Bernard Integral+ Training manual

COMMISSIONING INSTRUCTIONS
MANUEL DE MISE EN SERVICE
BEDIENUNGSHANDBUCH
INTEGRAL+ CONTROL AND
POSIGAM+
COMMANDE INTEGRAL+ ET
POSITIONNEUR POSIGAM+
INTEGRAL-PLUS STEUERUNG UND
POSIGAM-PLUS
INTEGRAL+
NR1088_AFD_rev G Art : 5100052

2
DRAWINGS Page 3
1 INTRODUCTION Page 4
2 FAST VALVE SET-UP Page 4
3 CONFIGURATION Page 4
4 POWER SUPPLY Page 4
4.1
Actuator power supply Page 4
4.2
Output power supplya Page 5
5 ACTUATOR OPERATION Page 5
5.1
Direction of rotation Page 5
5.2
Closing type Page 5
5.3
By-pass of open torque switch when starting to open from closed position Page 6
5.4
Rotation reverse relay Page 6
6 REMOTE CONTROL Page 6
6.1
Dry contacts control Page 7
6.2
Voltage control Page 7
6.3
Single dry contact control Page 7
6.4
Priority to open or to close Page 8
6.5
Emergency control (ESD) Page 8
6.6
Local control inhibition Page 9
7 LOCAL CONTROL Page 10
7.1
Self-holding local control Page 10
7.2
Local stop Page 10
7.3
General stop Page 10
7.4
Local/remote selector padlock Page 10
8 INDICATIONS Page 11
8.1
Blinking indications Page 11
8.2
Indication relay N°1 Page 12
8.3
Indication relay N°2 Page 12
8.4
Indication relay N°3 Page 12
8.5
Indication relay N°4 Page 13
8.6
Fault monitoring relay Page 13
9 FUSES PROTECTION Page 15
10 POSITIONER OPTION Page 15
10.1
Input signal configuration Page 15
10.1.1
Operation with signal 0-20mA Page 15
10.1.2
Operation with signal 0-10V Page 15
10.2
Operation direction configuration Page 15
10.3
‘Stay put’ function configuration Page 16
10.4
Dead band adjustment Page 16
10.5
Local operation Page 16
10.6
Adjustment of 0% Page 17
10.7
Adjustment of 100% Page 17
10.8
Split range Page 17
10.9
Operation with 4-20mA transmitter Page 18
10.10
Remote control AUTO/ON-OFF Page 18
11 LOCAL INDICATION OPTION Page 18
12 TIMING CONTROL BOARD OPTION Page 18
12 TROUBLESHOOTING INTEGRAL+ VERSION Page 20
14 TROUBLESHOOTING OF POSITIONER VERSION Page 23
15 USER’S SETTING Page 50
CONTENTS

3
GAM-K POSITIONER SETTING
CONFIGURATION POSITIONNEUR GAM-K
GAM-K POSITIONER EINSTELLUNG
100% setting potentiometer
Potentiomètre réglage 100%
Potentiometer für die 100%
Einstellung
Local control switch
Commutateur commande manuelle
Lokal- Kontroll-Schalter
Actuator running in open direction LED
Voyant manoeuvre d’ouverture
LED für die Laufanzeige in
Richtung offen
LED for actuator running
in closing direction
Voyant manoeuvre de fermeture
LED für die Laufanzeige in
Richtung schließen
Potentiometer for local control
Potentiomètre de commande locale
Potentiometer für lokale Steuerung
Dead-band setting potentiometer
Potentiomètre de réglage
de la bande-morte
Potentiometer für die
Totband-Einstellung
Configuration switches
Commutateurs de configuration
Konfigurationsschalter
Local control buttons
Boutons de commande locale
Lokale Steuerschalter
Terminal strip
Bornier de connexion
Klemmenleiste
Electronic board configuration
Carte de configuration
Konfiguration der elektronischen Steuerung
FPI HOUSING
BOITIER FPI
FPI GEHÄUSE
Furnished with screws,
nuts & diagram
Fourni avec vis,
rondelles et schéma
Ausgestattet mit
Schrauben, Muttern
& Diagramm
Switch off the power supply before removing the terminal strip cover.
Couper l’alimentation avant d’enlever le couvercle du bornier de connexion.
Bevor Sie den Klemmenleistendeckel entfernen, schalten Sie die Spannungsversorgung aus.
CI2701 INTEGRAL+ BOARD SETTING
CONFIGURATION
CARTE CI2701
INTEGRAL+
INTEGRAL-PLUS
PLATINEN
EINSTELLUNGEN
Configuration jumpers
Cavaliers de configuration
Jumper Einstellungen
Configuration switches
Commutateurs
de configuration
DIL-Schalter- Funktionen
Thermal sensor tripped LED
Voyant alarme
protection thermique
Anzeige-LED für
“Thermokontakt ausgelöst”
Torque switch tripped LED
Voyant limiteur
d’effort activé
Anzeige-LED für
“Drehmoment ausgelöst”
Secondary fuses
Fusibles secondaires
Zweitsicherungen
Secondary fuses
Fusibles secondaires
Zweitsicherungen
Actuator closing
LED indicator
Voyant fermeture
servomoteur
Anzeige-LED für “Antrieb
schließt”
Actuator opening
LED indicator
Voyant ouverture
servomoteur
Anzeige-LED für “Antrieb
öffnet”

