Watts Bar PKI Operational manual

2/2-way automatic valve

PKI (with bar-agturn or actubar)

EKI

bar-gmbh.de

IMPORTANT: This manual is only valid in conjunction

with the manufacturer documentation of the actuator

Translation of the original operating manual

2PKI/EKI-IM-DE-B-EN-01-23 Rev.0

Table of Contents

1. General information ...................................................................5

1.1 Reference documents.........................................................................................5

1.2 Validity of the operating manual......................................................................... 5

1.3 Notes to operating manual .................................................................................6

1.3.1 Signal words and symbols ......................................................................6

1.3.2 Explanation of the structure of the safety instructions..........................7

1.3.3 Descriptions in figures.............................................................................7

1.4 Responsibility of the operating company ..........................................................7

2. Safety ..........................................................................................8

2.1 General Safety Instructions ................................................................................8

2.2 Intended use........................................................................................................8

2.3 Reasonable foreseeable use ..............................................................................8

2.4 Organizational measures ....................................................................................8

2.4.1 Subsequent retrofitting or changes ........................................................8

2.4.2 Replacement of defective parts..............................................................8

2.5 Protective equipment..........................................................................................9

2.6 Personnel qualification .......................................................................................9

2.7 Dangers when handling the automatic valve...................................................11

2.7.1 Dangers during assembly, maintenance and disassembly ................. 11

2.7.2 Dangers during functional checks, commissioning and operation..... 14

2.7.3 Dangers when used in explosion-protected areas .............................. 15

3. Product description .................................................................17

3.1 Ball valve ...........................................................................................................17

3.2 Rotary actuator .................................................................................................17

3.3 Type plate..........................................................................................................18

PKI/EKI-IM-DE-B-EN-01-23 Rev.0 3

4. Transport and storage .............................................................19

4.1 Scope of delivery ..............................................................................................19

4.2 Incoming goods inspection ..............................................................................19

4.3 Transport, packaging and storage...................................................................19

5. Installation ................................................................................21

5.1 Installation conditions.......................................................................................21

5.2 Before installation .............................................................................................21

5.3 Installation of ball valve ....................................................................................21

5.3.1 Preparing for installation .......................................................................21

5.3.2 Installation of ball valve with welding ends ..........................................22

5.3.3 Mounting the valve with threaded connection.....................................23

5.4 Mounting the rotary actuator............................................................................ 23

5.5 Pressure test of the pipe section .....................................................................23

6. Commissioning and operation ................................................24

7. Maintenance and repair ...........................................................24

7.1 Maintenance of the actuator ............................................................................24

7.2 Maintenance of ball valve .............................................................................. 24

8. Troubleshooting .......................................................................24

9. Repair and spare parts ............................................................25

10. Disassembly .............................................................................26

10.1 Disassembly of the actuator.............................................................................26

10.2 Disassembly of the ball valve from the pipeline ..............................................26

11. Disposal ....................................................................................26

4PKI/EKI-IM-DE-B-EN-01-23 Rev.0

12. EU Declaration of Incorporation Type P... .............................27

13. EU Declaration of Incorporation Type E... .............................28

14. ATEX Declaration of Conformity Type P... .............................29

15. ATEX Declaration of Conformity Type E... .............................31

16. EU Declaration of Conformity Type E... .................................33

17. Annex / Technical data ............................................................34

17.1 Technical data of rotary actuator .....................................................................34

17.2 Technical data of 2/2-way ball valve of KI type...............................................34

17.3 Pressure-Temperature diagram .......................................................................35

17.4 Dimensional tables and dimensional drawings Type PKI with bar-agturn.....36

17.4.1 Dimensional drawing Type PKI with bar-agturn...................................36

17.4.2 Dimensional table Type PKI with bar-agturn........................................37

17.4.3 Actuator assignment Type PKI with bar-agturn...................................39

17.5 Dimensional tables and dimensional drawings Type PKI with actubar .........40

17.5.1 Dimensional drawing Type PKI with actubar .......................................40

17.5.2 Dimensional table Type PKI with actubar ............................................ 41

17.5.3 Actuator assignment Type PKI with actubar........................................43

17.6 Dimensional tables and dimensional drawings Type EKI ............................... 44

17.6.1 Dimensional drawing Type EKI .............................................................44

17.6.2 Dimensional table Type EKI.................................................................45

PKI/EKI-IM-DE-B-EN-01-23 Rev.0 5

1. General information

This operating manual is a part of the prod-

uct. The operating manual must be kept for

the entire life of the product and must be

passed on to each subsequent owner of the

product.

