KSB BOA-Control PIC User manual

Pressure-independent Control Valve
BOA-Control PIC
Operating Manual

Legal information/Copyright
Operating Manual BOA-Control PIC
Original operating manual
All rights reserved. The contents provided herein must neither be distributed, copied, reproduced,
edited or processed for any other purpose, nor otherwise transmitted, published or made available to a
third party without the manufacturer's express written consent.
Subject to technical modification without prior notice.
© KSB SE & Co. KGaA, Frankenthal 12/07/2021

Contents
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Contents
Glossary .................................................................................................................................................. 5
1 General.................................................................................................................................................... 6
1.1 Principles ...........................................................................................................................................................6
1.2 Target group.....................................................................................................................................................6
1.3 Other applicable documents............................................................................................................................6
1.4 Symbols .............................................................................................................................................................6
1.5 Key to safety symbols/markings.......................................................................................................................7
2 Safety...................................................................................................................................................... 8
2.1 General..............................................................................................................................................................8
2.2 Intended use .....................................................................................................................................................8
2.2.1 Prevention of foreseeable misuse.......................................................................................................9
2.3 Personnel qualification and training...............................................................................................................9
2.4 Consequences and risks caused by non-compliance with this manual .........................................................9
2.5 Safety awareness ..............................................................................................................................................9
2.6 Safety information for the operator/user.......................................................................................................9
2.7 Safety information for maintenance, inspection and installation ..............................................................10
2.8 Unauthorised modes of operation................................................................................................................10
3 Transport/Storage/Disposal ................................................................................................................ 11
3.1 Checking the condition upon delivery..........................................................................................................11
3.2 Transport.........................................................................................................................................................11
3.3 Storage/preservation......................................................................................................................................12
3.4 Return to supplier...........................................................................................................................................12
3.5 Disposal ...........................................................................................................................................................13
4 Valve Description ................................................................................................................................. 14
4.1 General description ........................................................................................................................................14
4.2 Marking...........................................................................................................................................................14
4.3 Operating data ...............................................................................................................................................14
4.4 Fluids handled.................................................................................................................................................14
4.5 Design details..................................................................................................................................................14
4.6 Pressure/temperature ratings ........................................................................................................................15
4.7 Materials .........................................................................................................................................................15
4.8 Function ..........................................................................................................................................................18
4.9 Scope of supply...............................................................................................................................................18
4.10 Dimensions and weights ................................................................................................................................18
5 Installation at Site................................................................................................................................ 19
5.1 General information/Safety regulations .......................................................................................................19
5.2 Installation position........................................................................................................................................19
5.3 Piping ..............................................................................................................................................................19
5.4 Installing the valve .........................................................................................................................................20
5.5 Mounting a manual gearbox or actuator.....................................................................................................22
5.6 Flushing the valve...........................................................................................................................................23
5.7 Insulation ........................................................................................................................................................24
5.8 Measuring computer......................................................................................................................................24
6 Commissioning/Start-up/Shutdown................................................................................................... 25
6.1 Commissioning/Start-up.................................................................................................................................25
6.1.1 Prerequisites for commissioning/start-up .........................................................................................25
6.1.2 Venting the valve (DN 65 - 150)........................................................................................................25
6.1.3 Setting the volume flow rate............................................................................................................26
6.1.4 Closing the valve................................................................................................................................29
6.2 Shutdown........................................................................................................................................................29
6.2.1 Measures to be taken for shutdown ................................................................................................29

Contents
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7 Servicing/Maintenance........................................................................................................................ 30
7.1 Safety regulations...........................................................................................................................................30
7.2 Maintenance...................................................................................................................................................30
7.2.1 Valves with actuator..........................................................................................................................30
8 Trouble-shooting.................................................................................................................................. 31
9 EU Declaration of Conformity for BOA-Control PIC .......................................................................... 32
Index ..................................................................................................................................................... 33

Glossary
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Glossary
EPDM
Ethylene propylene diene rubber
Pressure Equipment Directive (PED)
The 2014/68/EU Directive sets out the
requirements to be met by pressure equipment
intended to be placed on the market in the
European economic area.