4
1 INTRODUCTION
The configuration panel of the INTEGRAL+ board allows to adapt the actuator at each particular
application. Information to be transmitted and actuator behaviour configuration are set with swit-
ches and jumpers. The actuator is deliverable with standard configuration, or optional configuration
if requested at order. The configuration can be easily changed on site.
The jumper and switches settings can be reported in a table on page 39.
2 FAST VALVE SET-UP
If the INTEGRAL+/POSIGAM+ control doesn’t need specific configuration, you can refer directly to
the detachable document located in the center of this document for a fast and easy setting of
the valve position. This description considers valve closing on position. For POSIGAM+, description
considers input/output signals are 4/20mA.
For specific parameters, please follow the descriptions in the following chapters.
3 CONFIGURATION
Configuration is easily done by changing switches and jumpers position.
Basic/standard” configuration (default setting): all switches and jumpers are in position A.
4 POWER SUPPLY
4.1
ACTUATOR POWER SUPPLY
Actuator power supply can be 3 phase, single phase or DC.
Jumper 100 (located at the bottom of the board)
The electronic board includes an automatic phase correction device and a detection of missing
phase device. In 3 phase supply, whatever the power connection, the actuator always rotates
in the right direction. If, in 3 phase supply, one phase is lost, the actuator stops automatically
and the monitoring relay drops.
Figure 2
Switches configuration Figure 3 Jumpers configuration

5
English
In single phase or DC supply, one must inhibit the automatic phase correction
and the detection of missing phase by moving the jumper 100 to position M.
- Single phase or DC power supply
4.2 OUTPUT POWER SUPPLY
One power supply unit 23V - 1,2VA DC is available (through the card CI2701) to power a remote
position current transmitter and remote controls dry contacts. This power supply unit is isolated
from the other electrical circuits.
5 ACTUATOR OPERATION
5.1
DIRECTION OF ROTATION
In standard, the actuator closes clockwise.
Switch 7
Move the switch 7 to position B for the valves closing counter-clockwise. This switch reverses:
- The motor direction of rotation
- The limit switches
- The torque switches
- Closing counter-clockwise
5.2 CLOSING TYPE
In standard, the actuator closes on limit switch.
Switch 1
Move switch 1 to position B for closing on torque switch (only for actuator equipped with torque limit
switches). The associated limit switch must also be operated when the valve is closed.
- Closing on torque switch
The limit switch is used for valve closed indication and also allows to detect stopping on torque
switch at mid-stroke as a fault and stopping on torque switch in closed position as normal.

6
5.3 BY-PASS OF OPEN TORQUE SWITCH WHEN STARTING TO OPEN FROM
CLOSED POSITION
In standard, the open torque switch is active on the whole actuator stroke.
Switch 6
Move switch 6 to position B to by-pass the open torque switch by the closed limit switch when
starting to open from the closed position.
- By-pass the open torque switch
by the closed limit switch in closed
position
This must be used when actuator including mechanically maintained torque switches [SR type] is
set for closing on torque switch. This avoid the open torque switch to trip when starting to open.
5.4 ROTATION REVERSE DELAY
In standard the reverse delay is 50ms. Jumper on support 25 in position 50ms.
Jumper 25
Move the jumper on support 25 to position 200ms to have a reverse delay of 200ms.
- Reverse delay of 200 ms
Note: the setting of the reverse delay is a factory setting. It allows the use
of bigger single phase motors.
6 REMOTE CONTROL
Remote control of an actuator equipped with the electronic board CI2701 can be done from an exter-
nal voltage supply or an internal voltage supply.
Inputs on the board are completely isolated by opto-isolators.
Pulse commands (with self-holding) requires 4 wires connected to the customer terminal board: Com-
mon, stop, open and close. If the stop button is not used, do not connect the wire STOP, open contact
(or close) must be maintained to operate the actuator.

