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

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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