AQ SWITCH

RANGE
Start Up Guide SUG_17003 EN - Ind. D
Art: 5100466
 English

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TABLE OF CONTENTS

1 DOCUMENTS ------------------------------------------------------------- 5
2 INTENDED USE OF THE ACTUATOR ----------------------------------- 6
3 SAFETY-------------------------------------------------------------------- 6
4 PACKAGING, STORAGE AND MAINTENANCE ------------------------- 7
4.1 Packaging 7
4.2 Storage 7
4.3 Maintenance 7
5 HANDWHEEL OPERATION ---------------------------------------------- 8
6 ASSEMBLY ON THE VALVE OR DAMPER ------------------------------ 8
6.1 Changing closing direction visual indication 9
7 ELECTRICAL COMMISSIONING --------------------------------------- 10
7.1 Electrical configurations 10
7.2 Before wiring 11
7.3 Wiring without positioner option 12
7.4 Wiring with positioner option 13
7.5 After wiring 16
7.6 Heating element 16
8 CALIBRATION OF TRAVEL LIMITS ----------------------------------- 17
8.1 Calibration of cams corresponding to end position
switches 17
8.2 Calibration of mechanical stops 18
8.3 Calibration of cams corresponding to signaling
switches (if wired) 19
8.4 Calibration of positioner (OPTION) 19

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9 CALIBRATION OF POSITION OPTIONS ------------------------------ 21

9.1 Position feedback potentiometer (OPTION) 21
9.2 TAM position transmitter (OPTION) 23
9.3 Positioner board setting (OPTION) 25
10 TORQUE LIMITING DEVICE (EXCEPT ON AQ5/10/15) ------------ 27
10.1 Torque limiter operation 27
10.2 Torque limiter adjustment 28

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Thank you for choosing a Bernard Controls electric actuator.

Our actuator has been designed, manufactured and tested rigorously
to give you maximum satisfaction.
Bernard Controls develops a range of products and accessories to
meet your needs for various applications. Visit our website to
discover these innovative products: www.bernardcontrols.com
In accordance with its policy of continuous improvement, Bernard
Controls reserves the right to modify the specifications of all
products described herein without prior notice.
All measures are expressed in metric units. Converted values to other
systems (notably US and UK) are given for reference only.
Pictures are non-contractual ones.
© Bernard Controls 2019.

1 DOCUMENTS
Please keep this manual and all the documents that accompany it
nearby so that you can consult them if necessary.
We decline all responsibility for damages caused by not observing
the instructions of this manual.

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2 INTENDED USE OF THE ACTUATOR

Bernard Controls actuators are manufactured in accordance with the
latest technical evolutions and safety regulations.
The AQ SWITCH and AQ SWITCH POSITIONER are intended to operate
a valve or a damper in moderate environmental and operational
constraints.
All other uses are considered inadequate.
In no case will the manufacturer be held responsible for damages or
harm caused by using the actuator for any purpose other than that
for which it is designed. The user takes responsibility for all risks.
The notion of intended use also includes compliance with the
instructions in this manual and all accompanying documents, as well
as compliance with the installation and maintenance conditions.

3 SAFETY
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.
Warnings and cautions in this manual cannot cover all the risks
associated with the use of the actuator. In addition to the
 instructions given, it is important to exercise good judgment and
apply basic principles of safety.


As a standard, AQ actuators are configured to close clockwise.
If your actuator closes counterclockwise, please see §0.

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4 PACKAGING, STORAGE AND MAINTENANCE

4.1 Packaging
AQ actuators are delivered in a cardboard box of a size equivalent to
the actuator and sit in a cardboard wedge.
4.2 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.

The heating element must be connected to the power supply,

 especially if the storage place is wet (standard 230 VAC, except
otherwise specified).

AQ actuators include electrical components and lubricated gears.

Even with a weatherproof enclosure, oxidation, seizing 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 the micro-switches, buttons, selectors,
etc., to ensure their proper mechanical functioning.
3. Manually operate the actuator.
4.3 Maintenance
This actuator features lifetime lubrication. If the device is correctly
mounted and sealed, no specific maintenance is required.
Test the motor operation once a year and make sure that the
electrical compartment is free from condensation.
This actuator includes an anticondensation heater to avoid
condensation build-up when operating in a wet atmosphere.
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5 HANDWHEEL OPERATION
AQ actuators feature a handwheel for safety operation.
To avoid potentially harmful rotating protruding parts during
electrical operation, AQ handwheels feature a foldable handle: you
can fold it during electrical operation and unfold it if you need to
operate the actuator manually.

