Bernard Controls AT SWITCH RANGE User guide

AT SWITCH
RANGE
Start Up Guide
SUG_17010_EN - Ind. D
Art : 5100830

3
TABLE OF CONTENTS
1SAFETY ---------------------------------------------------------- 5
2PACKAGING, STORAGE AND MAINTENANCE----------------- 5
2.1 Packaging
2.2 Storage
2.3 Maintenance
3ASSEMBLY ------------------------------------------------------- 6
3.1 For actuators with a cam block spring (class III)
4EMERGENCY MANUAL COMMAND ----------------------------- 7
5ELECTRICAL COMMISSIONING --------------------------------- 8
5.1 Opening/Closing electrical compartment
5.2 Wiring
5.3 Calibration of travel limits
5.4 Calibration of position indicator (OPTION)
5.5 Calibration of position feedback (OPTION)
5.6 Calibration of positioner (OPTION)
5.7 Heating resistance
6TORQUE LIMITING DEVICE------------------------------------20
6.1 Torque limiter operation
6.2 Torque limiter calibration

English
4

English
5
1SAFETY
This device complies with current applicable safety standards.
The installation, maintenance, and use 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
The packaging of AT SWITCH actuators is comprised of a dual-layer
cardboard box strapped on a pallet. For certain non-EU countries or
on request, the pallets are heat treated to standard NIMP 15 and
IPPC stamped.
This packaging is identical for shipping by road, air or sea, unless
otherwise indicated in the contract.
2.2 Storage
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 the cover screws are correctly tightened to ensure
weatherproof sealing of the cover.
AT SWITCH actuators include electrical components and lubricated
gear stages. Even with a weatherproof enclosure, oxidation, galling
and other alterations may occur if actuators are not correctly stored.
What to check after storage
1. Visually check the electrical equipment.
2. Manually operate micro switches, buttons, selectors, etc., to
ensure their proper mechanical function.
3. Manually operate the actuator for a few travels.

The heating resistance should be connected to the power supply,
especially if the storage place is humid.

English
6
What to check on pre-installed actuators
If you expect a long delay between actuator valve mounting and
electrical wiring, visually check that the cable entries and cover are
tightly closed.
2.3 Maintenance
All AT SWITCH actuators feature lifetime lubrication and therefore
require no specific maintenance, under the condition that they were
correctly commissioned and used in the conditions they were
designed for.
3ASSEMBLY
The actuator should be secured directly to the valve using proper
bolts or via a proper interface.
After assembly, the actuator can operate in any position.

However:
•Do not lift or handle the actuator by its handwheel to avoid
shaft and gear damage.
•Cable glands must not be oriented upwards (loss of
watertightness).
•It is recommended not to position the motor downwards.

If the actuator is delivered mounted on the valve, basic calibration
should have been carried out by the valve supplier.
In this case, you do not need to calibrate the travel limits and
torque limiter again.

English
7
3.1 For actuators with a cam block spring (class III)
The spring (1) is located under the cam
block. Both positions and number of
turns have been calibrated in factory
according to customer request.
Before mounting the actuator on the
valve, manually or electrically put the
actuator in the same position as the
valve: either both open on both closed
(i.e., the travel limit for the open or
closed position should be triggered).
Once the actuator is mounted on the valve, the precise calibration
of the opening and closing positions can be done according to § 5.3.
4EMERGENCY MANUAL COMMAND
AT SWITCH actuators feature a handwheel for emergency operation.
To avoid potentially harmful turning protruding parts during
electrical operation, AT SWITCH handwheels feature a foldable
handle: you can fold it during electrical operation and unfold it if
you need to operate the actuator manually.
!
Caution, automatic clutch. Use the emergency manual
command only when electric motor commands are inactive.
Backlash risk.
1

English
8
5ELECTRICAL COMMISSIONING
5.1 Opening/Closing electrical compartment
You need to open the electrical
compartment to wire the actuator.
Position indicator option
If the closing direction is not standard
(clockwise), please configure the
position indicator accordingly
(see § 5.4) if this operation has not
already been performed.
How to open electrical
compartment
1. With a 10 mm angled socket
wrench or a flat blade screwdriver loosen the 4 screws.
2. Remove the cover along the axis of the position indicator
(see § 5.2).
How to close electrical compartment
1. Position the cover with the indicator window opposite the
position indicator.
2. Insert the cover on the position indicator until it reaches the
housing.
3. With a 10 mm angled socket wrench or a flat blade
screwdriver, tighten the 4 screws on the housing.

