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- bar pneumatische Steuerungssysteme GmbH
- The versatile pneumatic actuator for automation of valves
The versatile pneumatic actuator for automation of valves
The versatile pneumatic actuator for automation of valves
This manual is crucial for the operation and maintenance of the 2/2-way automatic valve of PKI type, effective since 2019. It includes reference documents and emphasizes safety instructions.
Safety instructions are vital for personnel working with the valve. The manual specifies its intended use for automatic shut-off of liquids and gases in pipelines and warns against unintended use. It details organizational measures, including retrofitting and replacement of defective parts, and stresses the use of protective equipment.
The product comprises a type plate, ball valve, and rotary actuator with various models. It provides functional descriptions and lists operating and display elements.
Guidelines for delivery, transport, packaging, and storage are provided to ensure product integrity.
Details on installation conditions and procedures for the ball valve and rotary actuator, including pressure testing of the pipe section, are provided.
Instructions for commissioning different variants and setting end positions are included to ensure proper operation.
Maintenance procedures for the rotary actuator and general maintenance are outlined to prolong the product's lifespan.
Common issues and solutions are provided to assist in resolving operational problems.
Information on rotary actuator types and the 2/2-way automatic valve is included, along with schematic diagrams.
Procedures for disassembling the rotary actuator and ball valve from the pipeline are detailed.
Guidelines for proper disposal of the product are provided.
The manual includes the EU Declaration of Incorporation and ATEX Declaration of Conformity.
Technical data for the rotary actuator and ball valve, pressure-temperature diagrams, dimensional tables, and actuator assignments are included to provide comprehensive technical specifications.
The document outlines required qualifications for personnel involved in pneumatic systems, specifying that only qualified electricians should handle electrical installations, while pneumatic specialists are required for pneumatic installations and maintenance.
Several dangers are highlighted, including risks from very cold or hot surfaces, electric voltage, corrosive substances, crushing hazards, flying parts, and risks associated with welding and uncontrolled start-ups. Protective measures such as wearing gloves, ensuring proper training, and securing components are emphasized.
The document warns about potential dangers during functional checks, commissioning, and operation, such as bursting parts, escaping media, and risks of burns. It stresses the importance of using valves designed for specific operating conditions and protecting against thermal or chemical burns.
Special precautions are necessary when operating in explosion-protected areas. The document advises on establishing equipotential bonding, protecting surfaces from high temperatures, and avoiding sparking.
The document provides an overview of different models of the rotary actuator bar-agturn, explaining its function, operating elements, and available accessories. It highlights the importance of using Ex-approved products to prevent explosions.
Before unpacking, verify the number of transport containers matches the delivery note, and check for visible damage to packaging, products, and accessories. Document any transport damages with photographs and a written protocol to claim against the transport company, as the manufacturer is not liable for transport damages.
When transporting with a crane, ensure the load does not exceed the hoisting equipment's capacity. Use approved lifting slings and handle loads with care. Store products in original packaging in a closed room, protected from dirt and moisture. Operate pneumatic rotary actuators at least once a year if stored for long periods.
Ensure personnel are trained and follow safety instructions. Check technical parameters like pressure, temperature, and electrical voltage before installation. Install piping and control systems properly, ensuring valves move in the correct direction without tension.
Before installation, ensure the control medium's dew point is at least 10°C lower than the lowest operating temperature. Follow specified switching times for rotary movements and consult the manufacturer for large-volume valves. For ball valves, follow detailed steps for installation with welding ends or threaded connections, ensuring proper tightening torques.
Ensure the actuator is mounted correctly on the valve spindle, using appropriate components and tightening screws according to specified torques. For pneumatic connections, remove silencers if necessary and connect to compressed air supply lines.
During pressure tests, ensure test pressures do not exceed specified values. For commissioning, adjust mechanical end positions of rotary actuators as needed, following safety precautions to avoid ejected parts.
1. Adjust the valve using the adjusting screw and secure it with the lock nut. Verify the valve's end positions by opening and closing it. If adjustments are needed, repeat the process.
2. The automatic valve is maintenance-free but should be checked every three months or after 50,000 cycles. Avoid harsh cleaning agents.
3. Rotary actuators and ball valves can be repaired by replacing seals and wear parts. It is recommended to have repairs done by bar GmbH.
1. Follow safety instructions to avoid life-threatening situations. Use only original spare parts from bar GmbH.
1. Detailed exploded-view diagrams and parts lists are provided for rotary actuators and automatic valves. Spare parts sets include sealing and wear parts.
1. Ensure safety by depressurizing and removing the medium before disassembly. Follow specific steps for disassembling rotary actuators and ball valves.
1. Customers are responsible for proper disposal according to safety and environmental regulations. The document includes EU and ATEX declarations of conformity.
