USER MANUAL'S Electrically Powered Emergency Shutdown System...

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Controlmatik ABW d.o.o., Fajfarjeva 15, 1230 Domzale, Slovenia, Europe

Tel. +386 1 7213552, Fax +386 1 7213552, [email protected]; web: www.controlmatik-abw.si

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U S E R M A N U A L ' S

Electrically Powered Emergency

Shutdown System with battery back-up

series M 3800 C

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These instructions generally describe the installation, operation and maintenance of ControlmatikABW shutdown system. ControlmatikABW d.o.o reserves the right to make any changes that may not be described herein. For any questions please refer to Controlmatik ABW d.o.o or your local representative.

TABLE OF CONTENTS

TABLE OF CONTENTS ..............................................................................................................2

• GENERAL INFORMATION ...................................................................................................4

• GENERAL DESCRIPTION ...................................................................................................5

• WARRANTY .........................................................................................................................5

• STANDARD EQUIPMENT ....................................................................................................6

• SPECIFICATIONS ................................................................................................................7

• DIMENSIONS .......................................................................................................................7

• OPERATION.........................................................................................................................9

• INSTALATION ....................................................................................................................10 1. Mounting the M 3800 EPESS-CP control panel on the wall:.......................................................10 2. Mounting the M 3800 EPESS-EA wall bracket: ............................................................................10 3. Flexible cable for electrical actuator ............................................................................................11

• GUIDE FOR MOUNTING SHUTDOWN SYSTEM ON CYLINDER ......................................12 1. Connecting the system and checks .........................................................................................12 2. Mounting the SHUTDOWN to a Cylinder valve ........................................................................13

• START UP THE SYSTEM ..................................................................................................15

MACHINE DRAWINGS, SCHEMES AND DRAWINGS OF CONTROL CIRCUITS ....................16

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• GENERAL INFORMATION Manufacturer Controlmatik ABW d.o.o. Address Fajfarjeva 15, 1230 Domzale, Slovenia Product Shutdown system Type M 3800 C Year of production 2013 Type of document User manuals

M 3800 C table on Control panel M 3800 EPESS table on actuator

M 3800 EPESS warning label on actuator

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• GENERAL DESCRIPTION Controlmatik ABW “Electrically Powered Emergency Shutdown System - M 3800 EPESS” is used for protection of personnel and property. Controlmatik ABW “M 3800 EPESS” works, in conjunction with chlorine gas detection equipment providing automatic closure of Chlorine cylinder or container valves in case of Chlorine gas leak. The Chlorine gas detector provides information about the leak and gives a signal to the “Electrically Powered Emergency Shutdown System” control panel. The control panel triggers the electrical actuators, mounted directly on the valve of the cylinder or container, which in turn, closes the valve in less than 4 seconds. The system can also be manually operated via an emergency button mounted outside the gas room. When all the valves are closed, the operator can safely enter the gas room. To reset the system the operator can manually open all the valves and set the “control panel in ready mode”. The system is very simple to install. Controlmatik ABW “M 3800 EPESS” can be used for multiple units (cylinder or container valves). As the system uses electrical power to operate it is battery backed-up, in case of power failure.

• WARRANTY ControlmatikABW M 3800 EPESS system has a warranty for period of 12 months since installation or 18 months since purchasing. Any failure item shall be replaced free of charge during the warranty period. Any damages due to negligence or other outside and environmental forces are excluded.

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• STANDARD EQUIPMENT

1. M 3800 EPESS-EA Electrical actuator with length of 10m flexible cable for connection between the system controller and actuator.

2. M 3800 EPESS-CP.Control panel with battery back up, controller and power supply Designed to controol up to six

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• SPECIFICATIONS • Temperature range: from - 10 to + 50 °C • Control panel supply voltage: 230V, 50/60Hz • Fuse : • Consumption : • Display : LCD 4 lines,12 characters • Relay output : 230 V 3A ind. burden; 8A ohm • Torque of actuator : Adjustable from to • Battery: • Actuator voltage supply: Adjustable from to • Actuator currnet supply: Adjustable from to

• DIMENSIONS

A – closed 106 mm max. / open 173 mm max. B – min. 290 mm / max. 318 mm

3.Emergency shutoff switch (OPTION) and enclosure. Recommended to be mounted inside and ouside of chlorination room.