The operating manual must always be avail-

able at the place of operation.

1.1 Reference documents

This manual, the data mentioned and de-

sign data sheets, additional assembly and

maintenance instructions as well as further

information – also in other language ver-

sions, can be obtained from:

bar pneumatische

Steuerungssysteme GmbH

Auf der Hohl 1

53547 Dattenberg

Tel.: +49 (0)2644-9607-0

Fax: +49 (0)2644-960735

Email: bar-info@wattswater.com

www.bar-gmbh.de

IMPORTANT

This manual is only valid in conjunction

with the manufacturer documentation of

the rotary actuator.

bar pneumatische

Steuerungssysteme GmbH

Auf der Hohl 1

53547 Dattenberg

Tel.: +49 (0)2644-9607-0

Fax: +49 (0)2644-960735

Email: bar-info@wattswater.com

www.bar-gmbh.de

Valpes

Z.I. Centr‘alp

89 rue des étangs

F - 38430 Moirans

Tel. +33 (0) 4 76 35 06 06

Fax +33 (0) 4 76 35 14 34

valpes-info@wattswater.com

www.valpes.com

1.2 Validity of the operating

manual

This operating manual is valid for the 2/2-

way automatic valve of PKI /EKI type since

year of manufacture 2019 with one of the

following rotary actuators:

bar-agturn

• agturn Type GD-032 till 040

• agturn Type GD/GS-052 till 400

actubar

• actubar Type AD-001

• actubar Type AD/AS-002 till 1200

Electric rotary actuator of company

Valpes

6PKI/EKI-IM-DE-B-EN-01-23 Rev.0

1.3 Notes to operating manual

The safety and hazard statements in the

document are intended for your protec-

tion, the protection of third parties and the

protection of the product. The instructions

must therefore be observed.

1.3.1 Signal words and symbols

DANGER

... indicates a hazard that, if not avoided,

will result in death or serious injury.

WARNING

... indicates a hazard that, if not avoided,

could result in death or serious injury.

CAUTION

... indicates a hazard which, if not avoid-

ed, could result in minor or moderate in-

jury.

NOTE

... indicates important information (e.g.

Material damage) but not hazards.

Electric voltage!

The text passages marked with

this symbol inform you about

dangerous situations with danger to life

and health of persons due to electrical

voltage.

Corrosive substances!

The text passages marked with

this symbol inform you about

dangerous situations caused by corrosive

substances.

Hot surface!

The text passages marked with

this symbol inform you about

dangerous situations with a risk of burns

due to hot surfaces.

Cold surface!

The text passages marked with

this symbol inform you about

dangerous situations with a risk due to

cold surfaces.

Suspended load!

The text passages marked with

this symbol inform you about

dangerous situations with a risks due to

suspended load.

Hand injuries!

The text passages marked with

this symbol inform you about

dangerous situations resulting in hand

injuries caused by bruising or punching.

The activities described in the relevant

text passage must be performed with the

utmost care to avoid dangerous situations

and resulting injuries such as loss of limbs.

PKI/EKI-IM-DE-B-EN-01-23 Rev.0 7

Use head protection!

Notes with this symbol indicate

that a head protection must be

worn.

Use protective clothing!

Notes with this symbol indicate

that a protective clothing must

be worn.

Use hand protection!

Notes with this symbol indicate

that a hand protection must be

worn.

1.3.2 Explanation of the structure of

the safety instructions

A safety instruction is initiated with a signal

word describing the severity of the danger

(

„Chapter 1.3.1 Signal words and symbols“

WARNING

Type or source of danger (possibly

with warning signs according to DIN

EN ISO 7010)

Consequences in case of not following

the instruction

• Avoidance of danger

1.3.3 Descriptions in figures

The ﬁgures in this operating manual are

intended to help you understand the facts

and procedures.

The descriptions in the ﬁgures are exem-

plary and may differ slightly from the actual

appearance of your product.

1.4 Responsibility of the operating company

• The installation, electrical and pneumatic connection as well as the commissioning of

the product may only be carried out by qualiﬁed personnel in accordance with the in-

structions described in this operating manual.

• The product may only be operated and maintained by personnel of the legal minimum

age and the corresponding personnel qualiﬁcation.

• This operating manual is an integral part of the product and must be available to the

personnel at all times. This operating manual must be read and understood before the

ﬁrst commissioning.

• The operating and technical personnel must be instructed about safety devices of the

product as well as safe working methods.

• The product may only be operated in perfect condition. No safety devices may be re-

moved or disconnected.