1 General
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1 General
1.1 Principles
This operating manual is valid for the type series and variants indicated on the front
cover.
The operating manual describes the proper and safe use of this equipment in all
phases of operation.
In the event of damage, immediately contact your nearest KSB sales organisation
responsible to maintain the right to claim under warranty.
1.2 Target group
This operating manual is aimed at the target group of trained and qualified specialist
technical personnel.
1.3 Other applicable documents
Table1: Overview of other applicable documents
Document Contents
Type series booklet Description of the valve
Flow characteristics1) Information on Kv and zeta values
General assembly drawing2) Sectional drawing of the valve
Sub-supplier product literature3) Operating manuals and other product literature
for the accessories
Observe the relevant manufacturer's product literature for the accessories.
1.4 Symbols
Table2: Symbols used in this manual
Symbol Description
✓Conditions which need to be fulfilled before proceeding with the
step-by-step instructions
⊳Safety instructions
⇨Result of an action
⇨Cross-references
1.
2.
Step-by-step instructions
Note
Recommendations and important information on how to handle
the product
1If any
2If agreed to be included in the scope of supply; otherwise refer to the type series booklet.
3If agreed to be included in the scope of supply

1 General
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1.5 Key to safety symbols/markings
Table3: Definition of safety symbols/markings
Symbol Description
!DANGER
DANGER
This signal word indicates a high-risk hazard which, if not avoided,
will result in death or serious injury.
!WARNING
WARNING
This signal word indicates a medium-risk hazard which, if not
avoided, could result in death or serious injury.
CAUTION
CAUTION
This signal word indicates a hazard which, if not avoided, could
result in damage to the machine and its functions.
General hazard
In conjunction with one of the signal words this symbol indicates a
hazard which will or could result in death or serious injury.
Electrical hazard
In conjunction with one of the signal words this symbol indicates a
hazard involving electrical voltage and identifies information about
protection against electrical voltage.
Machine damage
In conjunction with the signal word CAUTION this symbol indicates
a hazard for the machine and its functions.

2 Safety
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2 Safety
!DANGER
All the information contained in this section refers to hazardous situations.
In addition to the present general safety information the action-related safety
information given in the other sections must be observed.
2.1 General
▪This operating manual contains general installation, operating and maintenance
instructions that must be observed to ensure safe operation of the system and
prevent personal injury and damage to property.
▪Comply with all the safety instructions given in the individual sections of this
operating manual.
▪The operating manual must be read and understood by the responsible specialist
personnel/operators prior to installation and commissioning.
▪The contents of this operating manual must be available to the specialist
personnel at the site at all times.
▪Information and markings attached directly to the product must always be
complied with and kept in a perfectly legible condition at all times. This applies
to, for example:
– Manufacturer
– Type designation
– Nominal pressure
– Nominal size
– Flow direction arrow
– Year of construction
– Valve body material
▪The operator is responsible for ensuring compliance with all local regulations not
taken into account.
▪The design, manufacture and testing of the valve are subject to a QM system to
DINENISO9001 as well as the current European Pressure Equipment Directive.
▪Bear in mind that valves exposed to creep-rupture conditions have a limited
service life and have to meet the applicable regulations stipulated in the
technical codes.
▪In the case of customised special variants, further restrictions may apply with
regard to the operating mode and service life. Refer to the relevant sales
documentation for applicable limitations.
▪The operator is responsible for any eventualities or incidents which may occur
during installation performed by the customer, operation and maintenance.
2.2 Intended use
▪Only operate valves which are in perfect technical condition.
▪Do not operate the valve in partially assembled condition.
▪Only use the valve for fluids specified in the product literature. Take the design
and material variant into account.
▪Only operate the valve within the operating limits described in the other
applicable documents.
▪The valve's design and rating are based on predominantly static loading in
accordance with the codes applied. Consult the manufacturer if the valve is
subjected to dynamic loads or any other additional influences.
▪Consult the manufacturer about any other modes of operation not described in
the product literature.
▪Do not use the valve as a foothold.