3.Wall bracket for placement of actuator when maintanance, cylinder changes and tests. Wall brackets

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A – 90 mm B – 308 mm

A – 90 mm B – 324 mm

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• OPERATION M 3800 EPESS shutdown system is designed to close cylinder or container valves when any leakage is appeared. System is designed only for closing and NOT for opening the valves. The valve must be opened manually with chlorine wrench and checked for leaks prior to installing the electric actuator. After actuator is installed it is necessary to check the closing torque. During an emergency, the actuator will close the valves either triggered by manual command via emergency shutoff switch or automatically via gas leak detector or other automatic trigger. The M 3800 EPESS-CP control panel is designed to be mounted in corrosive environments therefore its housing is IP 65. The M 3800 EPESS-EA electric actuator is made of materials resistant to corrosive environment. Housing is made of PVC plastic, and sealed with Viton “O” rings. Clutch is made of special chemical and mechanical resistant plastic. The turning wheel is made of galvanized brass. Power for the terminator is provided from control panel with build in specially designed power module with adjustable voltage and current supply. Voltage and current supply are adjustable for purpose of torque adjustment. Each valve has different torque therefore we don’t want to close valves with excessive torque and even worse we don’t wont valves not to shutdown in case of any emergency.

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• INSTALATION Installation of the system has to be done by ControlmatikABW personal or personal with training certificate from ControlmatikABW d.o.o. Before starting the installation it is necessary to measure the length between control panel and electrical actuator. Standard cable length is 10m if longer cable is necessary please contact ControlmatikABW factory for possible solution. At any case do NOT change the cable by yourself. You may cause serious threat to personal and property.

1. Mounting the M 3800 EPESS-CP control panel on the wall: Control panel cabinet is equipped with tapped screw holes and mounting tabs for user friendly installation and to prevent any possible damage to panel housing. Mounting tabs are included in the panel. Insert the mounting tabs to the control panel cabinet and fasten them to the wall using proper tool. Make sure that the front of panel is easily observed by personal operating on the cylinder. Make sure that SYSTEM RESET button on the panel is easily reachable for operating personal. The Control panel must have at least 20cm of free space underneath therefore cables are easy to connection to control panel terminals. Control panel installation should be performed by an electrician in accordance with applicable electrical codes.

2. Mounting the M 3800 EPESS-EA wall bracket: Wall bracket is provided for temporary placement of the actuator when is not mounted on the cylinder.Install the wall bracket as close as possible to the cylinder but still be enough space for a smooth assembly and disassembly.

M 3800 EPESS-CP Contro Panel

M 3800 EPESS-CP Mounting tabs

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3. Flexible cable for electrical actuator

Flexible cable is pre-wired to the actuator drive motor. Length of the cable is 10m and cannot be replaced with any other cable. For special cable lengths it is necessary to consult with factory. Longer cables also means higher voltage drop therefore we cannot guarantee enough power (torque) at motor drive. The cable is 4 wire and to assure lowest voltage drop we combine 2 wires in 1. Make sure that you connect black/brown wire to + and yellow/grey wire to -.

CAUTION! VERIFY THAT POWER IS TURNED OFF BEFORE CONNECTING THE POWER CABLE FROM ACTUATOR TO CONTROL PANEL.

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• GUIDE FOR MOUNTING SHUTDOWN SYSTEM ON CYLINDER

1. Connecting the system and checks

Before proceeding with system checks make sure that all the cables are connected as indicated on electrical scheme (IZG00101) and make visual inspection of all items. With actuator dismounted make sure that hand wheel or square adapter is turning for at least 1/8 clock wise and counter clock wise. This turning space gives you smooth mounting on the handle type valves or square type valves without any need to rotate the valve.

