Formula Air BADA-VEX Bedienungsanleitung

BADA-VEX

ATEX non-return valves

Maintenance manual (EN)

V1.2-2023

Maintenance manual | BADA-VEX ATEX non-return valves

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Table of content

1. Introduction ..................................................................................................................................................... 4

2. Preamble......................................................................................................................................................... 4

3. Safety information............................................................................................................................................ 4

4. Standards and certificates............................................................................................................................... 5

4.1. BADA-VEX range is according to following standards :........................................................................... 5

4.2. Manufactured according to quality standards : ....................................................................................... 5

4.3. Conformity of complementary standard :................................................................................................. 5

5. Working features ............................................................................................................................................. 5

5.1. BADA-VEX range: DN 160 to DN800 (DN 6” to DN 32”)....................................................................... 5

5.2. Working airflow: Under-pressure airflow (pull flow) ................................................................................. 5

5.3. BADA-VEX installation features (Tab-1) : ................................................................................................ 6

6. BADA-VEX working ......................................................................................................................................... 6

6.1. Airflow rules : .......................................................................................................................................... 6

6.2. Explosion risk direction : .......................................................................................................................... 7

6.3. BADA-VEX working modes: .................................................................................................................... 8

6.4. Setting of working mode :........................................................................................................................ 9

6.4.1. Floating flap mode : ....................................................................................................................... 9

6.4.2. Flap kept open mode by mechanic system :.................................................................................. 10

6.4.3. Flap position indicator, when it’s opened : ................................................................................... 12

6.4.4. Flap position in idle position (only for floating flap mode) :............................................................ 12

6.4.5. Flap indicator in waiting position :................................................................................................ 13

6.4.6. Flap locked in closed position :..................................................................................................... 13

6.4.7. Indicator position with flap locked closed :................................................................................... 14

7. Installing the BADA-VEX................................................................................................................................ 14

7.1. Rules to install the BADA-VEX : ............................................................................................................. 14

8. Overall dimensions (The list of models is not exhaustive) ................................................................................ 19

8.1. BADA-VEX range in metric « DN » (TAB-4) ............................................................................................ 19

8.2. BADA-VEX range in imperial « DN » (TAB-5) ......................................................................................... 20

9. Flap locking sensor (in closed position)........................................................................................................... 20

9.1. Inductive sensor Ø12 non-ATEX zone (DN≤350 - DN≤14") : ................................................................. 21

9.2. Optional : inductive sensor Ø12 for ATEX zone - II 2 D (DN≤350 - DN≤14") :............................... 21

9.3. Inductive sensor Ø18 non-ATEX zone (DN≥400 - DN≥16") : ................................................................. 22

9.4. Optional : inductive sensor Ø18 for ATEX zone - II 2 D (DN≥400 - DN≥16"): ................................ 22

10. Dust build-up sensor.................................................................................................................................. 22

10.1. Capacitive sensor Ø12 for ATEX zone - II 1 D:.............................................................................. 24

11. ATEX marking............................................................................................................................................ 25

11.1. Certification features :........................................................................................................................... 25

11.2. Scope of the standards present on product marking :............................................................................ 25

11.3. Marking example : ................................................................................................................................ 25

12. Aeraulic pressure loss ................................................................................................................................ 26

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12.1. Pressure loss graphs.............................................................................................................................. 26

12.2. Pressure loss values (in mm H2O /inch Wg) measured at 20 m/s (4000 ft/min) (TAB-8). ........................ 27

13. Maintenance operations and periodic inspections..................................................................................... 28

13.1. Standard requirements :........................................................................................................................ 28

13.2. Periodic inspection operations : ............................................................................................................ 28

13.3. Check all following points (TAB-9):........................................................................................................ 29

13.4. Procedure in case of an explosion :....................................................................................................... 29

14. Dismantling and recycling ......................................................................................................................... 30

15. Maintenance log ....................................................................................................................................... 31

Contacts................................................................................................................................................................. 32

Maintenance manual | BADA-VEX ATEX non-return valves

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1. Introduction

This manual cannot be reproduced, even partially, without prior written consent by Formula Air Group. Every step of

the ATEX non-return valve range has been deeply analyzed by Formula Air Group in the expected area during the

design, construction, and user manual creation. However, it is understood that nothing can replace the experience,

training and good sense of those professionals who work with the device.