2 Safety
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2.2.1 Prevention of foreseeable misuse
▪Never exceed the permissible application and operating limits specified in the
data sheet or product literature regarding temperature, etc.
▪Observe all safety information and instructions in this manual.
2.3 Personnel qualification and training
▪All personnel involved must be fully qualified to transport, install, operate,
maintain and inspect the product this manual refers to and be fully aware of the
interaction between the valve and the system.
▪The responsibilities, competence and supervision of all personnel involved in
transport, installation, operation, maintenance and inspection must be clearly
defined by the operator.
▪Deficits in knowledge must be rectified by means of training and instruction
provided by sufficiently trained specialist personnel. If required, the operator can
commission the manufacturer/supplier to train the personnel.
▪Training on the valve must always be supervised by specialist technical personnel.
2.4 Consequences and risks caused by non-compliance with this manual
▪Non-compliance with these operating instructions will lead to forfeiture of
warranty cover and of any and all rights to claims for damages.
▪Non-compliance can, for example, have the following consequences:
– Hazards to persons due to electrical, thermal, mechanical and chemical
effects and explosions
– Failure of important product functions
– Failure of prescribed maintenance and servicing practices
– Hazard to the environment due to leakage of hazardous substances
2.5 Safety awareness
In addition to the safety information contained in this operating manual and the
intended use, the following safety regulations shall be complied with:
▪Accident prevention, health regulations and safety regulations
▪Explosion protection regulations
▪Safety regulations for handling hazardous substances
▪Applicable standards, directives and laws
2.6 Safety information for the operator/user
▪Actuator-operated valves are intended for use in areas which cannot be accessed
by unauthorised persons. Operation of these valves in areas accessible to
unauthorised persons is only permitted if appropriate protective devices are
fitted at the site. This must be ensured by the operator.
▪Fit protective equipment (e.g. contact guards) supplied by the operator for hot,
cold or moving parts, and check that the equipment functions properly. Do not
touch rotating parts.
▪Do not remove any protective equipment (e.g. contact guards) during operation.
▪Provide the personnel with protective equipment and make sure it is used.
▪Contain any leakage of hazardous fluids (e.g. explosive, toxic, hot) so as to avoid
any danger to persons and the environment. Adhere to all relevant laws.
▪Eliminate all electrical hazards. (In this respect refer to the applicable national
safety regulations and/or regulations issued by the local energy supply
companies.)

2 Safety
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2.7 Safety information for maintenance, inspection and installation
▪Modifications or alterations of the valve require the manufacturer's prior
consent.
▪Use only original spare parts or parts/components authorised by the
manufacturer. The use of other parts/components can invalidate any liability of
the manufacturer for resulting damage.
▪The operator ensures that maintenance, inspection and installation are
performed by authorised, qualified specialist personnel who are thoroughly
familiar with the manual.
▪Carry out work on the valve during standstill only.
▪The valve body must have cooled down to ambient temperature.
▪The pressure in the valve body must have been released and the valve must have
been drained.
▪When taking the valve out of service always adhere to the procedure described
in the manual.
▪Decontaminate valves which handle fluids posing a health hazard.
▪Protect the valve body and body bonnet/cover from any impacts.
▪As soon as the work has been completed, re-install and re-activate any safety-
relevant devices and protective devices. Before returning the product to service,
observe all instructions on commissioning. (ðSection6.1,Page25)
2.8 Unauthorised modes of operation
▪The valve is operated outside the limits stated in the operating manual.
▪The valve is not operated in accordance with the intended use.
(ðSection2.2,Page8)

