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INSTRUCTION MANUAL INSTALLATION, OPERATION, AND MAINTENANCE
B-3801 (Series) ELECTRIC REMOTE VALVE ACTUATOR SYSTEM
MIDLAND MANUFACTURING CORP. 7733 Gross Point Road Skokie,
Illinois 60077 Phone (847) 677-0333 FAX (847) 677-0138 Website
www.midlandmfg.net I:\GAGEDEPT\Documents\PRODUCTS\B-38\B-3801S01-2
IOM.doc Rev. October 5, 2009
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TABLE OF CONTENTS
PAGE
I. General Description
..........................................................................................3
II.
Installation.........................................................................................................4
Power Requirement
..........................................................................................4
Controller
Mounting...........................................................................................5
Actuator Connection
.........................................................................................6
Tool
Balancer....................................................................................................9
III. Operating
Instructions.....................................................................................10
Controller Start Up
..........................................................................................11
Shutdown and
Recovery.................................................................................11
Valve Operation in Normal
Mode....................................................................14
IV. Maintenance and Trouble Shooting
................................................................17
Uninterrupted Power Supply
...........................................................................17
Proximity Switch Sensor Adjustment
..............................................................18
Controller Fault Messages
..............................................................................19
Controller Enclosure Vent
..............................................................................20
Actuator
..........................................................................................................21
Tool
Balancer..................................................................................................21
V. Warranty
Policy...............................................................................................22
Appendix
..............................................................................................................23
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(Typical system components shown)
I. GENERAL DESCRIPTION
The B-3801 is an Electric Remote Valve Actuator System. It is
composed of a Controller and have one, or two , or three Actuators
(depending on your requirement) that operate top loading valves.
The Controller houses the major components such as Programmable
Logic Controller, Servo Drives, Heater, and Uninterruptible Power
Supply. Each Actuator has a servo motor and is contained in a
durable stainless enclosure. The Proximity Switch and a
specially-designed coupler on the Actuator determines the type of
valve (Midland or ACF 1 inch angle valve) it operates and relays
the info to PLC to provide the right closing torque and number of
turns to open the valve. The front of the Controller has control
buttons such as Emergency Close, Close Valve, Open Valve, Reset,
and Start buttons. The Feedback lights are Power On, Shutdown,
Fault, Ready, ACF, Midland, 100% Open, Partially Open, and
Closed.
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The B-3801 is programmed to:
Automatically shutdown 5 minutes after power failure. Manual
emergency shutdown can be executed within 5 minutes after power
failure.
To close the valves either by reaching the necessary torque
first or attempt to close for 10 seconds in normal mode and 20
seconds in emergency shutdown mode.
To minimize UPS battery usage by allowing only 20 seconds of
actuator rotation when not in use during power failure.
If you require a 2-actuator system, you should have model
B-3801XXX-2. The -2 represents the number of actuators . The XXX
are the Midland designated numbers in the series. If you have model
B-3801XXX-2, it should be a have two position Controller (operates
two loading stations). It has two sets of Ready, Midland, ACF, 100
% Open, Partially Open, and Closed feedback lights with Start, Open
Valve, and Close Valve pushbuttons. The Power On, Shutdown, and
Fault feedback lights with Reset, and Emergency Stop pushbuttons
are primary feedback lights and pushbuttons regardless of the
number of loading stations. Other special feedback lights and
control pushbuttons may be added in some cases and are considered
add-ons.
II. INSTALLATION
Power Requirement
o The Electric Remote Valve Actuator System must be supplied
with 230 VAC / 1PH / 50-60Hz power supply and must be wired thru
the enclosure and connected to the fused disconnect switch (with 60
amps fuse included) and ground bus (see electrical diagram
3801XXX-2 E01). If 120 VAC / 1PH / 50-60Hz power supply is
required, this must be requested before the controller is
built.
o Input line filtering to be supplied externally by customer. o
Wiring must be performed by certified electrician. o The photo
below is an example of power supply thru the enclosure. The
customer is responsible for determining the location and making
this hole.
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Controller Mounting o The Controller enclosure panel external
dimensions are 36 long x 30 wide x
16 deep (open, and plus 0.8 including closed door). o The 4
(four) - .5 [13mm] mounting holes are 34.5 high x 28.5 wide on
centers on the enclosure. o The mounting brackets are
preinstalled to the enclosure mounting holes and
therefore the controller can be mounted without opening the
controller. o The controller must be fastened using the mounting
bracket holes. The hole
on each bracket is .41 [12.7mm] and the center to center
distance of the holes is 37.5 high x 28.5 wide. See bolted mounting
bracket below.