The electrical system may be checked for proper polarity and status indication by test running the actuator motor with the actuator dismounted. Initiate the test with the emergency STOP button on control panel and observe that the actuator shaft is turning clock wise viewed from the top. Actuator motor should turn for about 3 seconds (factory settings) and then shut off automatically.

Square type valve (EPESS-EA/2):

Handle type valve (EPESS-EA/1):

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2. Mounting the SHUTDOWN to a Cylinder valve

1. Make sure all chlorine piping and installation are done by The Chlorine Manual or local procedures. Actuator can be mounted to new chlorine installation or on system in operation. System is designed so that it does not affect the joints where is the risk of chlorine leakage.

2. Make sure that cylinder valves are opened before mounting the Actuator EPESS. Actuator EPESS is designed for closing the valves ONLY! DO NOT USE ACTUATOR FOR OPENING THE VALVE IT MAY RESULT IN SERIOUS EQUIPMENT DAMAGE. Make sure that ECCENTRIC QUICK CLAMP is UNTIGHT before monted to the valve.

3. First put the adapter (handle wheel or square type) to the valve and make sure that adaptor slides down to the valve. If you have trouble with sliding down adapter to the valve then turn the adapter clockwise or counter clockwise until it fits perfectly. Then make sure that eccentric quick clamp in correct position as shown on picture 2.

Picture 1

Picture 2

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CAUTION! MOUNT THE ADAPTER ON VALVE AND MOTOR DRIVE ASSEMBLY IN ORDER TO BE LINED UP WITH CYLINDER VALVE.

RIGHT:

WRONG:

4. When the handle or square adapter fits to the valve and the eccentric quick clamp is in correct position then tighten the eccentric clamp. Motor drive assembly is still movable in order to follow the closing valve. Picture 3

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• START UP THE SYSTEM

1. When all the actuators are connected to the control panel and have been tested for correct turning direction and are correctly mounted to the cylinder valve then we can start the testing.

2. Open the control panel and adjust the DC POWER SUPPLY to 12V and 12A. The factory setting are done at 12 V 12A. Each customer has to adjust the voltage and current to suit the operating cylinder valve.

3. In order to find out what is the proper torque for you valves you can measure the torque of your valve and chose the proper set up from the torque table in the end of the manuals or you practically test the closing torque by increasing the voltage on the DC POWER SUPPLY module.

4. Adjustable torque is intended to protect valves which can be closed with low torques 5-10Nm. If the valve with closing torque of 5Nm is closed with 25Nm, damage to the valve may be caused.

5. TESTING THE TORQUE: START the CLOSING with EMERGENCY STOP button on control panel with 12V and 12A. IF the valves did NOT close then increase the voltage to 14 V and leave current at 12A.

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Repeat this step until all the valves are closed.

6.1 ISOLATE THE SYSTEM While doing maintenance on system or replacing the chlorine cylinder you can isolate the system by putting switch to 0 – ISOLATE 6.2 TRIGER THE SYSTEM All actuators cane be manually triggered by putting the switch to 2 – MANUAL mode. Make sure that after triggering switch is returned to 1 – AUTOMATIC mode in order to assure automatic operation in case of chlorine leakage.

NOTE! Each time when the EMERGENCY STOP button is pressed which means that shutdown procedure was started it is necessary to press the RESET button in order to confirm the closing procedure and to release the next closing.

MACHINE DRAWINGS, SCHEMES AND DRAWINGS OF CONTROL CIRCUITS System scheme:

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Electrical scheme for up to 6 actuators:

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Electrical scheme for up to 10 actuators:

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Single Output Laboratory Grade Switching DC Power Supply

Congratulations on your purchase of the ControlmatikABW 382275 (110V) or 382276 (220V) Single Output Laboratory Grade DC Power Supply. The dual action (coarse/fine tune) rotary encoder allows for quick and precise voltage and current level adjustments. Setting, changing, and checking the current limit level can be performed easily without sparking the output poles. The remote control feature allows the user to remotely perform the following tasks:

Output power ON/OFF Voltage and Current Level Adjustments

The three user-presets facilitate quick access to frequently used voltage and current settings. This power supply is shipped fully tested and calibrated and, with proper use, will provide years of reliable service.

