Bernard Controls ET Range Installation & Operation Manual

INSTRUCTIONS DE MISE EN SERVICE,

STOCKAGE ET ENTRETIEN

INSTRUCTIONS FOR START-UP,

STORAGE AND MAINTENANCE

NR 1278_ET_revD_A/F

Art: 5100217

ET

Gamme

Range

2

CONTENTS

1> SAFETY 3

2> MOUNTING 3

3> EMERGENCY HANDWHEEL AND DECLUTCH 3

4> TORQUE LIMITER 4

5> ET SWITCH - COMMISSIONING 5

6> ET LOGIC - COMMISSIONING 8

7> MAINTENANCE AND STORAGE OF ACTUATORS 24

APPENDIX 47

A - Wiring diagram - ET Logic Version (S5400000) 47

B - Wiring diagram - ET Switch Version (S5099901) 48

C - Wiring diagram - Pre-Wired Version (S5021009) 49

D - Torque limiter settings tables 50

E - F501 & F502 fuses characteristics 51

SOMMAIRE

1> SÉCURITÉ 25

2> MONTAGE 25

3> COMMANDE MANUELLE ET DEBRAYAGE 25

4> LIMITEUR DE COUPLE 26

5> MISE EN SERVICE – ET SWITCH 27

6> MISE EN SERVICE - ET LOGIC 30

7> ENTRETIEN ET STOCKAGE DES SERVOMOTEURS 46

APPENDIX 47

A - Schéma de câblage - ET Logic Version (S5400000) 47

B - Schéma de câblage pour ET Switch (S5099901) 48

C - Schéma de câblage pour version pré-câblée (S5021009) 49

D - Tableaux de réglage du limiteur de couple 50

E - Caractéristiques des fusibles F501 & F502 51

3

English

1> SAFETY

This device complies with applicable safety standards. Installation, maintenance and operation

must be carried out by a skilled and trained staff only.

Please read carefully this whole guide before mounting and starting the actuator.

2> MOUNTING

Actuator must be bolted on the device to drive.



Bernard Controls actuators are mechanically designed to work whatever its

orientation. However, please avoid:

• to position cable glands upwards to keep waterproofness,

• to place the motor downwards, to avoid internal condensation.

!

• Do not use handwheel to carry actuators to avoid damaging worm gears.

• If the actuator is supplied mounted on the valve, basic settings should have

been carried out.

See chapter 7 for storage care before commissioning.

3> EMERGENCY HANDWHEEL AND DECLUTCH

For every actuators, torque limiter adds an additional protection.They are ﬁtted with an

automatic declutching handwheel with motor drive priority.

To switch to manual drive, align the arrow of

clutch handle with the triangular mark of the

housing. You may have to turn the handwheel of a

few degrees to disengage clutch.

Return to electrical drive is automatic but can be

manual.

4

4> TORQUE LIMITER

ET Range actuators are equipped with torque limiters.

For ET Switch (see image), torque limiter micro-switches send

back a pulse.

After stopping motor, information can be mechanically stored by

adding a backstop cam clutch.

For ET Logic, torque is measured with a strain gauge. Triggering

information is stored by the board.

TO COMMISSION YOUR ET SWITCH

REFER TO CHAPTER 5.

TO COMMISSION YOUR ET LOGIC,

REFER TO THE CHAPTER 6

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English

5> ET SWITCH - COMMISSIONING

5.1> WIRING AND ELECTRICAL TESTS

Cables coming from the different components of the

actuator are plugged on a terminals plate with numbered

terminals.

These numbers are identical to wiring diagrams.

Thermal protection switch of motor and the 2 micro-

switches of torque limiter must be included into your

control logic (cf. wiring examples) to avoid risk of

mechanical breakage.

To check that wiring is correct:

1. Check that the power supply used matches the indication on the identiﬁcation plate of

the actuator.