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Actuator Connection (If Controller has pre-connected cables skip
this)
Open the door (also disables the main power supply) by turning
the red knob to OFF and turn the yellow lock clockwise to disengage
the knob from the switch stem.
Open the main door. There are two captive screws on the internal
swing door.
Turn the screws counter-clockwise to unscrew and open door. The
proximity switch, feedback, and power cables will pass thru the
weather tight
cable fittings (see below). Cable fittings are located under the
enclosure. The proximity switch cables have their own separate
weather tight cable fittings.
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Connect the power cable (see below).
Connect the feedback cable (see below).
Connect the proximity switch cable (see below).
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All field wiring cables shown inside the controller (see photo
below).
See Midland wiring diagram drawing 3801XXX-2 E04 for reference.
After making all the connection inside the controller, connect the
external
connectors to the actuators (see typical external connectors
below to 1 actuator). If the controller comes with pre-connected
cables for the actuator, power, and feedback cables, the
connections to be done in the field are the external connectors (3
connectors per actuator in the photo below) only. See Quick
Start-Up Guide.
See Controller Start-Up if you are ready to power up. Close the
doors by following the first two steps of Actuator Connection
in
reverse order.
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Tool Balancer
The tool balancer is designed to be hung above work area from a
stationary support such as an eyebolt or a movable trolley. It is
important that your tool balancer is supporting your actuator such
that it can be lowered directly on top of the valve to operate.
Hanging from a trolley with safety cable or chain affixed to a
second trolley is recommended (see C above). The trolley moving
along the direction of tank car is recommended for flexibility to
compensate for the position of the operating valve below it. Check
to make sure the hook or trolley from which the balancer will hang
will support six times the combined weight of the balancer and the
actuator. Make sure the tool balancer is adjusted to carry the
weight of the actuator. Hang balancer using hook at top of
balancer. Make sure safety latch on hook is
in place to prevent unhooking. Attached safety chain or cable
from eye at top of balancer to a separate trolley or
to a separate support (if statically mounted). Attach actuator
to balancer cable by lifting actuator to hook. This you will need
a
platform close to the tool balancer so lifting height is at
minimum to be able to attach the balancer hook to actuator lifting
eye. Follow safe lifting procedure. Do not attempt to pull hook
down to tool.
Adjusting tension
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Tension is adjusted by turning the hex drive on the housing at
the rear of the balancer. To increase tension, turn the hex drive
in a clockwise direction (+). To decrease tension, turn hex drive
counter-clockwise (-). If balancer will not hold actuator in raised
position, increase tension by turning
hex drive clockwise. If actuator is difficult to pull down,
increase tension by turning hex drive counter-
clockwise.
Avoid adjusting tension above or below rated capacity of
balancer. Tightening spring over its rated capacity will shorten
cable stroke and decrease spring life. If spring is loosened to
lower than minimum capacity, the safety device may engage
preventing operation.
III. OPERATING INSTRUCTIONS
Picture shows 2-Actuator System
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Controller Start-Up
The Controller unit is shipped with turned-off UPS
(Uninterrupted Power Supply battery) and must be turned on. Turning
on the main power supply only does not charge the UPS. The UPS may
need at least 24 hours charging from depleted to fully-charged and
must be kept charged all the time by the main power supply. The UPS
is fully charged before shipping. To turn on the UPS, follow the
steps. o Switch On main power supply. o Open the controller
enclosure main door by turning the main locks counter-
clockwise (quarter turn) to unlock. The locks are located on the
right side, top and bottom of the door
o Turn the power safety switch to OFF to open the main door.
This is the safety feature that disables the main power to
controller every time the door is opened.
o Open the internal door to access UPS. Turn 2 captive thumb
screws (upper and lower left) counter-clockwise to open internal
swing door to expose UPS power switches.
o Turn on the UPS by pushing and holding the button (with a line
inside the circle) until you hear a beep (after about 3 seconds
pushing the button). Note: To turn Off the UPS, press the button
(with a line cutting the circle) twice within 4 seconds. The UPS
will keep beeping indicating that it is on battery power (until the
power safety switch knob on the main door is switched to ON after
the door is closed).
o Close the enclosure swing doors in the reverse order of the
steps above. o Turn the power safety Switch to ON. This will stop
the UPS from beeping
and turns off the Battery Power indicator light. Shutdown and
Recovery
Emergency shutdown is executed by simply pushing the Emergency
button or
by means of automatic shutdown relayed by gas leak detector or
tank car motion sensor. The failsafe mode is To Close the Valves in
the event of emergency.
o Emergency shutdown occurs when : Emergency Stop button is
manually activated. The gas leak detector (not supplied by Midland;
may be
connected to controller relay) detects leaks and activate
shutdown.