Safety WARNING

Do not use this power supply near water. Do not operate or touch this power supply with wet hands. Do not open the casing of the power supply when it is connected to AC power. Refer all servicing to qualified service personnel only. Before replacing the fuse, identify and fix any problems. Replace the fuse with a fuse of the specified type and rating.

CAUTION

Use a grounded 3 pin AC source. This unit is intended for indoor use only. Do not operate or place this unit in direct sunlight or in a humid location Avoid environments where dust or dirt can enter the power supply casing.

Do not place the power supply near a heat source. Before plugging into local AC mains, check the rating label at the back of the unit for 110V or 220V operation. The model 382275 can be powered by 110V only. The model 382276 can be powered by 220V only.

Do not block the ventilation openings of the unit. This unit must be used within the specified rating; excessive continuous loading may cause damage to the power supply.

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The gauge size of the input power cable must be at least 3 “(0.75mm) and the total length of power cable must not exceed 118” (3m)

1 Power Switch ON/OFF 2 Voltage Display 3 Current Display 4 Constant Voltage Indicator LED 5 Rear Control Indicator LED (Switches ON when in Preset, Remote Control or Set Mode) 6 Output Voltage Control Knob (Controls both the main and auxiliary output voltage) 7 Output Current Control Knob (Controls both the main and auxiliary output current) 8 Positive Auxiliary Output Terminal (Max. 5 Amps) 9 Negative Auxiliary Output Terminal (Max. 5 Amps) 10 Constant Current Indicator LED

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1 Main Output (20 Amps Max.) 2 P1, P2 and P3 Recall Switch 3 Cooling Fan for Ventilation 4 AC input Plug and Fuse 5 Remote Control Connector 6 Mode Switch

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Mode Selection

The power supply has four (4) modes of operation: NORMAL, PRESET, SET and REMOTE CONTROL mode. Slide the Mode Selection Switch to the desired Mode. The power supply defaults to the NORMAL Mode.

Normal Mode Normal Mode is the factory preset mode. The power supply’s output voltage and current are controlled by the dual action volume knobs. Push the knobs to toggle the coarse and fine tuning; notice the subtle changes in brightness of the related LED. Adjust the knob to the desired value first with the Coarse adjustment and then with the Fine tune adjustment. Turn the Current knob gently in any direction to check the preset current level. The display will resume its normal brightness after a few seconds to confirm the adjustment.

Preset Mode In the PRESET mode, the Rear Control Light is switched ON to indicate that the panel voltage and current controls are de-activated. There are three preset outputs, P1, P2 and P3, selectable via the Recall Switch, located on the rear of the power supply. The preset values are factory set per the following table.

Presets Output Voltage Output Current P1 5V Maximum P2 13.8V Maximum P3 25V Maximum

Set Mode

In the SET mode, the Voltage and the Current values for the three presets (P1, P2, and P3) can be programmed.

1 Set the Mode Switch located on the rear of the power supply to the “SET” position. 2 Select a preset using the Recall Switch (set to the P1, P2 or P3 position). 3 Use the front panel Voltage Control Knob to set the desired voltage value. 4 Use the front panel Current Control Knob to set the desired current value. 5 Repeat this procedure for the remaining presets if desired. 6 Move the Recall Switch from the SET to the PRESET position to store changes.

Note: Presets reside in non-volatile memory meaning that the voltage and current settings for each preset are retained even when the power supply is switched OFF.

Caution: Check the output voltage of the preset in use before connecting to the Load. To check a preset value, move the Mode Switch to the PRESET position and then move the Recall Switch to the P1, P2 or P3 position. The Voltage and Current settings for the corresponding preset will display.