English
9
5.2 Wiring
Components (with cover open)
9–Cable entry plugs
8–Heating resistance
7–External ground
terminal
6–Internal ground
terminal
5–Terminal blocks
4–Torque limiter
3–Capacitor (only for
single phase actuators)
2–Modular reduction
gear
1- End position cams
The actuator and its components are wired to internal terminal
blocks.
Installing cable glands
AT SWITCH actuators are fitted with M20 cable glands.
How to install cable glands
For each cable entry used
1. Remove the plug from the cable entry with a 23 mm (M20
entry) open-end wrench.
2. Separate the sealing nut from its cable gland.
3. Screw and tighten the cable gland in the cable entry.
4. Thread the sealing nut on the cable and pass the cable
through the cable gland.
5. When the wiring is finished, tighten the sealing nut on the
cable gland.

Unused entries must be kept closed by their plug.
3
1
2
4
5
6
7
8
9

English
10
Wiring
•Internal wiring
To perform the wiring, remove the cover and pass the cables
through the cable glands, then connect the wires on the terminal
blocks.
Please refer to the supplied wiring diagram for terminal numbering.
Both the heating resistance (9) and torque limiter (5) switches must
be integrated into your control system to prevent potential damage
to the actuator or valve.
•Ground terminals wiring
Attach a ground wire fitted with a 6 mm ring terminal to the
internal (7) and external (8) ground terminals.
Checking wiring
You need to check the wiring once it is finished.
How to check the wiring
1. Make sure that the power supply voltage matches the
information on the label located on the side of the actuator.
2. Check that the cable glands are correctly tightened.
3. Manually drive the valve (see § 4) to a mid-travel position.
4. Electrically operate a counterclockwise rotation and check
that the motor rotates in the right direction.
5. Manually press on the counterclockwise travel limit switch,
which should stop the motor.
6. Repeat steps 4 and 5 for the clockwise direction.

If any fault is detected at this stage, please check all wiring.

English
11
5.3 Calibration of travel limits
Cam-block detail
To stop the movement at end positions, the AT SWITCH actuator
features a set of cams integrated as a cam block. Cams trip switches
to switch off the power at end positions, or for signaling.
The cam block is made up of 4 cams.
Each one has a specific function and
trips a specific switch.
Each cam can be calibrated thanks
to a screwdriver imprint on the top
of the cam block. The
correspondence between a cam and
its screwdriver imprint can be
determined thanks to numbers and
colors (see figure opposite).
Rep.
Color
Function
1
White
Counterclockwise (usually OPEN) travel limit
2
Black
Clockwise (usually CLOSED) travel limit
3
Beige
Counterclockwise signaling
4
Gray
Clockwise signaling

Except for specific valve configurations:
•Clockwise direction generally matches closing direction.
•Counterclockwise generally matches opening direction.
3
2
1
4

English
12
How to calibrate the cams
1. Drive the valve to the CLOSED
travel limit position.
2. Insert a flat blade screwdriver
in the imprint corresponding to
the CLOSED travel limit switch
(2) and push slightly
downwards to unlock it.
3. Turn the imprint until you hear
a click from the switch. This
indicates that it has been
tripped by the cam ring.
4. Release the imprint and check that it goes back to its original
position.
5. Drive the output slightly in the counterclockwise direction
using the manual command.
6. Perform steps 2 to 4 for the clockwise signaling switch (4).
7. Drive the actuator to the OPEN travel limit position.
8. Perform steps 2 to 4 for the counterclockwise direction
(cams 1 & 3).
9. Perform complete counterclockwise and clockwise electrical
operations. The motor should stop when the corresponding
cams are reached.

In the case of actuators with a cam block spring (class III), make sure
that the actuator has been prepared according to § 3.1.

Make sure that the cam operates the lever in the right direction;
otherwise the switch could be damaged.

English
13
5.4 Calibration of position indicator (OPTION)
Handling position indication
The position indicator (A) can indicate travels from 90° to 300°.
The angle is indicated by 2 markers held by 2 rotating rings:
•(2a): red marker tagged “C” (for CLOSED).
•(2b): green marker tagged “O” (for OPEN).
The position indicator (1) features a slit on its side to indicate the
current position between CLOSED and OPEN.
It can be turned to be better viewed in operation using the flat blade
screwdriver imprint on the top.
The angle between the 2 markers can vary depending on the
calibration of travel limits.
Opening/Closing position indicator
To open the indicator, unscrew the black ring at the base of the
transparent cap of the indicator (3) and remove it.
To close the indicator, put back the transparent cap (3) on the base
of the indicator and screw the black ring on the base.

You do not have to remove the actuator cover to set the indicator.

Make sure that the actuator cap is correctly reassembled on its
base, otherwise the tightness of the actuator is not guaranteed
anymore.
A

English
14
Calibration of the indicator
To calibrate position indicator
1. Open the indicator.
2. Operate the actuator electrically towards the CLOSED position
until it stops on the end position switch.
3. Set the position of the position indicator if necessary.
4. Set the red “C” marker in front of the indicator slit.
5. Operate the actuator electrically towards the OPEN position
until it stops on the end position switch.
6. Set the green “O” marker in front of the indicator slit.