2. Check that cable glands are well-tightened.

3. Bring the valve to mid-stroke with the handwheel.

Checking the end position control

4. With the electrical drive, run a valve opening then check that rotation direction is correct.

5. When turning, manually operate OPEN end position micro-switch: motor must stop.

6. Check the same way CLOSED end position micro-switch.

Checking the torque limiter

7. With electrical drive, run an opening.

8. Operate the OPEN micro-switch of the torque limiter: motor must stop.

9. Check the same way CLOSED torque limiter micro-switch for a closing operation.

In case of a failure in one of these tests, check the whole wiring.

6

5.2> SETTING OF END POSITION MICRO-SWITCHES

Operation of cam block and end position micro-switches

Cams triggering micro-switches consist in a monobloc unit whose parts can be set indipendently:

• the 2 white and black cams trigger end position micro-switches

• the 2 beige and gray cams trigger additional micro-switches that can be used for signaling

To set a cam

1. In the slot surrounded by a ring of the same color than the

cam, insert the blade of 3.5 or 4 mm screwdriver.

2. Slightly push downwards to free the rotation of setting

head and engage it in the cam.

3. Turn the setting head to drive cam to the desired position.

4. Release the screwdriver push.

5. Ensure that the setting head returned to its original

position, that automatically lock cam position.

To set cam block according to valve position

1. Bring the valve to close position.

2. Set the position of the cam triggering CLOSE end position micro-switch.

3. Bring the valve to the open position.

4. Set the position of the cam triggering OPEN end position micro-switch.

With electrical drive

5. Run a closing operation then check that the actuator stops when reaching CLOSE position.

6. Run an opening operation then check that the actuator stops when reaching OPEN

position.

5.3> CLOSING VALVE ON TORQUE WITH TORQUE LIMITER

CLOSED micro-switch may be used to avoid triggering torque limiter at the beginning of the

opening, to be able to get a breakout torque higher than the maximum set torque.

To get the actuator functioning this way, follow the cam block setting procedure (see §5.2).



When closing is electrically operated, ensure that the CLOSED end position

micro-switch is triggered shortly before motor stops, by opening CLOSED end

position micro-switch.

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5.4> TORQUE LIMITER

Actuator is equipped with a torque limiter set in factory.

It is factory pre-set at 100% of the maximum torque of the actuator.

If the torque limiter is triggered during operation, check that the valve shaft:

• is clean and well lubricated

• is not seized in the driving nut

• that its stufﬁng box is not too much tightened.



After triggering, torque limiter micro-switch remains in position if you have Irrever-

sibility option (see §6).

To adjust the settings of the torque limiter

After assembly on valve, you can adjust torque limits is needed.

To achieve this setting, torque limiter is ﬁtted with 2 screws

to adjust micro-switches positions when opening and closing.

This position is graduates with letters from A to I, determined

thanks to the settings tables in the appendix (D - Torque limiter

table).

Setting may be between 2 letters.

8

5.5> BACKSTOP CAM CLUTCH (OPTION)

In case of a high load that could lead to a partial opening of the valve, ET Switch has a Backstop

cam clutch option.

It makes the actuator mechanically irreversible.

In addition, it allows to hold torque limiter in position if it is triggered.

5.6> SIGNALING AUXILIARY MICRO-SWITCHES

Auxiliary end position micro-switches are used to signal OPEN and CLOSE position and are

triggered by beige or gray cams according to the rotation direction.

These micro-switches are connected to 20 to 25

terminals, as following:

5.7> ANTI-CONDENSATION HEATER

Every actuator is ﬁtted with an anti-condensation heater.

To avoid condensation, supply the resistor as soon as the actuator is installed.

5.8> PRECAUTIONS



Just after commissioning, mount back the covers and check that seals are clean.

Never let the electrical parts of the actuator without protection covers.

In case of water intrusion:

• dry electrical parts before putting back the cover,

• check electrical insulation.

6> ET LOGIC - COMMISSIONING

6.1> PRODUCT DESCRIPTION

ET Logic control features a local control, a 7-segments display showing valve opening percentage

and signaling LEDs.

Depending on the model, it can operate using single-phase or three-phase supply.

Control types

ET LOGIC control is available in 2 versions:

• Class A ON/OFF control: ET LOGIC manages only closed and open positions.



