bar agturn PKT Series User manual

3/2-way automatic valve of PKT type
Translation of the original operating manual
bar-gmbh.de

2PKT-GD/GS-IM-DE-B-EN-09-19 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 .................................................................................5
1.3.1 Signal words and symbols ......................................................................5
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..........................................................................................8
2.6 Personnel qualification .......................................................................................9
2.7 Dangers when dealing with the automatic valve.............................................10
2.7.1 Dangers during assembly, maintenance and disassembly .................11
2.7.2 Dangers during functional checks, commissioning and operation.....13
2.7.3 Dangers when used in explosion-protected areas ..............................15
3. Product description ................................................................ 17
3.1 Type plate..........................................................................................................18
3.2 Ball valve ...........................................................................................................18

PKT-GD/GS-IM-DE-B-EN-09-19 Rev.0 3
3.3 Rotary actuator bar-agturn............................................................................... 19
3.3.1 Overview of different models ................................................................ 19
3.3.2 Functional description........................................................................... 20
3.3.3 Operating and display elements ........................................................... 22
3.3.4 Accessories............................................................................................ 22
4. Transport and storage .............................................................23
4.1 Scope of delivery .............................................................................................. 23
4.1.1 Incoming goods inspection................................................................... 23
4.2 Transport, packaging and storage................................................................... 23
5. Installation ................................................................................25
5.1 Installation conditions....................................................................................... 25
5.2 Before installation ............................................................................................. 25
5.3 Installation of ball valve .................................................................................... 26
5.4 Installation of rotary actuator ........................................................................... 26
5.4.1 Installation of the pneumatic connection ............................................. 27
5.5 Pressure test of the pipe section ..................................................................... 28
6. Commissioning and operation ................................................29
6.1 General information for commissioning of different variants.......................... 29
6.2 Setting the end positions.................................................................................. 29
6.2.1 Adjustment of swivel angle for mounting variants F/E ........................ 31
6.2.2 Adjustment of swivel angle for mounting variants G/H ....................... 32
7. Maintenance and repair ...........................................................32
7.1 Maintenance of rotary actuator........................................................................ 32
7.2 Maintenance ball valve .................................................................................. 32

4PKT-GD/GS-IM-DE-B-EN-09-19 Rev.0
8. Troubleshooting ...................................................................... 33
9. Repair and spare parts ........................................................... 34
9.1 Rotary actuator agturn......................................................................................34
9.1.1 Type GD-032 (schematic diagram) .......................................................34
9.1.2 Type GS-075 (schematic diagram)........................................................35
10. Disassembly ............................................................................ 36
10.1 Disassembly of the rotary actuator ..................................................................36
10.2 Disassembly of the ball valve from the pipeline ..............................................36
11. Disposal ................................................................................... 37
12. EU Declaration of Incorporation ............................................ 38
13. ATEX Declaration of Conformity ............................................ 39
14. Annex / Technical data ........................................................... 40
14.1 Technical data of rotary actuator .....................................................................40
14.2 Technical data of 3/2-way ball valve................................................................41
14.3 Pressure-Temperature diagram .......................................................................41
14.4 Dimensional tables and dimensional drawings ...............................................42
14.4.1 Dimensional drawing 3/2-way automatic valve of PKT type ...............42
14.4.2 Dimensional table for 3/2-way automatic valve of PKT type...............44
14.5 Actuator assignment.........................................................................................46
14.6 Weight and volume of the rotary actuators bar-agturn...................................47
14.7 Switching positions of ball valve......................................................................48

PKT-GD/GS-IM-DE-B-EN-09-19 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.: [phone]
Fax: [phone]
Email: [e-mail]
www.bar-gmbh.de
1.2 Validity of the operating
manual
This operating manual is valid for the 3/2-
way automatic valve of PKT type since year
of manufacture 2019 with the following ro-
tary actuators:
• agturn Type GD-032 till 040
• agturn Type GD/GS-052 till 400
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.

6PKT-GD/GS-IM-DE-B-EN-09-19 Rev.0
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.
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.

