Watts Bar-positrol Service manual

Assembly, Mounting and Operating Instructions

Sicher und ﬂexibel –

die neue Antriebsgeneration actubar

-positurn2-positrol

Positioner and 3-position control unit

and

English

Operating Instructions

bar-positurn2 and bar-positrol

In General:

Reference Documents:

Read these instructions care-

fully and keep them near to

the device.

Read, understand and follow

the safety instructions.

These operating instructions are an inte-

gral part of the device. The operating in-

structions have to be kept with the device

for the whole of its service life.

If there is a change of owner, then the

operating instructions have to be handed

over with the device.

In addition to these operating instruc-

tions, all generally valid, legal and other

regulation & other relevant legislation –

even in the operator‘s country – as well

as valid environmental stipulations have

to be adhered to!

Locally valid stipulations from the trade

organisation or other governing bodies

are always to be adhered to!

These instructions, the so-called data

and layout sheets, additional assembly

and maintenance instructions as well as

further information and advice – even in

other languages – are available from:

bar pneumatische

Steuerungssysteme GmbH

Auf der Hohl 1

D-53547 Dattenberg

Tel.: +49 (0)2644-9607-0

Fax: +49 (0)2644-9607-35

E-Mail: bar-info@wattswater.com

www.bar-gmbh.de

Operating Instructions

bar-positurn2 and bar-positrol

English

Safety instructions and warnings:

Before commissioning, read these instruc-

tions carefully and follow all advice.

In this documentation we use different

types of instructions for safety and war-

ning signs:

Indicates a real and near dan-

ger. To ignore this sign means

possible death or serious inju-

ry as consequence.

Indicates a threat of danger.

To ignore this sign means pos-

sible serious injury or material

damage as consequence.

Indicates a possible danger.

To ignore this sign means

possible material damage as

consequence.

Stands for advice and tips

for a better understanding of

instructions or a better hand-

ling of the unit.

The afore-mentioned operating instruc-

tions are valid for bar-positurn2 / positrol,

a module of the new valve control sys-

tem bar-vacotrol. They are intended for

the operator that means the person that

works with the unit. This is not a techni-

cal handbook. For questions, arising from

the contents of this documentation, please

contact our customer service department.

The unit and this documentation are pro-

tected by copyright. Their reproduction wit-

hout written permission will be contested

in court. We reserve all rights to these

operating instructions and their contents

thereof, also for their reproduction and/or

duplication in whatever imaginable form,

e.g. through photocopies, print, on what-

ever data carriers or in whatever translated

form. The reprinting of this documentation

is only possible via the express written per-

mission of bar GmbH. The technical state at

the time of delivery of the unit and instruc-

tions is a deciding factor, in case no other

information is provided. We reserve the

right to technical changes without special

notice in advance. Earlier instructions lose

their validity. The General Terms and Con-

ditions for Sales and Delivery as prescri-

bed by bar GmbH are to be adhered to.

Scope of validity:

DANGER!

WARNING!

ATTENTION!

English

Operating Instructions

bar-positurn2 and bar-positrol

Safety instructions and warnings:

We guarantee the fault-free function of our

product according to our advertising, the

product information and this documentation

issued by us. Further product features are

not promised. We undertake no liability for

economy and fault-free function, when the

product is used for other purposes, as de-

scribed in the section „Designated Usage“.

Damages are generally excluded, except in

the case of criminal intent or gross negli-

gence committed by bar GmbH is proved,

or in the case of promised product features

being absent. If this product is exposed to

non-prescribed environments, for which it is

not suitable or does not correspond to the

technical standard as stipulated therein, we

cannot and will not be held responsible for

the consequences.

We accept no liability for damages to sys-

tems and equipment in whatever form in

the surrounding environment around the

product, which result from a fault of the pro-

duct or in this documentation. We are not

responsible for injuries to patents and/or

other third party rights outside the Federal

Republic of Germany.

We cannot be held liable for damages, re-

sulting from the incorrect operation and

non-adherence to the instructions laid down

in this documentation. We are not liable

for losses in proﬁt and resulting damage

thereof from the non-adherence to safety

instructions and warnings. We undertake

no liability for damage, resulting directly or

indirectly from the use of accessories and/

or consumable products, which have been

neither delivered nor certiﬁed by bar GmbH.

The products manufactured by bar GmbH

are designed to give a long service life.

They correspond to the state of the art for

science and technology and are individually

tested in all functions before dispatch. The

electrical and mechanical construction cor-

responds to valid standards and guidelines.

bar GmbH constantly carries out ongoing

tests on the products and the marketplace,

to ensure the further development and im-

provement of their products.

In case of faults and/or technical pro-

blems, please contact our service depart-

ment. We can assure you, that immediate

appropriate measures will be initiated.

