Operating instructions (Translation)
BBV1, BBV2 100 bar and higher

Pressure relief valve BBV1-2, BBVH1-2 100 bar and higher

BBV1-2 100 bar and higher
Englisch2018-11-26

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

11

4.1

General11

4.2

Permissible pressure range

12

4.2.1

Operating pressure

12

4.2.2

Layout pressure setting range - flow rate BBV1, 2

12

4.3

Permissible temperature range

12

4.4

Material data

12

4.5

Dimensions

12

5 Transport and storage

13

5.1

General13

5.2

Storage13

6 Installation

15

6.1

Safety instructions for installation

15

6.2

Mechanical installation

16

6.2.1

Preparation

16

6.2.2

Screw-in valve

16

6.2.3

Pipeline installation

16

6.3

Connection lines

17

6.3.1

General17

6.3.2

Mounting Connection lines

17

7 Operation start-up

18

7.1

Safety instructions for start-up

18

7.2

Pressure setting

19

7.3

Further operation start-up

21

8 Removal

22

8.1

Safety instructions for removal

22

8.2

General23

9 Maintenance

24

9.1

Safety instructions for maintenance

24

9.2

Maintenance work

25

9.3

Maintenance instructions

25

10

Repairs27

10.1

Safety instructions for repair

27

10.2

General28

10.3

Detecting and eliminating failures

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Pressure relief valve BBV1-2, BBVH1-2 100 bar and higher

1 General
1.1

About the documentation
These operating instructions describe the installation, operation and maintenanceof the following device:
Pressure relief valve BBV1-2 100 bar and higher,
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

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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.

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Pressure relief valve BBV1-2, BBVH1-2 100 bar and higher

2 Safety
2.1

Intended use
1.

The device has been designed for operation with fluid.

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.

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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).

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Pressure relief valve BBV1-2, BBVH1-2 100 bar and higher

3 Device description
3.1

Functional principle
Pressure relief valves of the BBV1-2 series are directly operated seat valves andare used to safeguard low-pressure hydraulic circuits.

Explanation
1 Housing
2 Valve cone
3 Valve seat
4 Threaded bush
5 Compression spring
6 Hexagonal 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 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

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3.2

Basic design
EBV1, 2

Explanation

BBV1, 2

Explanation

1. Damping plugs

1. Housing

2. Valve seat

2. Damping plugs

3. O-Ring

3. Valve seat

4. Valve cone

4. O-Ring

5. O-Ring

5. Valve cone

6. Support ring

6. O-Ring

7. Compression spring

7. Support ring

8. Threaded bush

8. Compression spring

9. O-Ring

9. Threaded bush10. Support ring

10. O-Ring(only NG 20)
11. Hexagonal nut

11. Support ring
(only NG 20)

12. Adjustment screw

12. Hexagonal nut

13. Protective cap

13. Adjustment screw
14. Protective cap

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BBVH1, 2

Explanation
1. Housing

10. O-Ring

2. Damping plugs

11. Support ring

3. Valve seat10

(only NG 20)

4. O-Ring

12. Check nut

5. Valve cone

13. Adjustment screw

6. O-Ring

14. Twist grip

7. Support ring

15. Washer

8. Compression spring

16. Hexagonal nut

9. Threaded bush

17. Washer

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Pressure relief valve BBV1-2, BBVH1-2 100 bar and higher

4
4.1

Technical data
GeneralGeneral information BBV1, 2
DesignSeat valve, directly operated

Fixing type

Screw-in valve / Pipeline installation
Connection KP 1 (BBV1, 2)
BBV1, 2 R 5

Whitworth pipe thread G ¾

BBV1, 2 D 1

Tank connection:
Whitworth pipe thread G ½

Type of damping

Valve cone with damper

Mounting position

preferably vertical, pressure set screw facing down

Max. flow capacity

Qmax.

Operating pressurep

Nominal pressurepN

Pressure setting ranges
Viscosity

See section 4.2 “Permissible pressure range”

pv min.
pv max.
νmin

1 mm2/s

νmax

600 mm2/s

Fluid temperature

ϑmAmbient temperatureϑu

See section 4.3 “Permissible temperature range”

Material

See section 4.4 “Material data”

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(1) Pipe thread: ISO 228-1

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4.2

Permissible pressure range

4.2.1

Operating pressure

Nominal size

Nominal pressure

Inlet pressurepN [bar]
400

10

4.2.2

pe min. [bar]Outlet pressure

pe max [bar]pR max [bar]

410

15

210

Layout pressure setting range - flow rate BBV1, 2

Pressure stage

Pressure setting ranges [bar]pv min.