5 382275/6 V4.1 11/10 • First, check the rating label of the power supply and make sure it complies with the AC mains voltage (110V or 220V). Next, set the Mode Switch located on the rear of the power supply to the Normal Position. • Listen for the cooling fan when switching on the power supply. The power supply performs a series of self test checks on startup which includes testing the cooling fan. The fan will stop completely after a few seconds after running at high speed indicating that it is in good order. The CV, V and A lights switch

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ON displaying voltage and 0.0 current. To check the current level, turn the control knob one click in either direction. The current display returns to 0.0 after a few seconds.

The Table below illustrates the Self-Test sequence:

Self test display and Sequence Test Description

Software version

Display check

C.V. Indicator check

C.C. Indicator check

Rear indicator check

C.V. recheck

Test continuing

Over voltage protection check

Over load protection check

Over temperature protection check

Fan check

Output off (remote control mode)

Using the Control Knobs The rotary control knobs offer fine/coarse tuning with notched movement. 1 Push the knobs to toggle between coarse and fine tuning, notice the subtlechanges in brightness of the related LED. 2 Adjust the knobs to the desired values by using coarse and then fine tuning. The display will resume its normal brightness after a few seconds to confirm the adjustment. Connecting to UUT (Unit under test) 1 Connect the equipment to the power supply. Red (+) is connected to the positive polarity input of the UUT and Black (-) is connected to the negative polarity input of the UUT. 2 Switch ON the power supply first; the panel meter & green CV Indicator should switch ON. 3 Switch ON the UUT; the panel meter & green CV Indicator should remain on. 4 The UUT is now ready. When operation is completed, switch off the UUT and then the power supply. 5 When disconnecting the power supply from the UUT, disconnect the remotesensing wire first and then disconnect the output cables.

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Remote Control

Remote control is made possible through the use of the supplied 8-pin Remote Control connector and 22AWG wire. The Remote Control feature offers remote adjustment of voltage and current and output ON/OFF switching.

Remote ON-OFF Control The Remote Control ON-OFF function can be activated in any of the operational modes (NORMAL, PRESET, REMOTE, and SET). Using the supplied 8-pin plug and 22AWG wire, follow the procedures below:

1 Remove the black portion of the remote control connector plug by removing the screw as shown. 2 If PIN 5 is open, the output is ON. 3 If PIN 5 is shorted to ground (PIN 4) the output is OFF. 4 When the output is OFF, the C.V. & C.C. LED will flash. The current output voltage and current setting will show on the panel meter. 5 The output voltage & current control knob can be used to adjust to the desired value when the output is off.

8 382275/6 V4.1 11/10 Remote Voltage/Current Control

There are two methods (Method A and Method B; see below) for the remote adjustment of voltage and current. Each method requires that the Current remote control portion be functional otherwise the unit will be in the CC mode all of the time.

Remote Control Method A: Using two external variable DC voltage sources A variable external voltage source of 0 ~ 5VDC is fed into the remote control terminal to adjust the output voltage level. Warning! Do not input voltage higher than 5V, otherwise the Over Voltage Protection (OVP) will be triggered.

1 Ensure that the load is disconnected and that the power supply is OFF. 2 Use ONLY the wires from Port 2 (Positive) and Port 4 (Negative) 3 Switch on the power supply. 4 Vary the external input voltage 0~5V to check and verify the full outputvoltage range of the supply. 5 Short the main output with 10AWG wire to check the CC display byvarying the external voltage source. 6 Switch OFF the power supply.

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Remote Socket PIN assignment for external variable voltage source

PIN FUNCTION NOTES

1 Internal +5VDC 50mA maximum

2 Voltage Adjustment 0 to 5V 3 Current Adjustment 0 to 5V 4 Ground 5 Output OFF Short to ground 6 Unused 7 Unused 8 Unused

1 Ensure that the load is disconnected and that the power supply is OFF. 2 Prepare two 5k ohm variable resistors as shown in the diagram below and use the wires from Port 1, 2 and 4 as shown. 3 Switch the power supply ON. 4 Adjust the Pin 2 5k ohm variable resistor from one end to other end to check and verify the full output voltage range of the power supply. 5 Short the main output with 10AWG wire and check the CC display byadjusting the Pin 3 5k ohm variable resistor. 6 Switch OFF the power supply.

