Bernard Controls AQL Range User guide

AQL Range
Start Up Guide
SUG_17002 EN –Ind. E
Art : 5100723

TABLE OF CONTENTS
1SAFETY ---------------------------------------------------------- 4
2PACKAGING, STORAGE AND MAINTENANCE----------------- 4
2.1 Packaging & Storage
2.2 Maintenance
3MECHANICAL SET-UP------------------------------------------- 5
3.1 Opening the cover
3.2 Configuring position indicator for counterclockwise
closing
3.3 Adapting the actuator to your valve input
3.4 Fastening the actuator on the flange
4ELECTRICAL CONNECTION AND TESTS----------------------- 9
4.1 Checking after wiring
4.2 Installation of the Fast Connector (OPTION)
5CALIBRATION OF POSITIONER OR TRANSMITTER----------11
5.1 Calibration of position transmitter board (OPTION)
5.2 Calibration of positioner board (OPTION)
6RESUMING FACTORY CALIBRATION -------------------------16
6.1 Resuming calibration of mechanical stops
6.2 Resuming calibration of cams
6.3 Resuming calibration of travel limits
7RE-STARTING TORQUE LIMITING DEVICE-------------------20
8MANUAL OVERRIDE--------------------------------------------21

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1SAFETY
This device complies with current applicable safety standards.
The installation, use, and maintenance, of this unit require a skilled
and trained staff.
Please carefully read this entire document before mounting and
starting-up the actuator.
2PACKAGING, STORAGE AND MAINTENANCE
2.1 Packaging & Storage
AQL actuators are delivered in a cardboard box equivalent to the size
of the actuator and sit in a cardboard wedge.
Actuators should be stored under a shelter, in a clean and dry place,
and protected from wide temperature variations.

•Avoid placing the actuator directly on the floor.
•Check that the plugs on cable entries are correctly
tightened.
•Check that cover screws are correctly tightened to
ensure weatherproof sealing of the cover.
What to check after storage
Visually check the electrical equipment.
Operate the actuator manually.
What to check on pre-installed actuators
If you expect a long period between the mounting of the actuator
and the electrical wiring:
Visually check that cable entries and cover are tightly closed.
In case of outdoor installation, cover the unit with a plastic
protective film.
2.2 Maintenance
This actuator features lifetime lubrication and does not require any
specific maintenance.
If the actuator operates in a wet atmosphere, it is advised to check
once a year that there is no condensation build-up inside the unit.

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3MECHANICAL SET-UP
After assembly on the valve or the damper, the actuator can operate
in any position.
3.1 Opening the cover
You may need to open the cover to change the orientation of the
position indicator, or to set the cams or the positioner board.

Before its 1st use, the actuator is submitted to an IP pressure
test that tends to cause the cover seal to leave its groove.
How to open the cover
Using an 8 mm angled socket wrench, unscrew the 4 screws
fixing the cover. Do not remove them from the cover.
Upon the 1st cover opening only: Before removing the cover,
slightly turn the cover while holding it on its housing to ensure
its seal remains in place.
Remove the cover by pulling it out along its axis.

Actuators are fitted with mechanical stops and under no
circumstances should the manual override be forced if a hard
point is detected.

However:
•It is not recommended to install the actuator with its
cover facing downwards.
•The cable glands must not be oriented upwards (loss
of water tightness).

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3.2 Configuring position indicator for counterclockwise
closing
As a standard, AQL actuators are configured to close clockwise. If
the actuator must close counterclockwise, you can change the
orientation of the position indicator cap.
Standard indicator orientation
for clockwise closing
Reverse indicator orientation for
counterclockwise closing
How to change cap orientation
Disassemble the cover then the
cap.
Turn the cap 90°.
Reassemble the cap then the
cover.

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3.3 Adapting the actuator to your valve input
3.3.1 Adapters
The actuator is supplied with a set of adapters to ensure the output
fits your valve shaft.
You only need to insert the suitable square adapter inside the socket.
The adapter can be oriented as a parallel square or as a diagonal
square, depending on the need.
Standard
On request
Standard
On request
Internal size in mm
Max. shaft length accepted
20 mm
Internal size in mm
Max. shaft length accepted
25 mm
AQ1L/AQ3L
AQ7L
Adapters shapes (view from under the actuator)

Both the actuator and the valve must be in the same position,
either fully open or fully closed.

