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

2
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.: [phone]
Fax: [phone]
E-Mail: [e-mail]
www.bar-gmbh.de

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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:
Copyright:
DANGER!
WARNING!
ATTENTION!

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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:

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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:

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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)

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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

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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.

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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

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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!

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Operating Instructions
bar-positurn2 and bar-positrol
English
Installation:
Mounting positrol
Mounting may only be carried
out by suitably trained skilled
persons. Otherwise there is
the danger of an incorrect in-
stallation.
The positrol can be mounted
onto quarter-turn actuators
acc. VDI/VDE 3845 where the
shaft including washer disk is
not bigger than ø 68 mm.
• Remove or mount the attached hexagon
socket screw sealing plug acc. the re-
quired drill template on the bottom of
the casing.
• If positrol should be mounted onto an
actuator type actubar with vacotrol-sur-
face please remove the screw sealing
plugs of the air ducts.
• Remove the protective foil and glue the
seal strip and the seal rings as shown
in the picture. To achieve optimum adhe-
sion please clean and degrease the
contact surface.
• Fix in position the bar-positurn2 and
solenoid valves by making use of the
mounting materials supplied.
• Place the position indicator on top and
take care to see that the symbol posi-
tion coincides with the valve function.
• Take care to ensure the correct direc-
tion when assembling the housing co-
ver. The flexible fibre-optic light guides
must be free from sharp bends and
enter the lead-throughs of the protec-
tive cover.
WARNING!

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Operating Instructions
bar-positurn2 and bar-positrol
• Open the bar-positrol 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-positrol during
mounting and commissioning.
• Fastening the bar-positrol with the provi-
ded mounting material.
• Place the position indicator on top and
take care to see that the symbol positi-
on coincides with the valve function.
• Take care to ensure the correct direction
when assembling the housing cover.
The flexible fibre-optic light guides must
be free from sharp bends and enter the
lead-throughs of the protective cover.
Pneumatic connection:
Air supply solenoid valve type M: G-1/4“
Air supply solenoid valve type S: G-1/8“
Positrol on actuator type actubar:
Air supply positrol G-1/8“
positurn:
Air
supply
Air
supply
Throttle
Throttle
positrol:
drill template 80 x 30
drill template
130 x 30
vacotrol-air ducts

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Operating Instructions
bar-positurn2 and bar-positrol
English
Electric connection / Functional scheme:
Electrical installation may only be carried
out by suitable qualified & skilled persons.
Otherwise there is a real
danger of electric shocks.
WARNING!
positrol on actuator type according to
VDI/VDE 3845: Air supply positrol G-1/8“
Throttle
Air supply
Connect working channels according to
connection designation (2→2; 4→4).

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Operating Instructions
bar-positurn2 and bar-positrol
Elektrischer Anschluss:
3-position-controller
Electric Connections:
M
odel positurn: PN2-3P-D; PN2-3P-E und PN2-3P-S
Digital
Inputs
1
2 Activate magnet B (clockwise Rotation) 24VDC
Go to middle position 24VDC
3
Digital
Outputs
4Counter-clockwise end position reached
5Clockwise end position reached
6Stand by
Middle position reached
7
8
Analogue
Outputs
9 Actual value pivoting angle (+)/( - ) to clamp 14
10 Actual value diff. press. (+) (optional) /( -)
to clamp 14
Activation
Safety valve
11 Magnet C (+)
12 Magnet C ( - )
Power
supply
13 24 VDC
14 GND (for Supply, analog signals and digital input
Activation
Solenoid
valve
15
16 Magnet A ( - )
Magnet A (+)
Magnet B (+)
17
18 Magnet B ( - )
Earthing Earthing point in the housing
Model positrol: PL-3P-D; PL-3P-E und PL-3P-S
Activate magnet A 24VDC (counter-clockwise rotation)
Electric Connections:
model positurn: PN2-D; PN2-E und PN2-S
Digital
Inputs
1 Activate magnet A (counter-clockwise rotation)
2 Activate magnet B (clockwise rotation)
3
Digital
Outputs
4Counter-clockwise end position reached
5Clockwise end position reached
6Stand by
7
Analogue Inputs 8 Set value for pivoting angle (+)/( - ) to clamp 14
Analogue
Outputs
9 Actual value pivoting angle (+)/( - ) to clamp 14
10
Actual value diff. press. (+) (optional) /( - )
to clamp 14
Activation
Safety valve
11 Magnet C (+)
12 Magnet C ( - )
Power
supply
13 24 VDC
14 GND (for Supply, analog signals and
digital inputs)
Activation
Solenoid valve
15
16 Magnet A ( - )
Magnet A (+)
Magnet B (+)
17
18 Magnet B ( - )
Earthing Earthing point in the housing
model positrol: PL-D; PL-E und PL-S
Positioner
Refeeding of clamps
1, 2, 3 and 8 results
accross clamp 14.
Please take care that
there is a potential equalisation
between voltage source for feed-in
and signal source.
Refeeding of clamps
1, 2, 3 and 8 results
accross clamp 14.
Please take care that
there is a potential equalisation
between voltage source for feed-in
and signal source.