Ignoring the cautions and warning from the present user manual, using improperly parts or the whole device supplied,

using unauthorized spare parts, manipulating the device by non-qualified personnel, violation of any safety norm

regarding design, construction and use expected by the supplier, exempt Formula Air Group from all responsibility in

case of damages to people or properties.

Formula Air Group does not take any responsibility for the non-observance of the user about the preventive safety

measures presented in this user manual.

Failure to comply with the requirements of the user manual or incorrect use of the ATEX non-return valve during

operation can lead to the damage of the ATEX non-return valve and improper functioning of the ATEX non-return

valve itself. This will result in termination of the warranty on the item and will release the manufacturer from any liability.

Certification

The BADA-VEX non-return valve range is conform to ATEX norms EN16447 & EN15089.

Warranty : Refer to the general sales condition in regards to the device’s warranty.

Attention !

All drawings and references contained within this user manual are non-contractual and are subject to change without

prior notice at the discretion of the Formula Air Group and its partners.

2. Preamble

Before proceeding to the installation of the valve, please read carefully the following instructions.

Warning :

All instructions contained within this manual have to be fully understood and absolutely followed in

order to guarantee the proper functioning of the BADA-VEX ATEX non-return valve. If you have any

questions, especially in specific applications, please contact FORMULA AIR.

3. Safety information

The BADA-VEX is a protection device for dust ATEX zone (EX II D). The facility manager has to implement the European

regulation 1999/92CE. To be sure that this device is correctly used, the authorized workers have to be trained on the

warning signs and safety rules to ensure the safety of people and facilities.

Non-return valve safety rules according to the standards EN 16447. The explosion isolation non-return valves

have not to be used to protect installations with the following substances, nor a mixture containing some of

these substances:

a) Gas, steams or hybrid mixing

b) Unstable chemical substances

c) Explosive substances

d) Pyrotechnic substances

It is mandatory to respect the pipe length between the protected vessel and the BADA-VEX according to

minimum (Lmin) and maximum length (Lmax) to assure the BADA-VEX isolation in case of explosion.

The vessel(s) connected to the BADA-VEX must be protected :

− Either by an explosion venting device (vent panel, flameless)

− Or a suppression system

BADA-VEX is designed to isolate a vessel with a pressure resistance of ≤0.5 bar (Pred). In case the vessel

has a higher resistance, the explosion discharge device has to be defined with maximum reduced pressure in

it of (Pred) ≤0.5 bar. The pipes before and after the BADA-VEX need to resist to 2 bar (like the BADA-VEX).

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Don’t use the BADA-VEX to support the pipes upstream or/and downstream. It should not be subjected to

strong vibration to keep its isolation integrity in case of explosion.

Assure the electrical continuity of the installation (earthing) by connecting the BADA-VEX with earth wires to

both pipes.

4. Standards and certificates

4.1. BADA-VEX range is according to following standards :

• 2014/34/UE ATEX regulation

• EN 16447 : 2014 Explosion isolation flap valves

• EN 15089 : 2009 Explosion isolation systems

• EN 1127-1 :2019 Explosion prevention and protection - Part 1

• EN 14460 : 2018 Explosion resistant equipment

4.2. Manufactured according to quality standards :

• 0080 N° of notified body in charge of checking (INERIS)

• INERIS 23ATEX0012X N° of EU type examination certificate

4.3. Conformity of complementary standard :

• NFPA 69 : 2019 Explosion Prevention Systems

5. Working features

BADA-VEX is an ATEX protective device equipped with a mobile flap which will close under explosion overpressure

and will lock in closed position to avoid the flame to propagate through the ducting to another part of the facility

(suction inlet, filter…).

BADA-VEX is certified for PUSH and PULL flow installations.

BADA-VEX seal the pipe to stop explosion from spreading, either if the explosion come from in opposite direction of

the air + dust flow (example: see picture 1, page 5: “position ”) or if the explosion come from the direction of the

clean airflow (example: see picture 2, page 5: “position ”). In this second case, you need to use the non-return valve

with the flap locked in open position.

Working limits of the BADA-VEX range are defined to ensure the safety of workers, equipment and the

installation. Upholding these limits are the responsibility of the Management exploiting the premises.