The tank car motion sensor (not supplied by Midland; may be
connected to controller relay) detects car movement and activates
shutdown.
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Manual emergency shutdown. This shutdown is by operators
discretionary action mostly driven by emergency guidelines in the
loading facility.
o To execute the manual emergency shutdown is to simply press
the red pushbutton labeled Emergency Stop. The system goes to
emergency shutdown mode. The system will close the valves or
rotates to close for a maximum time of 20 seconds.
o Recovery: When the condition returns to normal;
Turn the red emergency pushbutton clockwise (see button labeled
emergency stop). This gets you out of the emergency shutdown
mode.
Press the Reset (black pushbutton) to clear the system from
previous settings including shutdown. Pressing the Reset button
turns off the Closed light (valve status/position indicator) and
Shutdown indicator light. Pressing Reset before pulling the
Emergency Stop pushbutton will not get you out of emergency
shutdown mode; the Closed light will turn off momentarily but will
turn on again indicating you are still in the shutdown mode. The
Shutdown light will remain on.
Note: The Start (green pushbutton) must be pressed before any
valve function is executed. Pressing the Start pushbutton makes the
actuator close the valve and finds the home position then turns on
the Closed and Ready lights. Even if the valve is already in the
closed position it ensures the operator that the actuator is
homed-in thus a Closed light turns on to conclude that the closing
torque is reached. This homing process is necessary to establish
the fully closed position from which the number of turns to fully
open the valve is based.
Emergency shutdown by sensors (gas leak detector and tank car
motion sensor). The sensors are not supplied by Midland. More
relays may be provided as add-ons in addition to the
controller-provided-extra to accommodate these sensors.
o Automatic shutdown is executed in the event of commodity leaks
that are detected by gas leak detectors or in the event of car
movement that is detected by motion sensor (chord, laser,
proximityetc). This is an immediate shutdown (no time delay).
Emergency warnings are given by the sensors or a separate emergency
warning system (may be connected to the sensors).
o Recovery: When the condition returns to normal;
Press the Reset (black pushbutton) to clear the system from
previous settings including shutdown down. Pressing the Reset
button turns off the Closed light (valve status/position indicator)
and Shutdown indicator light.
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Note: The Start (green pushbutton) must be pressed before any
valve function is executed. Pressing the Start pushbutton makes the
actuator close the valve and finds the home position then turns on
the Closed and Ready lights. Even if the valve is already in the
closed position it ensures the operator that the actuator is
homed-in thus a Closed light turns on to conclude that the closing
torque is reached. This homing process is necessary to establish
the fully closed position from which the number of turns to fully
open the valve is based.
Automatic shutdown by power failure.
o The Uninterrupted Power Supply (UPS) takes over when external
power failure occurs and is indicated by the Battery Power light
(turns on) and a beeping sound every 10 seconds. Then a five-minute
delay will be in effect before automatic shutdown is executed. This
gives operator the necessary preparation with other loading or
unloading related equipments. In the event the external power is
restored before the automatic shutdown, the system makes sure the
external power remains restored for at least 60 seconds in order to
prevent the automatic shutdown. If the external power fails to
restore for 60 seconds, the five-minute count continues to
automatic shutdown. The system will close the valves or rotates to
close for a maximum time of 20 seconds.
o Recovery: Once the external power is back after the
Automatic
Shutdown is initiated, the Battery Power light turns off and the
beeping sound stops.
Press the Reset (black pushbutton) to clear the system from
previous settings including shutdown. Pressing the Reset button
turns off the Closed light (valve status/position indicator) and
Shutdown indicator light.
o Recovery: Once the external power is back before the
Automatic
Shutdown (before 5 minutes) is initiated, the Battery Power
light turns off and the beeping sound stops.
Leave as is. The system retains settings before the short
external power failure. The homing position is retained.