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3.3.2 Flange spacer (OPTION)
If the valve input rod is too long and does not allow you to mount
the actuator on the valve flange, you can mount a spacer under the
actuator.
This spacer is assembled on the flange of the AQL as shown below.
3.4 Fastening the actuator on the flange
Once the actuator is coupled with the valve, you need to fasten it
on the valve flange.
How to fasten the actuator on the valve
Screw the fasteners on the actuator through the valve flange
without fully tightening the actuator.
Turn the actuator to the maximum in the counterclockwise
direction.
Hold it in this position and tighten the actuator on the flange
using the screws.

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4ELECTRICAL CONNECTION AND TESTS
To perform the electrical wiring, please refer to the wiring diagram
stuck inside the actuator cover and follow the numbering of the
terminals.
!
Make sure not to wire an AC supply on terminals A, B, C
or a DC supply on terminals 1, 2, 3, this would damage
the board.
4.1 Checking after wiring
Once the wiring of the actuator is completed, please check the
following:
Make sure that the power supply voltage matches the
information on the sticker located on the side of the actuator.
Check that all connectors or cable glands are correctly tightened.
Electrically operate the opening and closing travels and check
that the actuator rotates in the right direction and stops at the
desired position.
If any fault is detected at this stage, please check that your wiring
is correct.

Never use a powered rotary equipment on the manual
override to operate the actuator.

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4.2 Installation of the Fast Connector (OPTION)
Bernard Controls provide a fast connector option for AQL actuators.
With this option, the male fast connection socket should be
connected to the actuator terminals inside the actuator. Sealing
must be done using the provided M20 cable gland.
The female fast connection socket needs to be
prepared by the customer by soldering the site
cable to the connection as indicated in the figure
below and in the wiring diagram. The pins on the
female connection socket are shown on the
adjacent figure.
!
Soldering must be done according to the provided wiring
diagram.

The outer diameter of the side cable of the actuator is
Ø13~Ø16 mm.

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5CALIBRATION OF POSITIONER OR TRANSMITTER
5.1 Calibration of position transmitter board (OPTION)
!
Make sure that the board is connected to the power supply
during the calibration process.
This operation must be carried out by a qualified
electrician.
The proportional transmitter
board allows you to get a
feedback of the current position
of the valve using a 4-20mA
analog signal.
Perform the electrical wiring
according to the wiring diagram
of the actuator.

The actuator is
delivered with its
position transmitter
already installed, and
calibration has already
been performed at our
factory.

Cams must be set before proceeding to this board
calibration.
5.1.1 How to set the position transmitter
Supply the actuator for opening.
Press during 5 s on the SW1 button.
The yellow LED starts blinking.
When the actuator reaches the OPEN position, press on SW1 to
validate this position as the OPEN position.
Cut-off supply for opening.
The yellow LED turns off.
Supply the actuator for closing.

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The yellow LED starts blinking.
When the actuator reaches the CLOSED position, press on SW1
to validate this position as the CLOSED position.
The yellow LED remains ON.
Check that the position transmission operates correctly by
measuring the current intensity between terminals 32 & 33.
If it does not, return to step 1.
How to set closing direction
You can use the SW2 Cdip switch to set the closing direction (A & B
are not used).
This setting must be done with the power off.
Closing
direction
C
ON
Clockwise
OFF
Counterclockwise

The current intensity should vary from 4 mA (CLOSED
position) to 20 mA (OPEN position).

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5.2 Calibration of positioner board (OPTION)
!
Make sure that the board is connected to the power supply
during the calibration process.
This operation must be carried out by a qualified
electrician.
The proportional analog
command allows you to
drive the valve to
intermediate positions.
The board is factory pre-
set.
Perform the electrical
wiring according to the
wiring diagram of the
actuator.
5.2.1 Setting up positioner board

The actuator is delivered with the proportional analog
command already installed, and calibration has already
been performed at our factory.
Only go through the setup procedure below if you previously had to
adjust the mechanical end stops positions.

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5.2.2 How to set the positioner board

The potentiometer has mechanical stops, be careful not to
turn the actuator too much on one side.
Check that the screw of the pinion on the potentiometer is
not too loose.
Press for 5 seconds on the SW1 push button located on the board.
The yellow LED starts blinking.
Use the Obutton to operate the actuator and go to the open
position.
Once the actuator is in the right position, press the SW1 button
to save the value.
The LED should be blinking rapidly.
Use the Cbuttons to operate the actuator and go to the closed
position.
Once the actuator is in the right position, press the SW1 button
to save the value.
The LED should be blinking slowly.
The actuator now performs several operations to configure the
controller.
The actuator then goes back to run mode and the LED remains ON.
If the LED continues to blink after the automatic process, it is
indicating one or several of the following errors:
Times blinking (blips)
2
3
4
5
Configuration
was not
correctly
loaded
4/20 mA
signal is
lost
Actuator is
blocked
during travel
•Direction of
rotation is wrong
•Actuator got to a
position out of
travel limits
•Actuator is
pumping