PKT-GD/GS-IM-DE-B-EN-09-19 Rev.0 7
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 commission-
ing of the product may only be carried
out by qualified personnel in accordance
with the instructions 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 removed or disconnected.

8PKT-GD/GS-IM-DE-B-EN-09-19 Rev.0
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.
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 use other operating medium then flu-
ids or want to use the ball valve for a differ-
ent purpose, contact our customer service.
We can help you with any possible neces-
sary configurations.
2.4.2 Replacement of defective
parts
Replace parts of the quarter-turn 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.
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 hair-
net and do not wear jewelery such as neck-
laces and rings!

PKT-GD/GS-IM-DE-B-EN-09-19 Rev.0 9
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.

10 PKT-GD/GS-IM-DE-B-EN-09-19 Rev.0
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
2.7 Dangers when dealing with the automatic valve
This product of bar GmbH is built according to the state of the art and the recognized safety
rules. Nevertheless, there remains a residual risk and may cause dangers to the life and limb
of the user or third parties or impairments of the product and other material assets in use, if:
• the product is not used as intended,
• the product is operated or repaired by untrained personnel,
• the product is improperly changed or modified and/or
• the safety instructions are not observed.
Eliminate faults that may affect safety.

PKT-GD/GS-IM-DE-B-EN-09-19 Rev.0 11
WARNING
Very cold and hot surfaces!
The body of the valve can be-
come 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 and installing or repair-
ing the valves have received appropri-
ate training.
2.7.1 Dangers during assembly,
maintenance and disassembly
DANGER
Electric voltage!
There is danger to life when work-
ing on electrical components.
• The electrical connections may be
performed only by qualified electri-
cians.
• When working on the components,
have the voltage released by a qual-
ified electrician and secured against
being switched on again.
• Let a qualified electrician check that
no current is present.
DANGER
Corrosive substances!
Depending on the type of medi-
um, there may be danger to life
when in contact with the medium.
• Check the properties of the medium.
• Protect yourself and your environment
from harmful or toxic substances.
• Follow the safety instructions in the
manufacturer's safety data sheets.
• Make sure that no medium can get
into the pipeline, valves during assem-
bly work.
• Make sure that personnel working
with the valves and installing or repair-
ing the valves have received appropri-
ate training.

12 PKT-GD/GS-IM-DE-B-EN-09-19 Rev.0
WARNING
Danger of crushing hands
and other body parts!
There is a risk of injury during as-
sembly/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.
• Keep hands and fingers away with the
compressed air supply connected.
• Always disconnect the compressed
air supply from the rotary actuator
before carrying out maintenance and
repair work on the valve and when
installing and removing the ball valve
from the pipeline.
• Pay attention to movements of the
ball.
• Keep hands, other body parts, tools
and other objects out of the swivel
range of the ball. Do not leave any for-
eign objects inside the pipeline.
• Perform works carefully when assem-
bling, disassembling and sampling.
WARNING
Flying parts!
Splashing medium!
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.
• Do not disassemble or remove the
valve from the pipeline as long as the
valve is pressurized.
• Always isolate the respective valve in
the piping system.
• Depressurise the valve and remove
the medium before working on the
valve and the rotary actuator.
WARNING
Ejected parts!
When adjusting the rotary actuators and
when the rotary actuator is opened un-
der pressure, there is a risk of parts being
ejected!
• Always disconnect the compressed
air supply before maintenance, disas-
sembly and repair!
• Never set the mechanical end posi-
tions on the actuator as long as there
is pressure on connection 2 or 4.
• Make sure the pinion of the rotary ac-
tuator is moving in the correct direc-
tion.