Reference marked ON identiﬁcation plate includes «FL» code:

ET XXXX FL XX XXX

• Class B Inching/Positioning control: ET LOGIC manages valve position: Position

feedback is provided.

It can be conﬁgured in ON/OFF mode.



Reference marked ON identiﬁcation plate includes «KL» code:

ET XXXX KL XX XXX

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6.2> ELECTRICAL WIRING

Carry out electrical wiring according to the wiring diagram supplied in control box. ET actuator is

ﬁtted with 3 M20 cable entries to ﬁt proper cable glands (cable glands are not supplied).

!

Do not open when the system is powered.

6.2.1> Supply board

Input/output cables are connected on terminal block.

1. Terminals 1 to 20:

control and signalling

connection

2. L3/L2/L1/PE for three-

phase supply

3. L/N/PE for single-phase

supply

4. Fuses

1

F502 (left)

F501 (right)

Supply board is ﬁtted with an additional control board connected to keypad and sensors.

1.

Characteristics in appendix

1

2

3

4

10

6.2.2> Control box access

1. Flat cable

2. Control board

3. Insulated side

To open the control box

1. Open the cover by unscrewing the 4 captive screws.

A ﬂat cable connects the keyboard to supply board.

To avoid a mechanical damage, this cable can be disconnected without effort when

opening the cover.

2. Disconnect this cable from the supply board.

3. Carry out the required wiring tasks.

4. After wiring, re-connect the ﬂat cable in its connector making sure that it lies on the

connector bottom.

!

Make sure that insulated side (3) is in front of you as the picture shows.

Do not twist cable.

5. Close the control box and tighten the 4 captive screws.

6.2.3> Connection supply wiring

Wire the supply board according to voltage indicated on the

indentiﬁcation plate:

• Three-phase: L1 / L2 / L3 / PE

• Single-phase: L / N / PE

1

2

3

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6.2.4> Remote control

Remote control of ET LOGIC actuator can be carried out using external supply (voltage control)

or internal supply (dry contacts control).

Input circuit is completely isolated by optocouplers. Pulse control (with self-locking) requires 4

connection wires on the terminal block: common, stop, opening and closing.

If the STOP push button is not used, do not wire terminal 14, opening (or closing) micro-switch

must be hold to operate the actuator.

Dry contacts control

Using dry contacts requires to create a bridge between terminals 9 & 10.

Remote pulse control

(self-holding)

Hold control

(non self-holding)

12

Voltage control

Remote control can be used with direct or alternative current.

!

Never connect voltage source upper than 55V on the terminal 9.

10 à 55 V

(common terminal 9)

90 à 250 V

(common terminale 8)

Remote pulse control

(self-holding)

Hold control

(not self-holding)

Proportional control (ET XXXX KL XX XXX XX only)

ET LOGIC ET XXXX KL XX XXX XX actuators can work with an input position signal

(e.g. 4-20 mA).

No setting is required, the signal is automatically adjusted on 0 to 100% position setting. You do

not need to set, signal automatically adapts to position setting from 0 to 100%.

Impedences of 15-16 inputs are:

• for 0/4-20 mA signal: 162 ohms

• for 0-10 V signal: 4052 ohms

Position feedback (ET XXXX KL XX XXX XX only)

According to actuator features, a position feedback signal may be available.

No setting is required, the signal is automatically adjusted on 0 to 100% position setting.

Default output signal is 4-20mA (4mA for 0% and 20mA for 100%).

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English

Position feedback 4-20mA signal

Position feedback 0-20 mA signal

or 4-20mA signal

External power supply of feedback loop can be in series or in parallel with the signal.

To get a 0-10V feedback signal (see §6.3), set the output feedback signal on 0-20mA and put

a 500 ohms resistance in series. Feedback voltage is measured between the terminals of the

resistance.

Feedback signal 0-10V

Maximum impedence on feedback loop is 750 ohms with 24VDC.

6.2.5> Open/Close signaling

ET LOGIC board is ﬁtted with 2 end position signaling relays (latching relays).

These relays indicate open or closed postions of the valve.

6.2.6> Alarm signaling

An Alarm relay (monostable relay) signals a fault when idle.