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How to set closing direction and fail position
You can use the SW2 dip switches to set the closing direction (dip
switch C) and the fail position (dip switches A & B) in case of signal
loss.
This setting must be done with the power off.
Closing
direction
C
Fail
position
A
ON
OFF
ON
Clockwise
B
ON
Fail
last
Fail
closed
OFF
Countercl
ockwise
OFF
Fail
open
Fail
last

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6RESUMING FACTORY CALIBRATION
As a standard, AQL actuators close in the clockwise direction.
6.1 Resuming calibration of mechanical stops
Mechanical stops are set for an electrical travel of 90±3°.
6.2 Resuming calibration of cams
The cam is attached on the
output shaft, then rotates in
the same direction and
triggers a switch by pushing
on its lever.
The orientation of the cams
is factory pre-set, but you
can re-adjust them upon
installation if necessary.
Rep.
Function
Status before
installation
1
Clockwise travel limit
Pre-wired, cam pre-set
2
Counterclockwise travel limit
Pre-wired, cam pre-set
3
Clockwise signaling
To wire, to set
4
Counterclockwise signaling
To wire, to set

Mechanical stops are factory set. You do not need to
calibrate them.
They must not be used as electrical travel limits.

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How to adjust a single cam
At the desired position of the actuator output:
1) Turn the setting screw of
the corresponding cam
with a screwdriver.
The cam disk is then turning.
2) Adjust the cam disk until
you hear a click from the
switch. It indicates that
the switch has been
triggered.
Travel limit cams and signaling cams
AQL actuators have 4 cams with
2 different functions:
•Travel limit cams cut the
power supply of the
motor when they trigger
the switch corresponding
to an end position.
•Signaling cams are not
wired by default. You can
use them to indicate
when the actuator gets
close to an end position.
Signaling cams must be set to
reach their corresponding switch
before the travel limit cams do.

If the actuator is supplied mounted on a valve, the following
settings should have been performed by the valve supplier.

Make sure that the cam operates the lever in the right
direction (as shown by the arrow in the figure below),
otherwise the switch could be damaged.

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6.3 Resuming calibration of travel limits
Travel limit settings are done with cams only. The actuator stops on
the open or closed position when the travel limit switch is tripped.
Remove the cover and, after the power supply is connected, proceed
to the following test.
How to test factory settings (without positioner)
Run a clockwise operation until the actuator stops with the
closing end position switch.
If the setting is correct (i.e. the valve is closed), the test
procedure is finished.
If the setting is not correct, resume the settings according to the
following steps:
Reset the clockwise end position cam to allow a slight extension
of the travel of the actuator and get your valve closed.
If the clockwise signaling switch is wired:
Drive the output slightly in the counterclockwise direction using
the manual override.
Set the cam corresponding to the clockwise signaling switch.
Once the clockwise cams are set, resume steps 1 to 4 for the
counterclockwise direction.

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How to test factory settings (with positioner)
Using the manual override, drive the actuator in the clockwise
direction to the end position.
According to the situation:
•If the end position cam trips the switch at the same time
as the valve is closed, you do not need to resume the
settings.
•If the end position cam trips the switch before the valve
is closed, set the cam slightly counterclockwise to get
the switch tripped and the valve closed at the same time
•If the valve is closed before the cam is tripped, set the
cam slightly clockwise to get the switch tripped and the
valve closed at the same time
If it is wired and if necessary, set the clockwise signaling cam
accordingly.
Using the manual override, drive the actuator counterclockwise
to the end position.
Proceed to the same checks as in step 2 with the opposite
directions.
If it is wired and if necessary, set the counterclockwise signaling
cam accordingly.

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7RE-STARTING TORQUE LIMITING DEVICE
In case of excessive torque on the actuator, a torque limitation
system shuts down the actuator.
A LED behind the switch board is lighting up when this protection is
ON.
How to re-start the actuator after an over-torque detection
Switch off the power supply.
Check if the issue comes from the valve (stiff point or jamming)
or the mechanical stops (over-travel).
Fix the issue.
Switch back on the power supply and electrically operate the
actuator in both directions.

The LED remains lit for a few seconds after the power supply
is switched off.
Wait those few seconds before switching back on the power
supply and operating the actuator.