6 ASSEMBLY ON THE VALVE OR DAMPER

The actuator should be directly attached to the valve using proper
bolts or via a proper interface.
If the valve is in the closed position, then the actuator should also
be installed in the closed position. If the valve is open, so should be
the actuator.
If you cannot reach the correct position because you are blocked by
 a mechanical stop, loosen the mechanical stop so that you have
enough space to go to the correct position.

After assembly on the valve or on the damper, the actuator can

operate in any position.
However:
• do not lift the actuator by the handwheel to avoid damage on
 •
internal gearing.
cable glands must not be oriented upwards (loss of water
tightness).

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6.1 Changing closing direction visual indication

As a standard, AQ 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 Reverse indicator orientation

for clockwise closing for counterclockwise closing

How to change cap orientation

1. Disassemble the cover then the
cap.
2. Turn the cap 90°.
3. Reassemble the cap then the
cover.

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7 ELECTRICAL COMMISSIONING
7.1 Electrical configurations
During the commissioning, the actuator will correspond to one of the
two following configurations:

8 - Capacitor
7 - Switches board
6 - Torque limiter (except on
AQ5/10/15)
5 - Motor
4 – Heating resistance
3 - Cams
2 - Terminal block
1 - Position indicator

Without Positioner

12 – Capacitor (Except 24 VDC

option)
11 – Handwheel
10 – Heating resistance
9 – Micro-switches
8 - Potentiometer
7 – Mechanical stop
6 - Cams
5 - Plug (cable gland)
4 – Power terminal block
3 - Push buttons
2 – Command and signaling
terminal block
1 - Position indicator

With Positioner

The actuator and its components are wired to internal terminal

blocks.

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7.2 Before wiring

• The electrical connection of the actuator must be carried out
by a qualified professional. All interventions inside the actuator
! •
must be carried out by a qualified professional.
In case of incorrect installation, there is a risk of electric shock
and damage to the device.

Before the electrical commissioning, you need to:

• open the cover
• install cable glands
• wire the actuator
•

How to open the cover

1. With a 10 mm angled socket wrench, unscrew the 4 cover
screws. Do not remove them from the cover.
2. Remove the cover by pulling it out along its axis.

How to install cable glands

• Cable gland size depends on what you ordered (M20 or ¾” NPT
 •
cable entries).
Unused entries must be kept closed by their plug.
For each cable entry used:
1. Remove the plugs.
2. Separate the sealing nut from its cable gland.
3. Thread the sealing nut on the cable and pass the cable
through the cable gland.
4. Screw and tighten the cable gland in the cable entry.

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7.3 Wiring without positioner option

How to wire actuator
The wiring must be done according to the wiring diagram that
matches the characteristics of your actuator.

Both thermal protector and torque limit switches must be

 integrated into your control system to prevent potential damage to
the actuator or valve.

1. Using a 3×0.5 mm flat blade screwdriver, connect the power

supply on the terminals as indicated in the wiring diagram.
2. Crimp a ring cable lug on the ground cable.
3. Remove the screw using a 4 mm hex key.
4. Install a washer between the head of the screw and the ring
cable lug.
5. Tighten the screw.
6. Tighten the sealing nut on the cable gland when you have
completed the wiring.

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7.4 Wiring with positioner option

7.4.1 Power terminal block
The power terminal block is located on a side of the electronic
assembly and consists of a screw-type terminal.
For three-phase supply, the positioner provides automatic phase
correction, thus phase sequency is not important. If one of the
phases is missing, the actuator does not start and sends an alarm
(Fault relay).

3Ph: L1, L2, L3 1Ph: L (Live), N (Neutral)

Direct Current 24VDC

Tighten the sealing nut on the cable gland when you have
completed wiring.

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Control and signaling terminal block

The control and signaling

terminal block (1) is located on
the top of the electronic
assembly.
1. Connect the control and
signaling wires (marked 1
to 13) on the upper
terminals.
2. Tighten the sealing nut on
the cable gland when you
have completed wiring.

7.4.2 Internal ground terminal

The ground terminal is a metal

tab with a threaded hole located
under the terminal board at its
bottom.

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How to wire actuator with Positioner

The wiring must be done according to the wiring diagram of your
actuator.

1. Using a 3×0.5 mm flat blade screwdriver, connect the power

supply on terminals marked L1, L2 & L3 (3Ph) or L, N (1Ph) or
24VDC+, 24VVDC- (DC) according to your supply type.
2. Crimp a ring cable lug on the ground cable.
3. Remove the screw using a 4 mm hex key.
4. Install a washer between the head of the screw and the ring
cable lug.
5. Tighten the screw.
6. Tighten the sealing nut on the cable gland when you have
completed wiring.

