBV2_EN 2018-11-27

19

Pressure relief valve BBV1, BBV2 up to 90 bar

8 Removal
8.1

Safety instructions for removal
DANGER
Hazardous fluids!
Danger of death when handling hazardous fluids.
1.

Comply with the safety data sheets and regulations on handling hazardous
fluids.

2.

Collect and dispose of hazardous fluids so that no hazards arise for peopleor the environment.

WARNING
Failure of load-carrying parts due to overload!
Danger of injury from flying parts.
Danger of injury from spurting fluids.
1.

Depressurise the device and all connection lines before doing any work.

2.

Securely prevent the restoration of pressure while working on the device.

CAUTION
Hot surfaces!
Burn injury to skin if touched.
1.

20

At temperatures ≥48°C the device must be allowed to cool down first.

BBV1, BBV2_EN 2018-11-27

Pressure relief valve BBV1, BBV2 up to 90 bar

8.2

General●Depressurise and de-energize the system.

●

Close existing shut-off elements upstream and downstream of the device.

●Open existing drain elements and loosen connection lines. Collect and dispose of discharging medium so that no hazard arises for persons or environment.

●

Dismantle the device.

●

Clean the device.

●

Close the device connections and lines to prevent dirt penetration.

BBV1, BBV2_EN 2018-11-27

21

Pressure relief valve BBV1, BBV2 up to 90 bar

9 Maintenance
9.1

Safety instructions for maintenance
DANGER
Hazardous fluids!
Danger of death when handling hazardous fluids.
1.

Comply with the safety data sheets and regulations on handling hazardous
fluids.

2.

Collect and dispose of hazardous fluids so that no hazards arise for peopleor the environment.

WARNING
Failure of load-carrying parts due to overload!
Danger of injury from flying parts.
Danger of injury from spurting fluids.
1.

Depressurise the device and all connection lines before doing any work.

2.

Securely prevent the restoration of pressure while working on the device.

CAUTION
Hot surfaces!
Burn injury to skin if touched.
1.

22

At temperatures ≥48°C the device must be allowed to cool down first.

BBV1, BBV2_EN 2018-11-27

Pressure relief valve BBV1, BBV2 up to 90 bar

9.2

Maintenance work
Checking and documentation of the operating data
Regular checking and documentation of all operating data such as pressure, temperature, current consumption, degree of filter soiling, etc. contributes to earlyproblem detection.
●

Perform maintenance according to specification.

●

Replace defective and worn components.

●

If required, request spare parts lists and assembly drawings from the manufacturer.

●

Document the type and scope of the maintenance work along with the operating data.

●

Compare the operating data with the values of the first commissioning.
Determine the cause in case of major non-compliances (> 10 %).

●Dispose of packing material and used parts in accordance with the local stipulations.

Barriers and instructions
All barriers and warning signs removed during this must be attached to their original position on completing maintenance and/or repairs.

9.3

Maintenance instructions
The following information provides recommendations on maintenance work andmaintenance intervals for the device being used.
Depending on the actually occurring loads in operation, the type, scope and interval of the maintenance work can deviate from the recommendations. The equipment builder/operator shall write an obligatory maintenance plan.

Within the framework of preventive maintenance, it is appropriate to replace wear
parts before reaching the wear limit.
With corresponding expertise and sufficient equipment, the replacement can be
carried out by the equipment builder/operator. Please consult the manufacturer
about this.
●Use spare parts approved by the manufacturer only.

●

Dispose of packing material and used parts in accordance with the local stipulations.

●

If required, request spare parts lists and assembly drawings from the manufacturer.

Warranty
In case of improper implementation, any warranty is voided.

BBV1, BBV2_EN 2018-11-27

23

Pressure relief valve BBV1, BBV2 up to 90 bar

Maintenance recommendations Pressure valve
Interval

Maintenance work

Employees Duration
approx.
[h]

Audiometric monitoring: Unusual noise
Daily

Cleaning: Remove dust deposits and dirt with a moist
cloth

1

0.1

1

1

Visual inspection: Leakages
Inspection: Operating pressureFirstly:
Inspection: Fluid temperature
after max. 24 h
Inspection: Device temperature--3000 Operating hours Inspection: Valve function
or after 12 months
Inspection: Condition of operating fluid24

BBV1, BBV2_EN 2018-11-27

Pressure relief valve BBV1, BBV2 up to 90 bar

10 Repairs
10.1

Safety instructions for repair
DANGER
Hazardous fluids!
Danger of death when handling hazardous fluids.
1.

Comply with the safety data sheets and regulations on handling hazardous
fluids.

2.

Collect and dispose of hazardous fluids so that no hazards arise for peopleor the environment.

WARNING
Failure of load-carrying parts due to overload!
Danger of injury from flying parts.
Danger of injury from spurting fluids.
1.

Depressurise the device and all connection lines before doing any work.

2.

Securely prevent the restoration of pressure while working on the device.

CAUTION
Hot surfaces!
Burn injury to skin if touched.
1.

BBV1, BBV2_EN 2018-11-27

At temperatures ≥48°C the device must be allowed to cool down first.

25

Pressure relief valve BBV1, BBV2 up to 90 bar

10.2

GeneralThe repairs covers:
1.

Troubleshooting
Determination of damage, pinpointing and localisation of the damage cause.

2.

Elimination of damage

Elimination of the primary causes and replacement or repair of defective components. The repair is generally made by the manufacturer.
Repairs by manufacturer●

Before returning the device, fill in the return notification form. The form can be
filled in online and is available as a pdf file download.

Device contains hazardous material
If the device was operated with dangerous liquids, it must be cleaned before thereturn. If this should not be possible, the safety data sheet of the hazardous material is to be provided beforehand.
Repair by equipment builder/operator
If corresponding expertise and sufficient equipment is available, the equipmentbuilder/operator can also make the repairs. Please consult the manufacturer about
this.
●

If required, request spare parts lists and assembly drawings from the manufacturer.

●

Use spare parts approved by the manufacturer only.

●

Dispose of packing material and used parts in accordance with the local stipulations.

Warranty
In case of improper implementation, any warranty is voided.

Barriers and instructions
All barriers and warning signs removed during this must be attached to their original position on completing maintenance and/or repairs.

26

BBV1, BBV2_EN 2018-11-27

Pressure relief valve BBV1, BBV2 up to 90 bar

10.3

Detecting and eliminating failures

FailurePotential causes

Possible measures

1

Increased noise
Mechanical vibrations

Air in the spring chamber

Bleed system

2

Response pressure too high Valve cone tight or jammed(Contaminated medium)

Clean the device
Replace the device
Provide filtration

3

Valve does not respond

Valve blocked

Adjust valve
Comply with the adjustment range

4

Leakages
Seal failure

Poor maintenanceComply with maintenance plan
Replace seals

Mechanical damage

Replace seals

Thermal overload

Check the operating datas
Replace seals

Corrosion/chemical impact

Check the material compatibility
Replace seals

Consult the manufacturer for all unidentifiable failures.

BBV1, BBV2_EN 2018-11-27

27