Flow [l/min]

pv max.

Qmax.
at pv max.

200

200

60

150

55

10
150

4.3

Permissible temperature range
Fluid temperature ϑm (1)Sealing material
ϑm min [°C]FKM

ϑm max [°C]80-15(1) Comply with media-specific properties.

Ambient temperature ϑu

Sealing material
ϑu min. [°C]

FKM

4.4

ϑu max. [°C]60-15Material data

Nominal size

Fixing type

Material
Housing

10

R

EN-GJL-250

Seal

Compression Other materials
springFKM

Spring steel

Steel

R = Pipe valve

4.5

Dimensions
Dimensions of the device can be found in the relevant technical data sheets.

12

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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.

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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

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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.

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Pressure relief valve BBV1-2, BBVH1-2 100 bar and higher

6.2

Mechanical installation

6.2.1

Preparation●

Check the device for transport damage and dirt.

●

Remove existing preservatives.

●

6.2.2

○

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.

Screw-in valve●

Screw the screw-in valve into the designated housing with the specified
torque.
○Do not damage seals during assembly.

Tightening torques [Nm]Nominal size
10

Pressure stage [bar]≤ 200
100 ±5

Select the material and dimensions of the planned housing to ensure sufficient
safety for all conceivable operating conditions.

6.2.3

16

Pipeline installation●

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

●

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

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6.3

Connection lines

6.3.1

GeneralWARNING
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.

Additional connections

6.3.2

1.

Provide measurement connections for pressure and temperature as close as
possible to device.

2.

If necessary, provide a facility to fill or empty the device and the line system.

3.

If necessary, provide a facility to vent the device and the line system.

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

Clean all lines.
○

Do not use cleaning wool.

○

Pickle and flush welded pipes.

●

Remove the protective plugs.

●

Mount the lines.

BBV1-2 100 bar and higher○

Comply with the manufacturer's information.

○

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

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Pressure relief valve BBV1-2, BBVH1-2 100 bar and higher

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.

18

Wear protective gloves at temperatures ≥48°C.

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7.2

Pressure setting
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 for precise adjustment

1 Hexagonal nut

3 Protective cap

2 Adjustment screw●

Remove the protective cap●

Remove hexagon nut●

Set the response pressure using the adjusting screw○

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

Tighten hexagonal nut●

Put on the protective cap

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).

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Pressure relief valve BBV1-2, BBVH1-2 100 bar and higher

Pressure setting for actuation type: B with knob

1 Check nut

2 Twist grip●

Loosen the lock nut●

Set the response pressure with the adjusting screw●○

clockwise = Higher response pressure○counterclockwise = Lower response pressure

Secure the twist grip with a lock nut

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

20

1.

Consider the permissible pressure setting range of the valve.

2.

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

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Pressure relief valve BBV1-2, BBVH1-2 100 bar and higher

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)

○

...

●

Document the operating data of the initial start-up for later comparison.

●

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.

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Pressure relief valve BBV1-2, BBVH1-2 100 bar and higher

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.

22

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

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Pressure relief valve BBV1-2, BBVH1-2 100 bar and higher

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.

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Pressure relief valve BBV1-2, BBVH1-2 100 bar and higher

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.

24

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

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Pressure relief valve BBV1-2, BBVH1-2 100 bar and higher

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

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Pressure relief valve BBV1-2, BBVH1-2 100 bar and higher

Maintenance recommendations Pressure relief valve
Interval

Maintenance work

Employees Duration
approx. [h]Inspection: Valve function
Inspection: Response pressure
Inspection: System pressureFirstly:
after max. 24 h

Inspection: Fluid temperature

1

1

1

0.1

1

1

1

1

Inspection: Device temperature
Inspection: Check potential equalisation forfirm seating and functionality (if existing)
Inspection: Condition of operating fluid
Audiometric monitoring: Unusual noise

Daily

Cleaning: Remove dust deposits and dirt witha moist cloth
Visual inspection: Leakages

Inspection: Valve function
3000 Operating hours
Inspection: Response pressure--Rotational direction monitor- Inspection: System pressure
ing of the motor, e.g. with a Inspection: Fluid temperature
rotating field instrument.
Inspection: Device temperature
After 12 months
Inspection: Condition of operating fluid
As required

26

Replace: Seals

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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.

BBV1-2 100 bar and higher

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

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Pressure relief valve BBV1-2, BBVH1-2 100 bar and higher

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.

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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.

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