English
15
Changing closing direction indication if necessary
As a standard, AT SWITCH actuators are configured to close
clockwise. If the actuator must close counterclockwise, you can
modify the opening and closing orientations of the position indicator.
To change closing direction indication
1. Open the indicator.
2. Remove and switch the red marker tagged “C” (CLOSED) with
the green marker tagged “O” (OPEN).
3. Close the indicator.

English
16
5.5 Calibration of position feedback (OPTION)
Position feedback board
Two components can be used
for position feedback:
•a potentiometer (1).
•a “TAM”(2), which gives
position feedback from a
4-20 mA signal.
The potentiometer can be used
alone (Positioner) or can be
combined with the TAM
(Position transmitter).
Position transmitter (OPTION)
The position transmitter delivers a 4 to 20 mA signal that is linearly
proportional to the opening percentage of the valve.
Electrical connections
To connect the TAM, please refer to the supplied wiring diagram.
A filtered or stabilized power supply should be provided within the
12 to 32 VDC range. The maximum admissible resistances for the
wiring are indicated in the following table:
DC supply
(volts)
Max. admissible resistance
(ohms)
12
150
24
750
32
1050
1
2

English
17
Signal direction inversion
If the TAM transmitter is fitted on an
actuator which closes in the
counterclockwise direction, it provides a
signal that increases from the closed
position to the open position.
If an opposite signal variation is required,
simply move 2 jumpers (1) on the board
near the potentiometer:
•direct signal: jumpers on 1-3 and
2-4.
•reversed signal: jumpers on 1-2 and 3-4.
How to calibrate TAM
You must always start by calibrating the 0/4 mA setting.
1. Connect a milliammeter with or without load to read the
output current.
2. Drive the actuator to the position corresponding to 0/4 mA.
As a standard, it is the position at the end of an operation in
the clockwise direction, which is the CLOSED position.
3. While holding the pinion located just under the plate marked
“0% position”, adjust the potentiometer by turning its screw
so that you reach the range where the current is at its
minimal value.
4. Turn the screw backwards to find the range where the
current starts to regularly increase.
5. Turn again the screw backwards and stop as soon as the
minimum value determined at step 3 is reached.
The potentiometer is then positioned at the beginning of its
track.
6. Precisely adjust the 0/4 mA using the TAM screw marked
“0/4mA”.
7. Drive the actuator to the position corresponding to 20 mA.
As a standard, it is the position at the end of an operation in
the counterclockwise direction, which is the OPEN position.
1

English
18
8. Turn the screw marked “20 mA” so that it reads 20 mA on
the milliammeter.
9. Come back to the closed position and check that for the 0%
position, the signal current shows a value close to 0/4 mA
and repeatable.
5.6 Calibration of positioner (OPTION)
The potentiometer used for actuator
signal feedback is driven by the position
indicator rod.
For clockwise closing:
•The 0% position indicates a closed
valve.
•The 100% position indicates an open valve.
The resistance value is measured between terminals 16 and 17.
How to calibrate potentiometer
You can calibrate the zero of the potentiometer with the 0% position
screw. Use a flat blade screwdriver to turn this screw.
1. Drive the actuator to the CLOSED position.
2. Hold the pinion located just under the plate marked with the
0% position while turning the potentiometer screw.
3. Adjust the potentiometer so that the resistance value exceeds
0 Ohm and regularly increases, then turn backwards to reach
the closest value to 0 Ohm.
4. Drive the actuator to the OPEN position and write down the
resistance value corresponding to the 100% position.
5. Come back to the CLOSED position and check that the
resistance shows a repeatable near zero value for the 0%
position.
Signal inversion
To change the signal variation direction, invert the potentiometer
wires on the terminal block (e.g. for a connection on 16/17/18,
invert 16 and 18).

English
19
5.7 Heating resistance
Each actuator includes a heating resistance.
As soon as the actuator is installed in the field, it is required to
supply the resistance to prevent condensation.

•Immediately put the cover back in place after start-up while
ensuring its seal is clean. Never leave the electrical
components of the actuator without their protective cover.
In case of water intrusion:
•Dry the electrical components before putting back the cover.
•Check the electrical insulation.

English
20
6TORQUE LIMITING DEVICE
6.1 Torque limiter operation
The actuator is protected by a torque limiting device in case of over-
torque.
4–Closing direction torque scale
3–Opening direction torque scale
2–Counterclockwise direction cam
1–Clockwise direction cam
The torque limiter is triggered as cams (1) or (2) trigger their
corresponding switches when rotating.
The torque limiter is fitted with 2 scale disks (3) and (4) to adjust
the torque limits for both directions. They have torque graduations
from 40 to 100% of the maximum torque deliverable by the actuator.

The torque limiter provides a maintained contact.

If the actuator stops in a position which is not the one required,
please check that:
•The valve stem is clean and well lubricated.
•The valve stem does not jam in the nut.
•The valve stuffing box is not too tight.