3 Transport/Storage/Disposal
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3 Transport/Storage/Disposal
3.1 Checking the condition upon delivery
1. On transfer of goods, check each packaging unit for damage.
2. In the event of in-transit damage, assess the exact damage, document it and
notify KSB or the supplying dealer and the insurer about the damage in writing
immediately.
3.2 Transport
The valves are delivered in cardboard boxes.
DANGER
The valve could slip out of the suspension arrangement
Danger to life from falling parts!
▷Only transport the valve in the specified position.
▷Never attach lifting accessories to the handwheel.
▷Observe the information on weights, centre of gravity and fastening points.
▷Observe the applicable local accident prevention regulations.
▷Use suitable, permitted lifting accessories, e.g. self-tightening lifting tongs.
▷For actuated valves observe the relevant actuator operating manual. Transport
aids on the actuator are not suitable for suspending the entire valve/actuator
assembly.
CAUTION
Improper transport
Damage to the valve!
▷Always transport the valve properly and in its original packaging.
▷Protect the valve in its cardboard box from heavy impacts.
▷Do not throw the valve.
CAUTION
Improper transport
Damage to pressure measurement connection branches or piping!
Measuring impossible
No valve function!
▷Do not use lifting accessories in the area of the pressure measurement
connection branches or piping.
To transport valves with flanged ends from DN65, suspend them from the lifting
tackle as shown.

3 Transport/Storage/Disposal
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Fig.1: Transporting the valve
3.3 Storage/preservation
If commissioning is to take place some time after delivery, we recommend that the
following measures be taken for storage:
CAUTION
Incorrect storage
Damage due to dirt, corrosion, humidity and/or frost!
▷Close the valve using little force and store in the closed position.
▷Protect valve parts made of EPDM from sunlight or UV light from other sources.
Observe the DIN7716 standard for the storage of elastomers.
▷Store the valve in a frost-proof room where the atmospheric humidity is as
constant as possible.
▷Protect the valve from dust during storage, e.g. with suitable caps or foils.
▷Protect the valve from contact with solvents, lubricants, fuels or other
chemicals.
▷Store the valve in vibration-free conditions.
If properly stored indoors, the equipment is protected for a maximum of 12months.
3.4 Return to supplier
1. Drain the valve as described in the manual.
2. Flush and clean the valve.
3. If the valve has handled fluids whose residues could lead to corrosion damage in
the presence of atmospheric humidity or could ignite upon contact with oxygen
also neutralise the valve and blow through with anhydrous inert gas to ensure
drying.

3 Transport/Storage/Disposal
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3.5 Disposal
WARNING
Fluids handled, consumables and supplies which are hot and/or pose a health
hazard
Risk of injury!
Hazard to persons and the environment!
▷Collect and properly dispose of flushing fluid and any residues of the fluid
handled.
▷Wear safety clothing and a protective mask if required.
▷Observe all relevant laws.
▷Decontaminate valves used in fluids posing a health hazard.
1. Dismantle the valve.
Collect greases and other lubricants during dismantling.
2. Separate and sort the valve materials, e.g. by:
- Metals
- Plastics
- Electronic waste
- Greases and other lubricants
3. Dispose of materials in accordance with current regulations or in another
controlled manner.

4 Valve Description
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4 Valve Description
4.1 General description
▪Valve for the hydraulic balancing of hot-water heating systems, air-conditioning
systems and cooling circuits
▪Pressure-independent control valve for limiting volume flow rate
4.2 Marking
Table4: General marking
Description Marking
Nominal size DN ...
Nominal pressure PN ...
Manufacturer KSB
Year of construction 20..
Material .......
Flow direction arrow →
CE marking
Customer's marking e.g. plant/system No., etc.
In accordance with the applicable Pressure Equipment Directive (PED), Article 4,
Paragraph 3, valves up to and including DN50 must not bear the CE marking.
From DN65 the valves are CE marked in accordance with the applicable Pressure
Equipment Directive.
4.3 Operating data
Table5: Operating properties
Characteristic Value
Nominal pressure 16/25
Nominal size 10 - 150
Max. permissible pressure [bar] 25 (DN 10-50)
16 (DN 65-100)
Min. permissible temperature [°C] ≥-10
Max. permissible temperature [°C] ≤+120
4.4 Fluids handled
▪Water
▪Water/glycol mixtures (glycol content ≤ 50%)
▪Other fluids on request.
4.5 Design details
Design
▪Pressure-independent control valve
DN 10 - 25
▪Straight-way valve with male threaded ends
▪Adjusting ring for presetting the flow rate limit
▪Prepared for actuator mounting