Valid here are the Terms of Warranty from

bar GmbH, which we will send to you upon

request.

The bar-positurn2 / positrol is a positio-

ner for mounting onto pneumatic actua-

tors of the series known as the actubar

series or actuators according to VDI/VDE

3845 with a pivoting angle of max. 180°.

With the help of external solenoid valves

and compressed air, bar-positurn2 or bar-

positrol converts analogue input signals

Exemption from liability:

Designated Usage:

Operating Instructions

bar-positurn2 and bar-positrol

English

Safety instructions and warnings:

into actuator pivoting movements. Usage

as a 3-position control unit with freely se-

lectable middle position and binary con-

trol (without analog activation) is possible

as an alternative, just as application as

position indicator without any activation.

Any other application of this device is to

be considered to be outside the designa-

ted use. If you have any questions, or

would like to use the unit for another pur-

pose, please contact our customer ser-

vice department. We will be pleased to

help with the necessary conﬁgurations.

For this device, we undertake the warran-

ty of faultless condition for duration of six

months within the framework of our Con-

ditions of Warranty. Parts subject to wear-

and-tear are excluded from this warranty.

The claim is invalidated, when tampering

is carried out by persons who are hereby

not authorised by bar GmbH.

Inside the warranty period of time, we

will repair damage or faults without cost,

which can be provably traced back to a

factory error, insofar as this is registered

by us immediately upon discovery, at the

latest however inside a time span of six

months following the date of delivery.

The warranty cover will be made accor-

ding to our estimation, through cost-free

repair maintenance of the faulty parts

or exchange of those parts with faultless

parts. Send the units, for which the claim

against warranty is being made, carriage-

paid and with a copy of the invoice i.e.

the delivery note to bar GmbH. Please

get in contact with our customer service

department before sending the goods.

The owner/operator of this device has to

ensure that only persons who:

• know the rules about safety at work

and prevention of accidents

• have been instructed in the operation

of this device

• have completely read and understood

these instructions

• can use and operate this device.

Persons, who operate this device, are ob-

liged:

• to observe all rules pertaining to safety

at work and the prevention of accidents

• to read these instructions thoroughly.

Persons to be seen as authorised, are

those with a successfully concluded pro-

fessional training, technical experience,

as well as knowledge of the appropriate

standards and guidelines, and who are in

a position, to appreciate the tasks they

are delegated, and lastly to recognise

and act upon possible dangers arising.

Guarantee:

Obligation of Customer:

Authorized Personnel:

English

Operating Instructions

bar-positurn2 and bar-positrol

Safety instructions and warnings:

Operator of positurn/positrol:

Authorized persons are instructed how to

operate bar-positurn and bar-positrol af-

ter they read and understood this instruc-

tion completely.

Operator for installation and service:

Authorized persons are instructed in all

points of the positioner after they read and

understood this instruction completely.

In its standard form, the bar-positurn2 /

positrol is designed and manufactured for

actuators with a closing direction for val-

ves in a clockwise manner (cw). The actu-

ator undertakes the basic position with a

closed valve. In the case of corresponding

units, the basic position corresponds to so-

called safety effect „current-free closed“.

In the initialisation process, the positioner

adjusts to the deﬁned actuator pivoting

range. The analog activation is triggered

from the control point and effects the pro-

portional allocation of the deﬁned pivoting

angle to the set value (input) signal.

In a similar manner, the deﬁned pivoting

angle is allocated an analog positioning

signal. Binary signals are formed additio-

nally at the start and end of the pivoting

range. Electrical connection is made at ter-

minal blocks inside the unit.

Pneumatic connection is made directly at

the external solenoid valves for positurn.

The pneumatic connection of the positrol

is made at the housing.

The bar-positurn2 is mounted

• with a bracket onto actuators with inter-

face acc. to VDI/VDE 3845

• or directly onto actuators type actubar.

Solenoid valves are ﬁtted to standard inter-

faces with type-related material.

The bar-positrol is mounted

• directly onto actuators with interface

acc. to VDI/VDE 3845 with a maximum

shaft diameter up to 70 mm and a

shaft heigth of 30 mm.