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7.5 After wiring

What to check after wiring
Once the wiring of the actuator is completed, please check the
following:
1. Make sure that the power supply voltage matches the
information on the sticker located on the side of the actuator.
2. Check that all connectors or cable glands are correctly
tightened.
3. Manually drive the valve to a mid-travel position.
4. Electrically operate in the closing direction (usually
clockwise) rotation and check that the motor rotates in the
right direction.
5. Using a screwdriver, press the lever on the closed limit switch
and make sure that the motor stops.
6. Repeat steps 4 and 5 for the opening direction (usually
counterclockwise).

 If any fault is detected at this stage, please check that your wiring
is correct.

7.6 Heating element

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

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8 CALIBRATION OF TRAVEL LIMITS

The actuator is factory-set for a 90° travel.
It features 2 devices to limit the travel:
• Cams trigger switches to switch off power at an end position
or to signal a position. They are factory pre-set, but you can
re-adjust them during commissioning if necessary.
• Mechanical stops mechanically limit rotation to protect the
valve in case of over-travel.
8.1 Calibration of cams corresponding to end position
switches
The actuator stops on the open and closed positions when the
corresponding end position switch is tripped.
You must never electrically
 stop the actuator
mechanical stops.
on

1. Turn the setting screw of

the blue cam corresponding
to the clockwise travel limit
switch (1 in Figure 1) with a
screwdriver (see Figure 2).
The cam disk is then turning. Figure 1 Switches
2. Set the cam disk until you
hear a click from the switch.
It indicates that the switch
has been triggered.
Make sure that the cam
operates the lever in the right
 direction (as shown by the
arrow in Figure 2), otherwise
the switch could be damaged.
3. Perform a short electrical Figure 2 Setting a cam
counterclockwise
operation, then go clockwise and stop on the switch.

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4. Check that the valve position is correct. If it is not, return to

step 1.
If you cannot reach the correct closed position because you are
blocked by the mechanical stop, loosen the mechanical stop so that
 you have enough space to go to the correct closed position, then
return to step 1.
5. Turn the setting screw of the gray cam corresponding to the
counterclockwise travel limit switch (2 in Figure 1) with a
screwdriver.
The cam disk is then turning.
6. Set the cam disk until you hear a click from the switch. It
indicates that the switch has been triggered.
Perform complete electrical valve opening and closing operations to
check that everything is correct. If it is not the case, return to step 1.
It is mandatory that the motor stops on the travel limit switch and
not on the mechanical stop (check available extra travel to the stop
with the handwheel).
8.2 Calibration of mechanical stops
1. Loosen the nut
corresponding to the
clockwise mechanical stop
(2 in Figure 3).
2. Turn back the mechanical
stop 1.5 turns.
3. Drive the actuator to the
clockwise travel limit
position.
4. Get the mechanical stop in
contact with the output
sleeve then move it back Figure 3 Mechanical stops
1.5 turns.
5. Tighten the nut to keep the mechanical stop in position.
6. Loosen the nut corresponding to the counterclockwise
mechanical stop (1 in Figure 3).
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7. Perform steps 2 to 5 for the counterclockwise direction.

8.3 Calibration of cams corresponding to signaling
switches (if wired)
1. Slightly drive the output in the clockwise direction using the
manual override.
2. Set the blue cam corresponding to the clockwise signaling
switch (3 in Figure 1).
3. Slightly drive the output in the counterclockwise direction
using the manual override.
4. Set the Gray cam corresponding to the counterclockwise
signaling switch (4 in Figure 1).
8.4 Calibration of positioner (OPTION)
1. With a voltmeter, check
that the voltage at test
points 2-3 of the
potentiometer is equal to
0.6 V.
The voltage must never go
below 0.6 V. If it does, adjust

 the potentiometer by turning

its shaft using a flat blade
screwdriver so that the voltage
reaches 0.6 V.
2. Press the S local setup
command (see Figure 4)
Figure 4 Local commands
for 5 seconds to enter the
stroke calibration mode.
The LED (1) starts blinking.
3. Press the O local open command until the required open
position is reached.
4. Once the opening switch is tripped, press the S local setup
command to validate the position.
5. Press on the C local close command until the device closes
completely.

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6. Once the closing switch is tripped, press the S local setup

command to validate the position.
The device performs an AUTOSET to self-calibrate the
deadband.
The device is now set. The LED stops blinking and stays ON.
If the LED continues to blink after the AUTOSET process, it is
indicating one or several of the following errors:
2 3 4 5
• Blocking/jam
Times blinking (blips)

• Loss of input ming detected

signal (not and/or
• Memory error valid for 0- Other (position
10V) • Incoherence out of range,
and/or between pumping error,
• Potentiometer and/or potentiomet thermal fault,
out of range • Loss of phase er measure etc.)
(for 3Ph power and end-of-
supply) travel
position

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9 CALIBRATION OF POSITION OPTIONS

9.1 Position feedback potentiometer (OPTION)
The potentiometer used for the actuator
position feedback is driven by the travel
cam block system.
For clockwise closing:
• 0% position indicates a closed
valve.
• 100% position indicates an open valve.
The resistance value is measured between terminals 16 and 17.

