CONTROLMATIK M 3800 C Series User manual

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Controlmatik ABW d.o.o., Fajfarjeva 15, 1230 Domzale, Slovenia, Europe
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USER MANUAL'S
Electrically Powered
Emergency
Shutdown System
with battery back-up
series M 3800 C

NAV00292
Controlmatik ABW d.o.o., Fajfarjeva 15, 1230 Domzale, Slovenia, Europe
Tel. [phone], Fax [phone], [e-mail]; web: www.controlmatik-abw.si
1

NAV00292
Controlmatik ABW d.o.o., Fajfarjeva 15, 1230 Domzale, Slovenia, Europe
Tel. [phone], Fax [phone], [e-mail]; web: www.controlmatik-abw.si
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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

NAV00292
Controlmatik ABW d.o.o., Fajfarjeva 15, 1230 Domzale, Slovenia, Europe
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NAV00292
Controlmatik ABW d.o.o., Fajfarjeva 15, 1230 Domzale, Slovenia, Europe
Tel. [phone], Fax [phone], [e-mail]; web: www.controlmatik-abw.si
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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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Controlmatik ABW d.o.o., Fajfarjeva 15, 1230 Domzale, Slovenia, Europe
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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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