4 Valve Description
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DN 32 - 50
▪Straight-way Y-pattern valve with female threaded ends
▪Adjusting ring for presetting the flow rate limit
▪Prepared for actuator mounting
DN 65 - 150
▪Straight-way Y-pattern valve with flanged ends
▪Prepared for manual gearbox4) for presetting the flow rate limit
▪Prepared for actuator mounting
4.6 Pressure/temperature ratings
Table6: Test pressure and operating pressure
PN DN Shell test Seat tightness test Permissible operating pressure5)
With water
Tests P10 and P11 to
DINEN12266-1
Test P12, leakage rate
A to DINEN12266-1
-10 to +100°C 120°C
[bar] [bar] [bar] [bar]
25 10-50 37,5 27,5 25 22
16 65-150 24 17,6 16 12
4.7 Materials
DN 10 - 25
100
131.1 131.2
350
580.1
950.1
161
411
79-11
200
580.2 580.3
950.2
734
Fig.2: Sectional drawing DN 10 - 25
4This accessory is mandatory for valve function.
5Static load

4 Valve Description
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Table7: Overview of available materials DN 10 - 25
Part No. Description Material Note
100 Body CW602N -
131.1/.2 Pressure
measurement
connection branch
CW617N -
161 Body bonnet CW602N -
200 Stem CW617N -
350 Valve disc CW617N -
411 Joint ring EPDM 70SH -
580.1 Cap Nylon 6 -
580.2/.3 Cap CW617N Red (580.2), blue (580.3)
734 Screwed union CW617N -
79-11 Flow controller PSU -
950.1/.2 Spring AISI302 -
DN 32 - 50
580.1
100
412
350 131.2
131.1
200
161
734
79-11
950.1
950.2
580.2
580.3
Fig.3: Sectional drawing DN 32 - 50
Table8: Overview of available materials DN 32 - 50
Part No. Description Material Note
100 Body CW602N -
131.1/.2 Pressure
measurement
connection branch
CW617N -
161 Body bonnet CW602N -
200 Stem CW617N -
350 Valve disc CW617N -
412 O-ring EPDM 70 -
580.1 Cap Nylon 6 -
580.2/.3 Cap CW617N Red (580.2), blue (580.3)
734 Screwed union CW617N -

4 Valve Description
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Part No. Description Material Note
79-11 Flow controller PSU -
950.1/.2 Spring AISI302 -
DN 65 - 150
353
144
540
310
131.1
580.1
200.1
412
443
484.1
20-1
01-39
734
161
350
700
950.1
100.2
101
100.1
563
356
950.3
950.2
722
200.2
901
732
Fig.4: Sectional drawing DN 65 - 150
Table9: Overview of available materials DN 65 - 150
Part No. Description Material Note
01-39 Ball valve Brass -
20-1 Adjusting stem CW617N -
100.1 Body (valve) EN-GL-250 (5.1301) Epoxy coating
100.2 Housing (actuator) G-AlSi4.5MnMg Epoxy coating
101 Lower housing section
(actuator)
G-AlSi4.5MnMg Epoxy coating
131.1/.26) Pressure measurement
connection branch
Brass -
144 Seat CW617N -
161 Body bonnet EN-GL-250 (5.1301) Epoxy coating
200.1/.2 Stem CW617N -
310 Plain bearing PTFE -
350 Valve disc CW617N -
353 Balanced plug CW617N -
356 Control valve plug CW617N -
412 O-ring EPDM -
443 Diaphragm EPDM -
484.1 Spring plate G-AlSi4.5MnMg Epoxy coating
540 Bush PTFE-coated stainless steel -
6Not shown in sectional drawing