PKT-GD/GS-IM-DE-B-EN-09-19 Rev.0 13
WARNING
Uncontrolled start-ups!
There is a risk of injury if pneumatic rotary
actuators create a very high torque during
actuation or by spring force.
• Secure the rotary actuator against any
unintentional start-up or unexpected
spinning.
• Work on the pneumatic rotary actua-
tors in a prudent way.
• In case of single-acting rotary actua-
tors (type GS), make sure that the ro-
tary actuator is in the home position
(relaxed springs) when disassembling.
CAUTION
Hand injuries!
When mounting the rotary actuator on
the valve spindle, the rotary actuator is
pushed to the connection point/flange of
the valve.
When disassembling the rotary actuator
or removing the rotary actuator from the
valve spindle, the parts can slip down.
There is danger of crushing the hands!
• Carefully pull off the rotary actuator.
• Keep fingers and hands away from
the connection point.
NOTE
Material damage to valve spindle!
Material damage can occur if you use
built-on rotary actuators as levers.
• Do not use built-on actuators as le-
vers as they could damage the actua-
tor and the valve.
2.7.2 Dangers during functional
checks, commissioning and
operation
DANGER
Bursting parts!
Escaping media!
There is danger to life if the maximum per-
missible pressure and temperature ranges
of the valve are insufficient for the operat-
ing conditions of the system. There is a
risk of injury and the risk of material dam-
age 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 materi-
als of the parts of the valve coming in
contact with the medium are suitable
for the media used.
DANGER
Escaping medium!
There is a risk of death from es-
caping medium as a result of
leaks (scalding, hazardous sub-
stances).
• Protect yourself from thermal or
chemical burns.
• Leave the danger area in case of leak-
age and keep third persons out of the
danger zone. Use appropriate barriers
or name supervisors.

14 PKT-GD/GS-IM-DE-B-EN-09-19 Rev.0
WARNING
Danger of being pulled in,
danger of crushing and
locking
Danger due to moving parts of the ma-
chine/valve which can be accessed
through assembly, disassembly, remov-
able covers at openings for functional
checks, sampling, etc. and through auto-
matically operated valves.
• Keep hands and fingers away with the
compressed air supply connected.
• Please note that single-acting rotary
actuators can move the valve to the
"open" or "closed" position when
closing or disconnecting the com-
pressed air supply.
• Perform works carefully when com-
missioning, making functional checks
and sampling.
WARNING
Risk of burns!
Devices and system components
can become very hot during op-
eration.
• Wear protective gloves and protective
clothing to protect against burns.
• At operating temperatures > 65°C a
short contact (approx. 1s) of the skin
with the surface of the machine/valve
may cause burns (DIN EN ISO 13732-
1).
• At operating temperatures = 60 °C a
long contact (approx. 3s) of the skin
with the surface of the machine/valve
may cause burns (DIN EN ISO 13732-
1).
• At operating temperatures
55 °C – 60 °C a long contact (approx.
3S to 10s) of the skin with the surface
of the machine/valve may cause burns
(DIN EN ISO 13732-1).

PKT-GD/GS-IM-DE-B-EN-09-19 Rev.0 15
CAUTION
Self-loosing components!
Components and fasteners may become
loose if not properly installed.
• Observe the information on tightening
torques in this operating manual.
• Check the tightening torque of screw
connections and tighten with the
torque wrench, if necessary.
CAUTION
Noise!
When venting the pneumatic rotary actua-
tor, noise can be hazardous to health.
• Use silencer at vent port or take other
personal protection measures.
2.7.3 Dangers when used in
explosion-protected areas
DANGER
Danger of explosion!
An explosion can occur if the following
protective measures are not observed:
• Establish an internal electrically con-
ductive equipotential bonding be-
tween the rotary actuator and all metal
mounting parts and the pipeline and
make sure that sufficient lightning pro-
tection is available.
• Protect the surfaces against inadmis-
sibly high temperatures due to solar
radiation. Shading covers can possi-
bly be required.
• Protect the actuator against excessive
heating due to heat transfer with hot
media inside the pipeline. If necessary,
mounting kits or shaft extensions are
required.
• Please be aware of that the max.
surface temperature significantly de-
pends on the operating conditions.
Make sure that the actual max. sur-
face temperature is not an ignition
source.
• When selecting the pneumatic valves
and the end position feedbacks, pay
attention to the combination with
Ex-approved products.
• Avoid sparking when using the tool

16 PKT-GD/GS-IM-DE-B-EN-09-19 Rev.0
DANGER
Danger of explosion
(continuation)
• Always observe the max. permissible
operating pressure. Exceeding can
cause material failure which can lead
to sparking.
• Avoid dust accumulation.
• Do not install rotary actuators in pit-
like cavities if there is a predictable
dust accumulation.
• Do not carry out leak detection with
ultrasonic transmitters.