Various signaled faults are:

• Power supply loss

• Phase loss (when three-phases)

• Primary and control fuses

• Motor thermal protection

• Torque limiter triggering

• Motor blockage

• Loss of analog input signal (4-20mA)

• Position sensor fault

• Torque sensor fault

• Selector on Local

• Postion overrun fault

To wire the relays, check wiring diagram of your actuator (see appendix).

14

6.3> DIP-SWITCHES CONFIGURATION

!

Any change of conﬁguration must be carried out with power supply disconnected.

A modiﬁcation is only applied after power is disconnected.

You can set up some conﬁgurations using

dip-switches of the control board.

Dip-switches units have SW400 and

SW500 part references on the control

board and dip-switches are marked from

1 to 4.

To activate a dip-switch (ON position) or

deactivate it, use a small point and change

its position.

6.3.1> Closing conﬁguration

Actuator closes clockwise as a standard (looking to its rotation from above of the valve)

Rotation direction are conﬁgured the following way:

Clockwise

direction

No SW400 micro-switch is on ON.

Counter-clockwise

direction

SW400 micro-switch 1 is on ON.

6.3.2> Proportional signal conﬁguration

(ET XXXX KL XX XXX XX only)

Proportional signal and position feedback signal are 4-20 mA signals as a standard. Feedback

loop requires a 12-30 VDC external power supply .

Proportional signals are conﬁgured the following way:

4-20 mA SW400 micro-contacts 2 & 3 are on ON.

0-20 mA SW400 micro-switch 3 is on ON.

0-10 VDC

SW400 micro-switch 3 is on ON and SW500

micro-switch 1 & 2 are on V.

15

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6.3.3> ON-OFF / proportional control selection

(ET KL XX XXX only)

ETXXXX KL XX XXX XX are set on proportional control as a standard.

Control type selection is set as the following:

Proportional mode SW400 micro-switch 3 is on ON.

ON-OFF mode No SW400 micro-switch is on ON.

Remote control will be able to use dry contacts control (see § 6.2.4).

6.4> LOCAL CONTROL USE

6.4.1> Control keypad

Keypad functions

1

9

10

7

6

3

5

4

2

8

1. Status indication: opening percentage, user

information

2. Control type choice: local (Local), remote

(Remote) or Back in the menus (Esc.)

3. Closing command (Close) in Local mode

or Go down in the current menu

4. Stop command (Stop) in Local mode

or Validate a choice in the menus (OK)

5. Opening command (Open) in Local mode

or Go up in the current menu

6. Close position indication: Fixed LED when

position reached, blinking when operating,

customisable green or red.

7. Open position indication: Fixed LED when

position reached, blinking when operating,

customisable green or red.

8. Setting menu LED

9. Alarm LED

10. Local mode indicator LED

Local control inhibition

Keypad is protected by a local control inhibition function.

This function is automatically activated if the keypad is idle for 1

minutes or when pressing STOP key during 5 seconds.

When Local control is locked, a key

appears on the display.

To unlock the keypad, press 5 seconds continously on STOP.

16

6.4.2> Using the menu

Menu is organized and is scrolled through as described below.

17

English

Menu sections

Set position

allows to the set up on valve:

•

runs the closing

•

runs the opening

Set torque

set maximal torque percentage to open or to close

Set conﬁguration

Allows to set up:

• local control

• failsafe position in stayput , open or closed

in case of 4-20mA signal loss

• LED color for opening and closing

• Set dead band

Read conﬁguration

allows to read local control conﬁguration, proportional control

status and its type, voltage type and closing rotation direction

Read error

allows to display Error codes when there is an Alarm (several

codes can be displayed at the same time)

To enter main menu:

1. If the KEY

logo appears, unlock local control pressing 5

sec. on OK.

2. If the voyant (10) est éteint, appuyez sur la touche Local/

Remote pendant 3 s.

Local LED gets lit.

3. Press the Stop key then on Local/Remote key

and keep them pressed during 3 seconds.

Display shows

and the indicator Setting is ON.