Note: The Start (green pushbutton) must be pressed before any
valve function is executed. Pressing the Start pushbutton makes the
actuator close the valve and finds the home position then turns on
the Closed and Ready lights. Even if the valve is already in the
closed position it ensures the operator that the actuator is
homed-in thus a Closed light turns on to conclude that the closing
torque is reached. This homing process is necessary to establish
the fully closed position from which the number of turns to fully
open the valve is based.
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Valve Operation in Normal Mode
The normal valve operation starts when the system is not in the
emergency mode. The operator must begin with pressing the Reset
button to clear from any previous commands such as emergency
shutdown (this will be indicated with shutdown light) and home-in
position. Pressing the Reset button turns off the shutdown light
and other lights except the Power On, Midland or ACF (depending on
the type of valve the actuator is currently operating). When the
actuator is not on any valve, it defaults to ACF (ACF light
on).
The actuator is engaged onto the valve (see Actuator handwheel
engagement). The Midland light will turns on when the actuator sits
on the Midland valve. And ACF light will remain on (as default)
when the actuator is on ACF valve. o Press the Start button to
home-in the Actuator. This closes the valve and
reaches the required torque to close then establishes this
position as its origin. The number of turns to open and close the
valve is based from position of the origin. The Closed light will
turn on and the Ready light is turned on. This START button must
always be pressed first before the Close Valve or Open Valve is
pressed every time the Actuator is removed from the valve.
Otherwise the origin is not properly established and the valve can
be over-torqued.
o To open the valve, press the Open Valve button. The Partially
Open button turns on when the valve is not fully open and remains
on when the Actuator is between fully open and fully closed
position. When the valve is fully open, the Partially Open button
turns off and the 100% Open turns on.
To close the valve, press the Close Valve button. The Closed
light turns on when the valve is fully closed. The Button must
remain depressed to fully close the valve. Pressing and releasing
the button will jog the valve. Once the Closed light comes on, the
button can be released. Note: Pressing the Start pushbutton when
the actuators are not on the valve, will make the actuator
handwheel adapter turn for 10 seconds. The Ready and Closed Valve
lights will not turn on. Always press the RESET button before
removing the Actuators from the valve. Always press the RESET
button before putting the Actuators on the valve to clear the
Controller from previous commands. Actuator Handwheel engagement
Midland/ACF (see Tool Balancer Adjustment before proceeding to this
instruction)
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Raise the safety shroud. Hold actuator by its hex handle and
bracket frame (see above). Mount the actuator on top of the
handwheel
o For Midland valve, the actuator coupler pins and lower plate
sits flat on the square recessed surface of the handwheel. This is
the proper engagement.
o For ACF valve, the actuator pins drop down through the
handwheel holes.
Handl
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Let the actuator first sit on the handwheel. The actuator
coupler must be manually rotated to make proper engagement with
the handwheel. A tool is available to rotate the actuator
coupler (see left picture below of tool, see middle picture below
of the tool engaged with the half-round cut of the knurled coupler
body, see right picture below of tool when used on the
assembly).
The proximity switch sensor is factory adjusted before shipment
to automatically
sense the type of valve the actuator is operating. After the
coupler is properly engaged to the handwheel, lower the safety
shroud
to begin the actuation.
See Proximity Switch Adjustment of Maintenance and Trouble
Shooting section
in the event the sensor light does not correctly sense the right
type of valve.
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IV. MAINTENANCE AND TROUBLE SHOOTING
Uninterrupted Power Supply (UPS) Battery
The Battery Power light will turn on when UPS takes over during
power failure.
A yearly battery check-up is recommended to maintain optimum
performance. Manual Battery Test To initiate a manual battery test,
press the ON (line inside the
circle) button for at least one second while operating from
utility power with no alarm condition present.
o If only three of the five battery LEDs illuminate, allow the
UPS to recharge the batteries for 24 hours.
o After 24 hours, retest the batteries. o After the batteries
have been retested, if only three of the five battery LEDs
illuminate, contact Midland Customer Service 847 677 0333 ask
for customer service).