4 Valve Description
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Part No. Description Material Note
563 Pin CW617N -
580.1/.26) Cap CW617N Red (580.1), blue (580.2)
700 Piping (capillary tube) Copper -
722 Top flange G-AlSi4.5MnMg -
732 Holder (actuator) AISI304 -
734 Screwed union CW617N -
901 Hexagon head bolt Stainless steel A2 -
950.1/.3 Spring AISI302 -
950.2 Spring Steel 2FD -
4.8 Function
Design The valves basically consist of body 100, body bonnet 161 and the functional unit.
Nominal sizes DN10-25 have male threaded ends and nominal sizes DN32-50 have
female threaded ends to ISO288. From DN65, the valves have flanged line
connections.
Function The valves maintain a constant volume flow rate as defined by the presetting,
irrespective of fluctuating pressures in the system. This function is achieved by means
of an integral fluid-controlled actuator which moves the functional unit. The valve is
provided with a shut-off function.
The flow rate can be measured at the two pressure measurement connection
branches 131.1/.2 in conjunction with a differential pressure gauge.
4.9 Scope of supply
The following items are included in the scope of supply:
▪Valve
Valves from DN65 require an actuator or manual gearbox to be fully functional.
4.10 Dimensions and weights
For dimensions and weights please refer to the type series booklet.

5 Installation at Site
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5 Installation at Site
5.1 General information/Safety regulations
The consultant, construction company or operator are responsible for positioning
and installing the valves. Planning errors and installation errors may impair the
reliable function of the valves and pose a substantial safety hazard.
The valves are supplied ready for operation.
5.2 Installation position
Non-compliance with the following installation instructions may result in failure of
the measuring function!
CAUTION
Flow in opposite direction of flow direction arrow
No valve function!
▷Flow through the valves must be in the direction indicated by the flow direction
arrow cast on the valve body.
Fig.5: Installation positions
The valves can be installed in supply lines as well as return lines, and in any position.
Valves combined with an actuator must not be installed with the actuator pointing
downwards.
5.3 Piping
WARNING
Impermissible piping forces
Leakage from or rupture of the valve body!
▷Connect the pipes to the valve without transmitting any stresses or strains.
▷Take structural measures to prevent any piping forces from being transmitted
to the valve.
▷Avoid mechanical loads beyond normal levels, e.g. piping forces, moments and
vibrations.
CAUTION
Welding in close proximity to soft-seated valves
Damage to the seat/disc interface!
▷Ensure that the valve is not heated beyond the specified temperature limits.
(ðSection4.3,Page14)

5 Installation at Site
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CAUTION
Painting of the piping
Valve function impaired!
Loss of important information provided on the valve!
▷Protect stem and plastic components prior to applying paint.
▷Protect printed name plates prior to applying paint.
5.4 Installing the valve
CAUTION
Improper installation
Damage to the valve!
▷Protect the body and body bonnet from any impacts.
CAUTION
Outdoor installation
Damage due to corrosion!
▷Provide weather-proof protection to protect the valve against moisture.
CAUTION
Welding beads, scale and other impurities in the piping
Damage to the valve!
▷Remove any impurities from the piping.
▷If necessary, install a strainer.
1. Thoroughly clean, flush and blow through all vessels, piping and connections
(especially of new installations).
2. Check that the inside of the valve is free from any foreign objects. Remove any
foreign objects.
3. If required, install a strainer in the piping.
Threaded connection (DN 10 - 50)
The valves have male threaded ends (DN10-25) or female threaded ends (DN32-
50) to ISO228 for installation in the piping.
CAUTION
Tightening the threaded connection with an unsuitable tool
Damage to the valve!
Leakage at the valve body!
Leakage of fluid!
▷Tighten the threaded connection with an open-ended spanner only.
üThe thread is free of dirt.
1. Always apply sealing material to the male thread of the threaded connection
only.
2. Tighten the threaded connection with an open-ended spanner.