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Operating Instructions
bar-positurn2 and bar-positrol
English
Einstellmöglichkeiten:
Do not damage switches!
ATTENTION!
Operating
Potentiometer
Initialising switch
Button for automatic initialisation
Program switch:
analog = Positioner mode
3P = 3-Position mode
LED indication
Current / Voltage switches
1
2
3
4
5
5 5
5
5 5
6
7
Set current / voltage switches according to the signal type for the unit.
Analog signals
4–20 mA
Analog signals
0–20 mA
Analog signals
0–10 V
Analog signals
2–10 V
1
23
5 6
7
4

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Operating Instructions
bar-positurn2 and bar-positrol
Left-rotating actuator in switch position ccw (L)
Input and Output signal ccw increasing
Right-rotating actuator in switch position cw (R)
Input and output signal cw increasing
Individual Settings:
Initialising / Commissioning:
Set operating direction switch according to the direction of actuation for the valve actuator.
Automatic initialisation of Positioner- and 3P-mode (Learning the end-positions and other
specific values). The automatic initialising is recommended. If it is not satisfying, initiate
the positioner manually.
When initialising, the operating direction switch must be set in accordance
with the operating direction of the valve actuator, in order to ascertain the
real function correctly. In real operation, the operating direction switch may
be adjusted when the increase in signal for special cases is to be changed.
1. Check whether the operating direction
switch has been set in accordance with
the operating direction of the actuator
(L/ccw or R/cw).
2. Make the electrical connection accor-
ding to the connection diagram.
3. Select program by the program switch:
Choose between „analog“ or „3P“ (see
also „individual settings”) .
4. Choose type of signal.
5. Set the initialisation
switch to „Init“.
1
1
3
5
6

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Operating Instructions
bar-positurn2 and bar-positrol
English
6. Establish power supply.
7. Press the red button for the automa-
tic initialisation longer than 2 seconds.
Chaser light during the initialisati-
on process
Both end-positions will be reached
two times automatically
8. Initialisation is completed
successfully when all LEDs
illuminate permanently
9. Start up by switching back the
Initialisation switch from „Init“ to
„Run“.
10. Commissioning is completed.
ATTENTION!
6
7
• Please note that all safety functions are immediately available when swit-
ching the initialisation switch from „Init“ to „Run“. This can cause an im-
mediate switching of the actuator!
• In case of every (even accidental) switching to „Init“, the whole initialisation
process must be carried out anew, because the previously learned values
will have been lost.
• After every change of the end position and reassembling the actuator, do not
forget to make a new initialisation.

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Operating Instructions
bar-positurn2 and bar-positrol
Manual initialisation of Positioner mode (learning the positions and other specific values):
1. Check whether the operating direction
switch has been set in accordance with
the operating direction of the actuator
(L/ccw or R/cw).
2. Link electrical connections according to
the connection diagram.
3. Select program by the program switch:
Choose „analog“ (see also „individual
settings”).
4. Choose type of signal.
5. Set the initialisation switch to „Init“.
6. Establish power supply.
chaser light illumiates
7. The actuator has to be driven to each
end position at least two times by ma-
king use of the emergency manual over-
ride of the solenoid valve. Alternatively,
terminals 1 and 2 can be connected
alternately with terminal 13 (24 VDC).
Terminal 1 and 2 have to be supplied
with power for more than 10 seconds
after the end positions are reached.
8. Initialisation is completed successfully
when all LEDs illuminate permanently.
9. Start up by switching back the Initiali-
sation switch from „Init“ to „Run“.
10.Commissioning is completed.
1
3
5
6
6

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bar-positurn2 and bar-positrol
English
ATTENTION!
Manual Initialisation of 3-Position mode (learning end positions and other specific values):
1. Check whether the operating direction
switch has been set in accordance
with the operating direction of the actu-
ator (L/ccw or R/cw).
2. Link electrical connections according to
the connection diagram.
3. Select program by the program switch:
Choose „3P“ (see also „individual set-
tings”).
4. Choose type of signal.
5. Set the initialisation switch to „Init“.
6. Establish power supply.
chaser light illumiates
7. The actuator has to be driven to each
end position at least two times by ma-
king use of the emergency manual over-
ride of the solenoid valve. Alternatively,
terminals 1 and 2 can be connected
alternately with terminal 13 (24 VDC).
Terminal 1 and 2 have to be supplied
with power for more than 10 seconds
after the end positions are reached.
8. Initialisation is success-
fully completed when all
LEDs are illuminating
constantly.
1
3
5
6
• Please note that all safety functions are immediately available when switching
the initialisation switch from „Init“ to „Run“. This can cause an immediate
switching of the actuator!
• In case of every (even accidental) switching to „Init“, the whole initialisation
process must be carried out anew, because the previously learned values will
have been lost.
• After every change of the end position and reassembling the actuator, do not
forget to make a new initialisation.

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Operating Instructions
bar-positurn2 and bar-positrol
Manual Initialisation of 3-Position mode (learning end positions and other specific values):
9. Start up by switching back initialisa-
tion switch from „Init“ to „Run“.
10.Set the middle position by terminal 3 (24
VDC) and adjust via the Potentiometer.
11.Subsequently drive to the desired end
position.
The green status-LED illuminates and
a yellow LED illuminates depending on
the particular end position.
12.Commissioning is finished.
or or
2
6