2. Safety

2.1 General Safety Instructions

Personnel assigned to work on the auto-

matic valve must read the operating instruc-

tions before starting work and, in particular,

understand the chapter “Safety” before

starting work. This is particularly valid for

personnel working only occasionally on the

rotary actuator.

2.2 Intended use

• The automatic valve is used for the au-

tomatic shut-off of liquids and gases in

pipelines.

• The automatic valve is designed for use

in process engineering plants.

• The operating values, limit values and

setting data speciﬁed in the operating

manual and the corresponding data

sheet must be observed.

• Intended use also includes the obser-

vance of these operating instructions.

2.3 Reasonable foreseeable use

Any use other than that described in

„Chap-

ter 2.2 Intended use“

and any use not ap-

proved by the manufacturer is considered

as unintended.

DANGER

Danger of explosion!

The automatic valve in combination with

an electric actuator is not intended for use

in potentially explosive atmospheres as

standard. For this purpose, an electric ac-

tuator suitable for ATEX applications must

be selected.

• Do not use the automatic valve with

standard E drive in potentially explo-

sive atmospheres.

2.4 Organizational measures

2.4.1 Subsequent retrofitting or

changes

The operator must make a corresponding

assessment of the hazards when dealing

with subsequently integrated components

and retroﬁtting.

If you want to use a different medium or use

the ball valve for a different purpose, contact

our customer service. We can help you with

any possible necessary conﬁgurations.

2.4.2 Replacement of defective

parts

Replace parts of th rotary actuator that are

not in perfect condition immediately with

original spare parts.

Please note that only original spare and

wear parts of bar GmbH are to be used.

In the case of usage of the third-party parts,

it is not ensured that they are designed and

manufactured to suit the requirements.

8PKI/EKI-IM-DE-B-EN-01-23 Rev.0

2.5 Protective equipment

If necessary, the protective equipment shall

be used. Keep your hair and clothing away

from moving parts. If necessary, wear a

hairnet and do not wear jewelery such as

necklaces and rings!

Use head protection!

Wear suitable head protection

during transport.

Use protective clothing!

Wear suitable protective clothing

during commissioning, mainte-

nance and troubleshooting.

Use hand protection!

Wear suitable hand protection

during transport, commissioning,

maintenance and troubleshooting.

2.6 Personnel qualification

Only trained or instructed personnel who

has known and understood the operating

instructions as well as the possible dangers

of the rotary actuator is allowed to work with

the rotary actuator. The responsibility of the

personnel for operation, maintenance and

repair must be clearly deﬁned by the oper-

ator.

Personnel to be trained, instructed or un-

dergoing training may work on the rotary

actuator only under the constant supervi-

sion of an experienced person.

The individual activities on the rotary actua-

tor require different personnel qualiﬁcations

which are listed in the following table. The

different qualiﬁcations are characterized by

the following skills and knowledge:

• Instructed persons must operate the rotary actuator and be able to detect possible

damage and dangers on the rotary actuator.

• Instructed persons with technical training must also be aware of the dangers of han-

dling pressurized equipment, hot and cold surfaces, harmful and hazardous materials

and the process of installing and removing the valves in a process line, the speciﬁc and

potential risks of the process and the most important safety regulations.

• Trained electricians must read and understand electrical circuit diagrams, commission,

put electric machines into operation, service and maintain them, wire switch and control

cabinets, install control software, ensure the functionality of electrical components and

identify potential hazards in handling electrical and electronic systems.

• Trained pneumatic specialists must read and understand pneumatic circuit diagrams,

put pneumatic systems into operation, service and maintain them, disconnect and

connect pneumatic hoses, ensure the proper functioning of pneumatic components,

assess the work performed on the pneumatic system and identify potential hazards.

PKI/EKI-IM-DE-B-EN-01-23 Rev.0 9

Read this table as follows:

“The electrical installation requires the qualiﬁcation of a qualiﬁed electrician.”

Activities Instructed

persons

Instructed persons with

technical training

Electri-

cians

Pneumatic

specialists

Installation X

Electrical installation X

Pneumatic installation X

Setting and equipping X

Commissioning X

Troubleshooting X

Cleaning X

Troubleshooting, repair and

maintenance of mechanics X

Troubleshooting, repair and

maintenance of electrics X

Troubleshooting, repair and

maintenance of pneumatics X

Functional checks X

Shutdown X X

Transport X

Disposal X

Tab. 2-1 Overview of the required personnel qualiﬁcations

10 PKI/EKI-IM-DE-B-EN-01-23 Rev.0

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