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Proximity Switch Sensor Adjustment
The proximity switch sensor determines the type of valve when
the actuator is mounted on the handwheel. It gives the signal to
the controller and the Midland or the ACF light turns on and thus
the programmable logic controller (PLC) will select the right
program to initiate the required number of turns to close or open
the valve it operates. This switch sensor is set to the right
sensing range before the actuator is shipped to the customer and
can be adjusted if the need arise. To adjust the sensing range of
the switch, simply move the threaded body of the switch so the
sensing tip is closer or farther from the coupler plate. This
adjustment can be done by the following steps: o Pull the rubber
weather plug and move about 6 away from the cable tubing. o Loosen
the screws that hold the cable protective tubing. o Once the
protective tubing is free, raise it to expose to the proximity
switch. At
this point, the expose proximity switch can be seen mounted on
the bracket with a lock washer and a nut on each side of the
bracket.
o The nuts are loosened and re-tightened so the sensor is
positioned to the desired range. The sensing range is 7mm (.27
inch). The sensor tip must not touch the coupler plate.
o Follow the steps above in reverse when assembling after
adjustment.
Note: The proximity switch cable protection tubing is not a
handle for lifting the Actuator.
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Controller Fault Messages and Trouble Shooting
The steady on Fault light indicates servo drive fault. The
controller must be opened to determine fault codes from the Servo
Drive. Servo fault codes are available in Midland.
Picture shows 2 drives for 2-Actuator System The flashing Fault
light indicates UPS common fault. The controller must be opened
to see UPS common fault. Consult with Midland.
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Controller Enclosure Vent
The Controller Enclosure is provided with a vent. A periodic
check may be required to keep this vent useful. The vent is covered
with an external shroud that protects it from the weather.
To check the vent inside the enclosure: o Open the controller
enclosure main door by turning the main locks counter-
clockwise (quarter turn) to unlock. The locks are located on the
right side, top and bottom of the door.
o A small flat screw driver will be needed to fit into the slot
on the right side of the On-Off knob. In the slot, reach in with
small screw driver with the flat horizontally into top portion of
the hole and move the lock down. This allows the operator to open
the door without turning the external power.
o There are two captive screws on the internal swing door. Turn
the screws counter-clockwise to unscrew and open door.
o The vent is located on the lower right, check the grill inside
the enclosure, if obstructed clean with a soft brush.
Checking the external shroud. The under side of shroud is
visible from the outside o Look under the shroud, without opening
the enclosure door, and check
obstruction that could prevent air from passing. o Clean with
soft brush if necessary. Vent shroud may be located on the left
of
the controller (Picture below shows right side location).
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Actuator
It is necessary that the adapter pins be periodically checked on
its capability to slide down easily thru the drive plate (plate
that engages on Midland valve handwheel).
Make sure that the pins are not soiled. They maybe stained with
piping sealant
on some cases due to handling. This sealant stain must be
removed from the pins.
Apply Teflon base dry spray lubricant to these pins to prevent
foreign material from adhering to the pins.
The Actuator motor must be serviced for lubrication after 10,000
hours of total continued use.
The Actuator motor maximum static output torque is 150 ft-lbs,
and the maximum running output is 83 ft-lbs.
Tool Balancer
All bearings are pre-lubricated and require no periodic
lubrication. Periodically check both hooks and cable for wear.
Replace if hooks or support show
excessive wear or if cable is frayed. Periodically check safety
chain or cable. Check fastener for tightness. Tighten as
required. Replace chain or cable if there is undue wear.
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STANDARD WARRANTY
Midland Manufacturing Corp. warrants that its products shall be
free from defects in workmanship and materials, and shall conform
to Midland Manufacturing Corp.'s published specifications, or other
specifications accepted in writing, for a period of one (1) year
after the product is placed into service, but no later than
eighteen (18) months from the date of Midland Manufacturing Corp.
shipment. Claims must be entered prior to the above dates.
LIMITS OF WARRANTY LIABILITY
This warranty does not apply to any products which have been
subject to misuse, neglect, accident, modification, or otherwise
installed outside the original application for which the Purchase
of equipment was specified and intended. Midland Manufacturing
Corp.'s sole obligation under its warranty shall be to repair, or
supply a replacement for, the part, component or product, or issue
credit at its sole discretion. Midland Manufacturing Corp.'s
warranties and remedies are exclusive and are made expressly in
lieu of all other warranties expressed or implied, either in fact
or by operation of law, statutory or otherwise, including
warranties of merchantability and fitness for use. Midland
Manufacturing Corp. shall not be liable for damages due to delays
in deliveries or use and shall in no event be liable for incidental
or consequential damages of any kind, whether arising from
contract, tort, or negligence, including but not limited to loss or
profits, loss of customers, loss of goodwill, overhead or other
like damages.
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APPENDIX