7
English
6.1 DRY CONTACTS CONTROL
In case of dry contact control, a jumper must be put on customer terminals 5-6
6.2 VOLTAGE CONTROL
Remote control can be done either in AC or DC voltage.
For lower voltages from 10 to 55V, use common terminal 5.
For higher voltages from 90 to 250V, use common terminal 4.
6.3 SINGLE DRY CONTACT CONTROL
It is possible to control the actuator with a single external dry contact.
- Contact closed: opening of the valve
- Contact open: closing of the valve
One must configure the actuator for priority to open (see 5.4).
The opposite control is possible :
- Contact closed: closing of the valve
- Contact open: opening of the valve
One must configure the actuator for priority to close (see 5.4).
4
5
6
7
8
9
10
4
5
6
7
8
9
10
4
5
6
7
8
9
10
4
5
6
7
8
9
10
8
90
4
5
6
7
8
9
10
4
5
6
7
8
9
10
Caution : never connect
voltage higher than 55V
on common terminal 5.

8
6.4 PRIORITYTO OPEN OR TO CLOSE
In standard there is no priority to open or to close. These priorities are used to:
- Change the direction during operation without going through a stop command. In that case prio-
rity to Open and to Close are needed.
- Give priority to one position: if the actuator receives both open and close command and a priority
to Open or to Close are needed.
- Control by a single dry contact
Switches 9 and 10
Move switch 9 to position B for priority to Close.
Move switch 10 to position B for priority to Open.
- Priority to Close
- Priority to Open
- Change of operation
direction without going
through a stop command
Priority command stops the pending operation and is immediately active.
6.5 EMERGENCY COMMAND (ESD)
ESD (Emergency Shut Down) is a remote emergency control, with priority on all other controls.
According to the valve operation, ESD can be open command or close command. To increase
the availability of the actuator in extreme conditions, ESD can also override the motor thermal
sensor.
Note: ESD is not available when local / remote selector is in position «OFF».
In standard, ESD control is performed by closing a contact. Jumper 27 position:

9
English
Jumper 27
Move jumper 27 position to have ESD by opening a contact.
In standard, ESD control is a close command. Jumper 28 position
CLOSE.
Jumper 28
Move jumper 28 to position OPEN for open command.
In standard, ESD control does not override the motor thermal
sensor
Switch 8
Move switch 8 to position B to by-pass the motor thermal sensor
when ESD control.
- Configuration of ESD control: jumpers 27 and 28
- By-pass of motor thermal sensor
when ESD control.
6.6 LOCAL CONTROL INHIBITION
The inhibition of the local control is a remote command. This command freezes open and close
commands sent in local and authorise remote commands even if the local / remote selector is in local position.
In standard configuration, local stop and general stop remain possible locally on the actuator.
For inhibition of local stop and general stop, see 6.3 (switch 4 on position B).
Caution : In this configuration,
if ESD input is not connected,
the actuator receives an ESD
operation command as soon
as powered on. If no ESD wire
is available at the start-up
stage, it is recommended to
add a jumper at the wiring
terminal strip (in place of ESD
wire) prior to power on.
Note: the command inhibition of local control is not available with the option positioner.
It is replaced [automatically] by the function AUTO / ON-OFF CONTROL.
4
5
6
7
8
9
10
11
12
4
5
6
7
8
9
10
11
12
90

10
7 LOCAL CONTROL
As for remote control, local control can be used. A local selector allows to choose between remote
and local control. The button for local control open, close allows to operate the actuator in the
appropriate direction. Local stop is done by a momentary rotation of the local / remote selector.
7.1 SELF-HOLDING LOCAL CONTROL
In standard, local controls are self-holding. (One pulse is enough to send a close or open command)
Switch 5
Move switch 5 to position B to cancel
the self-holding. (Open or close com-
mand must be maintained during the
operation)
- Local control without self-holding
7.2 LOCAL STOP
In standard, it is possible to stop the actuator locally, even if the selector local / remote is on remote
position.
7.3 GENERAL STOP
In standard, it is possible to do a general stop of the actuator. Move the selector local / remote
to position OFF. No electrical controls in local or remote is therefore possible. If the remote command
local control inhibition is used, priority remains to the function general stop.
Switch 4
Move switch 4 to position B to prohi-
bit local stop and OFF position when
local control inhibition.
- Local stop impossible if local control
inhibition.
7.4 LOCAL / REMOTE SELECTOR PADLOCK
The local / remote selector can be padlocked in position OFF, local or remote.