You can scroll menus (cf. menu tree)

18

6.4.3> Set-up on valve

Set-up is done in 2 steps:

1. Setting closing and opening torque

2. Setting closing and opening positions

To set the closing torque

1. Enter in the setting mode as detailed in § 6.4.2.

2. Go down in the menu until you reach

et press on OK.

is displayed.

3. Press on OK.

The set torque percentage value is displayed.

4. With arrows, choose desired torque value then validate with OK.

Setting range goes from 40% to 100% with 10% steps.

5. Press twice on Esc. to exit the menu.

To set the opening torque

1. Enter in the setting mode as detailed in § 6.4.2.

2. Go down in the menu until

and press on OK.

is displayed.

3. Press the arrow

one time. is displayed.

4. press on OK.

The set torque percentage value is displayed.

5. With arrows, choose desired torque value then validate with OK.

Setting range goes from 40% to 100% with 10% steps.

6. Press twice on Esc. to exit the menu.

To set open and closed positions (if closing on torque not activated)

1. Enter Setting mode as described in §6.4.2.

is displayed.

2. Press OK (Stop) key to enter Setting mode.

is displayed.

3. Close the valve keeping Close pressed and checking valve index at the same time.

4. When index gets close to Closed position, release Close key.

5. Go to closing index with the manual handwheel, then press on OK.

Closing position is set and stored.

is displayed.

6. Open the valve by keeping Open pressed and monotoring opening with valve index.

7. When valve index gets close to opening end position, release Open key.

8. With the handwheel, continue opening until you reach a stop.

9. Turn handwheel 2 turns back then press OK.

Open position is set and stored.

To set open and closed positions (if Closing on torque activated)

1. Enter in the setting mode as described in §6.4.2,

is displayed.

2. Press OK (Stop) key to enter Setting mode.

is displayed.

3. Close the valve by keeping Close pressed until the actuator stops.

Stop occurs when closing torque reaches set value.

for Closed position in the

menu

.

Closing position is set and stored.

is displayed.

4. Open the valve by keeping Open pressed and monotoring opening with valve index.

5. When valve index gets close to opening end position, release Open key.

6. With the handwheel, continue opening until you reach a stop.

7. Turn handwheel 2 turns back then press OK.

Open position is set and stored.



Once settings done, proceed to a veriﬁcation cycle.

19

English

6.4.4> Set conﬁguration

To enter setting menu, scroll in the menu as detailed in § 6.4.2 and press on OK (Stop) when

appears on the display.

To set local control mode

Local control uses pulse as default.

To choose a holding control, select

.

Validate by pressing on OK (Stop).

To set safety position

This choice is only possible in 4-20mA conﬁguration.

It allows to set safety position of the valve in case of loss of proportional signal.

As default, there is no safety position if a control signal loss occurs.

Default setting is Stayput

, that is a stop on position.

• to deﬁne a safety positon when opening, select

.

• to deﬁne a safety position when closing, select

.

Validate with OK.

To set the LED colors for Open and Closed valve positions

On default conﬁguration , the green LED signals Open valve position and red LED

signals Closed valve positions.

To reverse the 2 LEDs position allocation, select conﬁguration

then valdiate by pressing

OK.

Red LED now indicates Open valve position and green LED indicates Closed valve position.

You can get back to standard conﬁguration by selecting conﬁguration

.

To set dead band

Dead band is a range of setpoints around a position which does not lead to valve movement.

All setpoints inside this range will be ignored.

It remedies to hunting chances or potential electrical disturbances of your control.

Setting values from 1 to 10 deﬁnes a range of +/-1 to +/-10% around the current position of

your valve.

20

6.4.5> Consulter la conﬁguration

To check conﬁguration, scroll in the menu as detailed in § 6.4.2 and press OK (Stop) when

appears on display.

To access to the different conﬁguration items:

Local control

Pulse control

Hold control

Proportional

control

inactive

active

signal 4/20 mA signal associated to a safety position: position

holding

, open , closed

0/20 mA signal

Applicable voltage

single-phase

three-phase

Closing direction

Clockwise

counter-clockwise

Closing type

on position

on torque

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Bernard Controls ET Range Installation & Operation Manual

Bernard Controls ET Range Installation & Operation Manual

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