How to set the potentiometer circuit board

1. Drive the actuator to the CLOSED position.
2. Loosen the positioner pinion blocking screw with a hex key.
3. Adjust the potentiometer by turning its shaft using a flat
blade screwdriver so that the resistance value exceeds 0 Ohm
and regularly increases, then turn backwards to reach the
closest value to 0 Ohm.
4. Tighten back the positioner pinion blocking screw.
5. Drive the actuator to the OPEN position (usually
counterclockwise).
6. Write down the resistance value corresponding to the
100% position.
7. Come back to the CLOSED position (usually clockwise).
8. Check that the resistance shows a repeatable near zero value
for the 0% position.

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Position feedback potentiometer (Left) & TAM position transmitter

(Right)

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).

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9.2 TAM position transmitter (OPTION)

The TAM transmitter delivers a 4 to 20 mA signal that is linearly
proportional to the angular position of the valve.
Electrical connections
A filtered or stabilized power supply should be provided within the
12 to 32 VDC range. Maximum admissible resistance values are given
in the following table:
DC supply Max. admissible
(volts) resistance (ohms)

12 150
24 750
32 1050

Signal direction inversion

The TAM transmitter, when supplied with a clockwise closing
actuator, provides a signal that rises from closed position to open
position.
If an opposite signal variation is required, simply move 2 jumpers 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 set TAM

1. Connect a milli-amp meter on the terminal block and bring
power (24 VDC).
2. Always start by adjusting the 4 mA.
3. Drive the actuator to the position corresponding to 4 mA
(CLOSED position).
4. Loosen the potentiometer pinion blocking screw with a hex
key.

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5. Adjust the potentiometer by turning its shaft with a flat blade

screwdriver so that the output current reaches a minimum
value.
6. Turn backwards until the current value regularly increases,
then turn backwards again and stop as soon as the minimum
value determined above is reached.
7. Tighten back the potentiometer pinion blocking screw.
The potentiometer is then positioned at the very beginning of
its track.
8. Use the TAM adjustment screw marked 0/4 mA to adjust the
current to a value as close to 4 mA as possible.
9. Drive the actuator to the position corresponding to 20 mA
(open position).
10. Turn the screw marked 20 mA so that it reads exactly 20 mA
on the milli-amp meter.
11. Come back to the closed position.
12. Check that, for the 0% position, the signal current shows a
repeatable value that is close to 4 mA.

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9.3 Positioner board setting (OPTION)

9.3.1 Input signal

The valve can be controlled in

2 different ways:
• 0-10V/0-20mA signal
• 4-20 mA signal
Depending on the type of signal
chosen, set the inverter (1) to
the Volt (0-10V signal) or mA (4-
20mA signal) position.

9.3.2 Dip switches position

There are 4 dip switches to set

the following:
• Closing type
(AQ25/30/50 only)
• Fail position and
input signal
• Direction of
rotation

 Set the dip

switches
according to
your
installation.
Closing type

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Switch A Actions
ON Close on torque
OFF Close on position

Fail position and input signal

Switch B Switch C Signal type Fail position

ON ON 0-20 mA / 0-10 V Fail last
ON OFF 4-20 mA Fail open
OFF ON 4-20 mA Fail closed
OFF OFF 4- 20 mA Fail last

Direction of rotation

Switch D Actions
ON Closing counterclockwise (CCW)
OFF Closing clockwise (CW)

You must power off and power on the actuator for the changes to
 take effect.

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10 TORQUE LIMITING DEVICE (EXCEPT ON

AQ5/10/15)
If the actuator stops on a position which is not the one required,
 please check that the actuator did not reach a mechanical stop or
that the valve has no stiff point.

Actuators are set and tested in our factory according to the torque
stated on the order. If no torque is specified, the actuator is supplied
with the limiter set to the maximum output torque (100%).
In both cases, you can adjust the torque limiter if necessary.
10.1 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 when 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 limit 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.

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10.2 Torque limiter adjustment

The torque scale disk is factory-set and is a reference for cams
 setting. Do not modify its position or you will not be able to set
the torque limiter accurately.

 To adjust torque limits, set the tips of the cams to match

the required percentage of maximum torque.

1. For the closing torque

limit, set the tip of cam
(1) on the required
percentage on the CLOSE
scale.
2. For the opening torque
limit, set the tip of cam
(2) on the required
percentage on the OPEN
scale.

On the above figure, the closing torque limit is 100% and the opening
 torque limit is 70%.

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