Functional Description:

Overview of versions

Product Version Actuator type In case of power failuer

bar-positurn PN2-D double acting fail to stay

bar-positrol PL-D double acting fail to stay

bar-positurn PN2-S double acting fail to close / open

bar-positrol PL-S double acting fail to close / open

bar-positurn PN2-E single acting fail to close / open (depending of springs)

bar-positrol PL-E single acting fail to close / open (depending of springs)

Operating Instructions

bar-positurn2 and bar-positrol

English

Technical data:

Device Type positurn positrol

Materials Housing GD-AlSi 10Mg (Aluminiumdruckguss)

Screws A2-70 (Edelstahl)

Viewing glass PMMA

Optical ﬁbre TPE

Cable connection PA

Pivoting angle 10° to 190°

Protection Type IP65 IP67

Mounting position random

Ambient temperatur -10°C to + 50°C

Ambient humidity 10–90 % , non-condensing

Weight Without valve ca. 0,65 kg /

Variant D Mini-valves: ca.1,0 kg

Midi-valves: ca. 1,1 kg ca. 1,2 kg

Variant S Mini-valves: ca.1,2 kg

Mid-valves: ca. 1,4 kg ca. 1,3 kg

Variant E Mini-valves: ca.1,2 kg

Midi-valves: ca. 1,4 kg ca. 1,3 kg

Analog control signal Effective direction reversible by sliding switch

Signal Type selectable 4–20 mA, 0–10 V, 0–20 mA, 2–10 V;

proportional to pivoting angle

Dead-zone ± 2% of nominal pivoting angle

Travel speed Adjustable by throttles on

solenoid valve

Adjustable by throttles

on housing

Position signal Signal type selectable 4–20 mA, 0–10 V, 0–20 mA, 2–10 V nominal,

activ, proportional pivoting angle

System 4,75 kOhm at 0–10 V or 2–10 V;

0 Ohm at 2–20 mA or 0–20 mA

Resolution < 0,5% of nominal pivoting angle

Limit feedback Voltage 21–24 VDC

Output power 0,3 mA at 1 kOhm load

System Opto-coupler, short-circuit-proof

Indication 3% of nominal pivoting angle before initiated end position

Supply 24 VDC

English

Operating Instructions

bar-positurn2 and bar-positrol

Technical data:

Pneumatic Scheme:

Pneumatic scheme for

bar-positurn2 PN2-D

positurn

PN2-E (single-acting) PN2-S (double-acting)

Please note the unit-specific safety descriptions.

Pneumatic schemes for the safety-orientated bar-positurn2

Power consumption Variant D Mini-valves: 1,8 W

Midi-valves: 3,6 W 1,8 W

Variant S Mini-valves: 3,6 W

Midi-valves: 7,2 W 3,6 W

Variant E Mini-valves: 3,6 W

Midi-valves: 7,2 W 3,6 W

Terminal strip Clamping range up to 0,75 mm²

Cable to PCS Ø 7 to 13 mm, 0,5 mm2, random cable length

Binary input signals ON/OFF Valves < 10 V for „0“; > 18 V for „1“

Operating pressure 2,5 to 8 bar

Air quality Filtered air according to DIN ISO 8573-1/Class 4

Conformity:

The products bar-positrol and bar-posi-

turn are complying with the directives

2014/30/EU (EMC) and 2011/65/EU

(RoHS). The directive of conformity will

be send on request.

Operating Instructions

bar-positurn2 and bar-positrol

English

Pneumatic Scheme:

Delivery and Unpacking:

Pneumatic scheme

for bar-positrol PL-D

PL-E (single-acting) PL-S (double-acting)

Please note the unit-specific safety descriptions.

The unit is dispatched from bar GmbH

and transported by selected transport

companies i.e. parcel services. At the

point of arrival on your premises you

should check the following:

• Are the number of packages that arrived

the same as on the bar delivery note?

• Is the packaging free from visible signs

of damage?

• Are the unit(s) and the accessories free

from visible signs of damage?

• Are there any signs of careless hand-

ling during transport (e.g. burn marks,

scratches, paint)?

To be able to present all claims against

the transport companies, you should docu-

ment all possible transport damage (e.g.

with photographs and a written report),

before you unpack the unit. bar GmbH is

not responsible in any way for transport

damage and cannot accept responsibility

or liability in any way whatsoever.

Carefully remove the transport packaging.

Please observe all laws and regulations

for the disposal of packaging materials.

bar-positurn2 / bar-positrol comes sup-

plied with the external or internal soleno-

id valve version D, S or E – depending on

the actuator type and safety concept.

Check the scope of delivery with the de-

livery note and the order documentation.

Controlling the Delivery:

Scope of Delivery:

Pneumatic schemes for the safety-orientated bar-positrol

English

Operating Instructions

bar-positurn2 and bar-positrol

Any differences should be registered im-

mediately to bar GmbH. Later complaints

about incomplete or damaged deliveries

cannot be accepted.

Scope of Delivery:

Mounting:

Mounting positurn

Mounting may only be carried

out by suitably trained skilled

persons. Otherwise there is

the danger of an incorrect in-

stallation.

• Open the bar-positurn2 and set it onto

the actuator.

• Take special care to avoid the entry of

dust, dirt and moisture getting into the

open housing of the bar-positurn2 duri-

ng mounting and commissioning.

• Guide the base of the positioner into the

corresponding groove at the actuator.

WARNING!

This manual suits for next models

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