5.1. BADA-VEX range: DN 160 to DN800 (DN 6” to DN 32”)

5.2. Working airflow: Under-pressure airflow (pull flow)

Over-pressure airflow (push flow)

• Bends are allowed upstream and downstream of the BADA-VEX, no quantity limit or position restrictions,

• The BADA-VEX can be installed in vertical position (Pictures 15 + 16)

Kst,max ≤250 bar.m/s

Pred,max * ≤ 0.5 bar Airflow speed Clean air side : ≤ 30 m/s

Loaded air side : ≤ 45 m/s

Kst,min No limit BADA-VEX

resistance 2.0 bar Placement Air & dust ducting

Clean air ducting

Pmax 10 bars ATEX marking II D Airflow range Under-pressure : Pull flow

Over-pressure : Push flow

MIE ≥ 10 mJ ATEX inside Zone 20 (II 1 D) Over-pressure

limit 500 mbar max

MIT ≥ 400°C Dust type** All dust types Under-pressure

limit - 800 mbar max

MESG 1.7 mm Dust

concentration No limit Qty.of bends No limit

* Vessel (potential explosion source)

** Organic dust, synthetic dust or metal dust according to the limits defined above.

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Working temperature

Standard : flap gasket in EPDM -30°C to +70°C / -22°F to 158°F

Option : flap gasket in SILICONE -10°C to +180°C*** / 14°F to 356°F***

***Caution: With standard sensor, the working temperature is limited to 70°C / 158°F. Option is available up to

150°C/302°F only for locking sensor.

5.3. BADA-VEX installation features (Tab-1) :

DN Vmin Lmin Lmin +2m Lmax

Ø160 (6") 0,70 m³ 4,0 m 6,0 m 17 m

Ø160 (6") 1,35 m³3,0 m 5,0 m 17 m

Ø180 (7") 0,70 m³4,0 m 6,0 m 17 m

Ø180 (7") 1,35 m³3,0 m 5,0 m 17 m

Ø200 (8") 1,35 m³4,6 m 6,6 m 17 m

Ø250 (10") 1,35 m³4,0 m 6,0 m 17 m

Ø300 (12") 2,90 m³4,6 m 6,6 m 17 m

Ø350 (14") 2,90 m³4,2 m 6,2 m 17 m

Ø400 (16") 4,50 m³5,2 m 7,2 m 17 m

Ø450 (18") 4,50 m³4,7 m 6,7 m 17 m

Ø500 (20") 6,05 m³5,8 m 7,8 m 17 m

Ø550 (22") 6,05 m³5,5 m 7,5 m 17 m

Ø600 (24") 7,65 m³7,2 m 9,2 m 17 m

Ø650 (26") 7,65 m³6,7 m 8,7 m 17 m

Ø700 (28") 7,65 m³6,4 m 8,4 m 17 m

Ø750 (30") 10,00 m³7,3 m 9,3 m 17 m

Ø800 (32") 10,00 m³6,9 m 8,9 m 17 m

Vmin : Min vessel volume being protected by BADA-VEX isolation valve.

Lmax : Max installation distance between the vessel and the BADA-VEX.

Lmin : Min installation distance between the vessel and BADA-VEX, for floating flap with straight horizontal pipe,

no bends.

Lmin + 2 m : Min installation distance between the vessel and BADA-VEX in at least one of following cases :

− Flap locked open by its spring system,

− Pipe with bend between isolated vessel and BADA-VEX, flap in horizontal position ±10° (see picture

18),

− Pipe with bend between isolated vessel and BADA-VEX, flap in vertical position, observe following rules :

 Min installing distance = Lmin+2m, if vertical pipe from bend to BADA-VEX > 5 x Øpipe,

 Min installing distance = Lmin+2m +5 x Ø, if vertical pipe from bend to BADA-VEX = 5 x Øpipe.

Installation of BADA-VEX in vertical position must be with vertical pipe of min 5 x Øpipe between bend and

BADA-VEX (see picture 16).

6. BADA-VEX working

6.1. Airflow rules :

BADA-VEX is certified to work with under-pressure airflow (Pull flow) or over-pressure airflow (Push flow).

BADA-VEX can be installed in position A and B (picture 1) on the LOADED air side or in position D and E (picture

2) on the CLEAN air side. In position D and E the BADA-VEX needs to be locked open with the mechanical

system.

The working direction of airflow (Push flow or Pull flow) has no influence on the min installation distance.