Remote Socket PIN assignment for external variable resistors

PIN FUNCTION NOTES 1 Internal +5VDC

2 Voltage Adjustment Variable part of resistor

3 Current Adjustment Variable part of resistor

4 Ground 5 Output OFF Short to ground 6 Unused 7 Unused 8 Unused

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Overload Protection

This unit has a built-in over-voltage protection feature. In the event of an output voltage exceeding the allowable range (refer to the specifications section for range limits), protection will be triggered and the output power will be switched off. (OUP warning appears). To reset the warning, switch off the power supply and remove all loading. Switch the unit to resume normal operation. If this problem persists, please contact ControlmatikABW Technical Support.

OTP: Over Temperature Protection

The unit houses a thermo-sensor that monitor to determine if an over-heating condition exists. The OTP warning will appear on the display and the output will switch off in over-heating condition does exist. When this warning appears, switch off the unit and remove all loading. In these cases, check the load and the output settings and then allow the unit to cool for at least 30 minutes. Ensure that the ventilation openings are not blocked and that the power supply has proper clearance. Ensure that the cooling fan is operational; never use the power supply with a faulty cooling fan.

OLP: Over Load Protection

Normally the overload protection is provided by the CC constant current mode. However, if the CC mode fails it may cause serious damage to the test piece or to the load. OLP is used to minimize the extent of the damage to the load. Switch off the power supply as soon as this warning appears. To reset this warning, switch off the unit and remove all loading and then switch the unit on again. If this problem persists, please contact ControlmatikABW Technical Support.

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Rear Output Variable Output Voltage 1 to 30VDC

Variable Output Current 1 to 20A Voltage Regulation

Load (10 to 100% Load) 50mV Line (170 to 264VAC 20mV

Current Regulation

Load (90 to 10% Rated Voltage) 100mA

Line (170 to 264VAC Variation) 50mA

Ripple & Noise (peak-peak) Voltage 50mV

Current Ripple & Noise (rms) 30mA

Front Output Variable Output Voltage 1 to 30VDC

Variable Output Current 1 to 5A Voltage Regulation

Load (10 to 100% Load) 350mV Line (170 to 264VAC 20mV

Current Regulation

Load (90 to 10% Rated Voltage) 100mA

Line (170 to 264VAC Variation) 50mA

Ripple & Noise (peak-peak) Voltage 50mV

Current Ripple & Noise (rms) 30mA

Meter Accuracy Voltage Meter ±(0.2% +3

digits) Current Meter ±(0.2% +3

digits) Tracking Over 1 to 5V Default Value is

+2V

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Voltage Protection 5 to 20V Default Value

is+3V

20 to 30V Default Value is +4V

Input Voltage 100 to 120VAC 50/60Hz (Model

382275) 210 to 230VAC 50/60Hz (Model

382276) Rated Load Input Current

3.1A Model 382276)

5.9A (Model 382275) Efficiency 87% at optimal load Switching Frequency 75 to 95 KHz Cooling Method Thermostatic Control Fan from Zero

to full speed Protections Overload, Short Circuit by Constant

Current, Output Tracking Over Voltage, Over Temperature Transient Response Time

1.5ms (50-100% of load)

Power Factor Control >0.95 at optimal load Special Features Three (3) user defined presets and

Remote Control Operating Humidity Range

10 to 80%RH

Altitude 7000 Feet (2000 meters) Pollution Degree 2 Main Supply Voltage Fluctuation

±10% of the nominal voltage

Dimensions (WxHxD) 7.9 x 3.5 x 8.5“(200 x 90 x 215 mm) Weight 5.7 lbs (2.6 kg) Approvals CE EMC: EN 55011, 55022 LVD:

EN 60950, 61010

Maintenance and Repair Services Cleaning the meter housing

Prior to cleaning the meter housing, disconnect the mains plug from the power outlet. Clean only with a damp, soft cloth and a commercially available mild household cleaner. Ensure that no water gets inside the equipment to prevent possible shorts and damage to the equipment.

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