PKT-GD/GS-IM-DE-B-EN-09-19 Rev.0 17
3. Product description
The 3/2-way automatic valve of PKT type is
a combination of the following components:
• 3/2-way ball valve of KT type made of
stainless steel, with floating precision
ball
• Rotary actuator bar-agturn, types GD-
032 to 040, GD/GS-052 to 400
The valve is operated pneumatically (dou-
ble- and single-acting) and is characterized
by a long service life and high operational
safety.
Product features:
• Reduced passage
• Maintenance-free
• 4-fold bearing of the ball in the half-shells
• Optionally available with end position
feedback, position controllers and sole-
noid valves
• Anti-blowout spindle
• Usage also with vacuum and high flow
velocities
• Alternatively also can be delivered with
electric rotary actuator, hand lever or
gearbox

18 PKT-GD/GS-IM-DE-B-EN-09-19 Rev.0
3.1 Type plate
The type plate of the automatic valve is attached to the rotary actuator.
Fig. 3-1 Type plate
Legend
30010898 bar article number
PKT-2/0-T2-038-GD105 Article/order designation (see data sheet)
PN 50 Maximum permissible medium pressure
P (St)= 3-8 bar Control pressure range for the pneum. rotary actuator
Ex II 2 GD c 26/07/19 ATEX marking and date of manufacture (year of construc-
tion)
3.2 Ball valve
The 3/2-way ball valve of KT type is intended for installation in piping systems. Its function
is to shut off or regulate a medium in pipelines.

PKT-GD/GS-IM-DE-B-EN-09-19 Rev.0 19
3.3 Rotary actuator bar-agturn
3.3.1 Overview of different models
Fig. 3-2 Product variants bar-agturn GD-032 till 040, GD/GS-052 till 270, GD/GS-300 till 400
Fig. 3-3
2
4
7
bar-agturn GD-032 overview of components (left: top view, right: bottom view)
Fig. 3-4
16
24
5
7
bar-agturn GD/GS-125 overview of components (left: top view, right: bottom view)

20 PKT-GD/GS-IM-DE-B-EN-09-19 Rev.0
Fig. 3-5
13
3
6
2
4
5
7
bar-agturn GD/GS-300 overview of components (left: top view, right: bottom view)
Legend
1. Position indicator and interface to
the end position feedback as well as
position controllers according to VDI/
VDE 3845 (Namur)
2. Pneumatic interface connection of the
actuator according to VDI/VDE 3845
(Namur)
3. Ring nut from GD/GS-160
4. Pneumatic interface connection of the
actuator according to VDI/VDE 3845
(Namur)
5. Adjusting screws
6. Lock nuts of the adjusting screws
7. Valve interface according to
EN ISO 5211
3.3.2 Functional description
The pneumatic rotary actuator agturn is
used for the automatic actuation of industri-
al valves continuously moving between the
end positions.
The rotary actuator is actuated exclusively
with compressed air or other suitable con-
trol media via control valves. The swivel an-
gle range is 90° and can be set as standard
in both end positions (0° and 90°) from +
5° to -5°.
The pneumatic rotary actuator is delivered
as required in a double- and single-acting
function (with safety springs which return
the rotary actuator to the basic position).
The respective valve position is indexed
via the standard optical position indicator
(see
Fig. 3-10 and Fig. 3-11 ). The end posi-
tion feedback device can be ordered as an
accessory.
The sizes GD-032 till 40 are designed only
as double-acting devices.