The working position D and E are advised to inject back the clean air inside the workplace. It’s recommended to

not use the position C (picture 3) and F (picture 4).

Maintenance manual | BADA-VEX ATEX non-return valves

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6.2. Explosion risk direction :

BADA-VEX installation must observe the direction of the "EXPLOSION RISK" arrow. In fact, this arrow

indicates the direction of explosion flame which has to be stopped by the BADA-VEX, not the normal

working airflow.

Loaded airflow

Clean airflow

Angular position

indicator of flap

Installation direction

Standard working

airflow

Maintenance manual | BADA-VEX ATEX non-return valves

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6.3. BADA-VEX working modes:

BADA-VEX can function following 2 modes: either with floating flap (picture 5) or flap kept open (picture 6).

According to the chosen mode, you have to observe the installation distance Lmin and Lmax. These values have

to be checked following the chosen mode as well as the volume of vessel with potential explosion risk (see Tab-

1 page 4).

Floating flap mode, the flap is opened by the working airflow. When the fan stops, the flap closes itself by its

weight without locking (wait to open).

Kept open flap mode, flap is kept open by strip spring system in max opened position. In this mode, the BADA-

VEX can be installed on the clean air side. The kept open flap position can support air speeds up to 30 m/s (6000

ft/min) without closing. It also can be installed in loaded air to reduce the pressure drop especially with low

airflow speeds.

We advise using BADA-VEX in floating flap mode when it’s installed in loaded airflows (working flow in opposition

direction of explosion). However, BADA-VEX has to be used in keep opened flap mode when it’s installed on the

clean air side (explosion flame in same direction than working flow) according to direction of explosion risk.

Only the overpressure of an explosion is capable of activating the locking system of the valve.

Clean airflow

Picture 5

Picture 6

Mode with floating flap

without spring system(s)

Mode with flap kept open

Arm blocked by spring

system

Loaded airflow

Maintenance manual | BADA-VEX ATEX non-return valves

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6.4. Setting of working mode :

The BADA-VEX is delivered from the factory in the ‘Locked Open’ position. If you want to use the BADA-

VEX with a ‘Floating Flap’ remove the external protection cover and take the following measures :

Be sure that the installation is switched off before operating on the BADA-VEX and remove the protect

cover.

6.4.1. Floating flap mode :

To set up the BADA-VEX in mode : floating flap, you have to take off the spring strip(s) to allow the flap to move

freely (picture 7 and 7b).

Caution : the outside arm is part of the moving parts. The weight of this subassembly is high for the BADA-

VEX ≥DN 400 (16"). Be especially careful when handling it, don’t put your hand either in the moving zone nor

in the gasket zone of the flap inside the body.

The arm of the flap is

locked in closed position

by the mechanical

locking system

Cover

Picture 7

BADA-VEX floating flap mode DN160 (6")

to DN450 (18")

Remove the following parts :

A) Spring strip

B) Pin

C) Bolt and screw

D) Pin lock

E) Locked open leaf spring

A B

Damper arm

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6.4.2. Flap kept open mode by mechanic system :

The BADA-VEX is delivered from factory in mode: Flap kept open by mechanic locked system. If you have to

change the working mode into floating flap position, to set back the BADA-VEX in flap « locked open position”

mode or to place again the flap in kept open position, you have to take off the protection cover and undertake

the following operations :

1. To set back on mode: flap kept open by mechanic system, you have to put in place the spring strip(s) ref. A

on the bracket(s) ref. E operate in opposite way as described in the pictures 7 or 7b. Then tighten the bolt

to 5 Nm and loosen by a ¼ turn.

2. To place again the flap in kept open position by mechanic system (picture 8 and 8b). Step 1, you have to

turn the spring strip(s) ref. A to outside position in order to raise the arm against the top stop part ref. F.

Step 2, you have to turn back the spring strip(s) under the outside arm and slowly release the arm. Now, you

have to lock the spring strip(s) in position with the pin ref. B and pin lock ref. D.

It’s forbidden to use the BADA-VEX without protection cover.

You have to put the cover back in place with fixing screws after each operation.

Picture 7b

BADA-VEX floating flap mode DN500 (20")

to DN800 (32")

Remove the following parts :

A) 2 spring strips

B) 2 pins

C) 2 bolts and nuts

D) 2 pin locks

E) Locked open leaf springs

Cover

Damper arm

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