1. Rotary actuators are available in double-acting and single-acting types, with various mounting positions and materials. They operate within a temperature range of -20°C to +160°C and a control pressure of 2 to 8 bar.
2. 2/2-way ball valves have nominal sizes from DN15 to DN100, with pressure ratings up to PN 63. They are made of stainless steel and operate within -20°C to 180°C.
1. Pressure-temperature diagrams and dimensional tables provide detailed specifications for various components.
2. Actuator assignments and weight/volume data for rotary actuators are included for different types and sizes.
The document provides a table detailing the weight and volume of rotary actuators, specifically the bar-agturn PKI-GD/GS-IM-DE-B-EN-09-19 Rev.0 model. The table lists measurements at different intervals with corresponding weights and volumes, including a note on weight with the maximum number of springs.
The document states that descriptions and images are for informational purposes only and are not guaranteed. It mentions that bar GmbH reserves the right to make technical and constructive changes to its products without prior notice.
Warranty claims can be made within one year from delivery for manufacturing defects, with bar GmbH offering replacement or free repair at its discretion. Damages from normal use, friction, or unauthorized repairs are excluded from the warranty. All purchases require acceptance of the General Terms and Conditions of Sale and Delivery, available on the company's website.
The document provides contact details for bar pneumatische Steuerungssysteme GmbH, including their address in Dattenberg, Germany, phone and fax numbers, and email and website information.
Catalog excerpts
2/2-way automatic valve of PKI type Translation of the original operating manual
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This operating manual is a part of the product. 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. This operating manual is valid for the 2/2way automatic valve of PKI type since year of manufacture 2019 with the following rotary actuators: Validity of the operating manual The operating manual must always be available at the place of operation. • agturn Type GD-032 till 040 Reference documents This manual, the data mentioned and design data sheets, additional assembly and maintenance instructions as well as further...
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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. Hand injuries! The text passages marked with this symbol inform you about dangerous...
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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“). • he installation, electrical and pneumatic T connection as well as the commissioning of the product may only be carried out by qualified personnel in accordance with the instructions described in this operating manual. 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...
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2.4.1 Subsequent retrofitting or changes General Safety Instructions Personnel assigned to work on the automatic valve must read the operating instructions 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. The automatic valve is used for the automatic 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...
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Wear suitable head protection during transport. 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 operator. Use protective clothing! Wear suitable protective clothing during commissioning, maintenance and troubleshooting. Use hand protection! Wear suitable hand protection during transport, commissioning, maintenance and troubleshooting. Personnel qualification...
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Read this table as follows: "The electrical installation requires the qualification of a qualified electrician." Activities Instructed persons Instructed persons with technical training Pneumatic specialists Electrical installation Commissioning Troubleshooting Troubleshooting, repair and maintenance of mechanics Troubleshooting, repair and maintenance of electrics Troubleshooting, repair and maintenance of pneumatics Functional checks Shutdown Tab. 2-1 Overview of the required personnel qualifications Dangers when dealing with the automatic valve This product of bar GmbH is built according to...
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2.7.1 Dangers during assembly, maintenance and disassembly DANGER Electric voltage! There is danger to life when working on electrical components. • The electrical connections may be performed only by qualified electricians. • When working on the components, have the voltage released by a qualified electrician and secured against being switched on again. WARNING Very cold and hot surfaces! The body of the valve can become very cold or very hot during operation. • Wear protective gloves and protective clothing to protect against frostbite or burns. • Make sure that personnel working with the valves...
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WARNING Danger of crushing hands and other body parts! WARNING Flying parts! Splashing medium! There is a risk of injury during assembly/disassembly by movements of the ball. The shut-off body (e.g. ball or disc) of the valve works as a separating element. It makes no difference whether a rotary actuator is mounted or not. The position of the ball may change during transport or handling of the valve. There is a risk of injury when the valve is removed under pressure or with present medium. The disassembly or removal of a pressurised valve causes an uncontrolled pressure drop. • Keep hands and...
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Welding works! Hand injuries! Welding and flying sparks can cause fires. When mounting the rotary actuator on the valve spindle, the rotary actuator is pushed to the connection point/flange of the valve. • Make sure that the prescribed safety precautions are taken before carrying out welding works. • Inform the relevant employees such as security officer, shift leader, company fire brigade. When disassembling the rotary actuator or removing the rotary actuator from the valve spindle, the parts can slip down. • Apply for a written welding permit. There is danger of crushing the hands! • Provide...
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2.7.2 Dangers during functional checks, commissioning and operation DANGER Bursting parts! Escaping media! There is danger to life if the maximum permissible pressure and temperature ranges of the valve are insufficient for the operating conditions of the system. There is a risk of injury and the risk of material damage by wrongly selected materials. In addition, there is a risk of damage to the piping system. • Only use the valves that are designed for the operating conditions. • Make sure that the selected materials of the parts of the valve coming in contact with the medium are suitable for...
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