HALOGEN VALVE SYSTEMS Terminator User manual

Terminator™ Actuator
with Gemini™Controller
Emergency Valve Shutoff System
Installation, Operation and Maintenance Manual
Bulletin: 800.06
1/17
For Chlorine Cylinders
& Ton Containers

1/17
These instructions generally describe the
installation, operation and maintenance of
Halogen Valve System’s, automatic Terminator
Actuator ™ safety system. Halogen Valve
Systems reserves the right to make engineering
refinements that may not be described herein.
Any questions that cannot be answered by these
instructions should be directed to Halogen Valve
Systems or your local sales representative.
Halogen Valve Systems takes all possible
precautions in packaging each item to prevent
shipping damage. Carefully inspect each item
and report damages to the shipping agent,
Halogen Valve Systems,or your local sales
representative. Inspect all packing materials
before discarding to prevent loss of accessories,
mounting hardware or instructions.
Halogen Valve Systems or your local sales
representative can provide technical consultation
and personnel training on the installation and
operation of this system.
For more information concerning procedures for
the handling of chlorine cylinders and ton
containers, refer to The Chlorine Manual
published by The Chlorine Institute, Washington,
DC.
17961 Sky Park Circle, Ste A
Irvine, CA 92614 USA

I. Introduction ............................................... 1
A. General .................................................... 1
B. Equipment ............................................... 1
C. Specifications ......................................... 1
II. Operation ................................................... 2
A. General .................................................... 2
III. Installation ..............................................2-5
A. General .................................................... 2
B. Gemini Controller.................................... 3
C. Actuator Storage Bracket …………..…..3
D. Actuator Cable ........................................ 3
E. Input Wiring............................................. 4
F. Output Relay Wiring .............................. 4
G. 115 / 230 VAC Power............................... 4
H. Battery ..................................................... 4
I. Status Lights……………………………..…5
J. System Check…………………………..…..5
IV. Mounting to a Cylinder Valve ................... 6
V. Mounting to a Ton Container Valve…….7-8
VI. Placing System in Operation .................... 8
A. Opening the Valve................................... 8
B. In-Service Testing ................................... 8
C. Corroded Valves…………………..……..8-9
VII. Maintenance………………………………...9
A. Operational Testing………...…………….9
B. Emergency Shutoff Testing…….............9
C. Battery
1. Operating Characteristics…….……..10
2. Storage………………………….….……10
3. Replacement…………...…………........10
D. Microprocessor Circuit Board……...….11
VIII. Troubleshooting................................... 12
IX. Typical Circuit Board Wiring ................. 13
X. Relay Interface Module Circuit Board….14
XI. Relay Interface Module Wiring…………..15
XII. Remote Input Circuit Wiring (N.O.)...…..16
XIII. Remote Input Circuit Wiring (N.C.)……17
XIV. Actuator Cable Extension……………….18
XV. Emergency Shutoff Switch……...………19
XVI. Optional Auxiliary Valve Adapter……...20
Annual Actuator Certification Program……..21
Warranty……………………………………….….22
Notes…………………………………………...23,24
1/17
Table of Contents

A. General
The Halogen Valve Systems Terminator™
Actuator and Gemini™ Controller are designed to
be used on standard 150 lb. cylinder and ton
container valves approved for chlorine service by
The Chlorine Institute. DO NOT USE ON OTHER
VALVE TYPES WITHOUT FIRST CONSULTING
FACTORY TO INSURE COMPATIBILITY. The
Terminator Actuator is an automatic valve closer that
supplements the manual operation of these valves
by providing for powered valve closure in case of an
emergency. No modification of existing cylinder or
ton valve is required to install the system.
B. Equipment
Standard
The Terminator/Gemini emergency shutoff system
consists of the following major components and
accessories:
Major Components
1. Gravity or clamp mount
Terminator Actuator which
mounts directly to the valve
or yoke assembly.
2. Gemini Controller with
actuator power supply
designed to be mounted
adjacent to the cylinder or
ton container.
3. Power cable assembly to
provide a flexible two-wire
connection between the
controller and actuator.
Included Accessories
1. Storage bracket for each actuator to provide
temporary storage of the actuator during
cylinder or tank change, testing, and
maintenance.
2. One (1) remote mountable
Emergency Shutoff Switch
(Normally Open, momentary
contact). For additional
switches, order P/N 6430.00
and specify Normally Open or
Normally Closed contacts.
Additional Elements Required for Installation
1. 115 VAC or 230 VAC electrical source for
battery charging circuit (dedicated
disconnect).
2. Corrosion resistant conduit and fittings.
3. Suitable anchors for mounting controller,
storage brackets and emergency shutoff
switch.
Options
1. Relay Interface Module (RIM)
P/N 4500.05
Dry contact output relay
with latching capability to
indicate when an
emergency close operation
has been performed. Rated
5A@115/230V (see pages 4, 14, 15).
2. Relay Reset Button Assembly
P/N 4500.06-A
External manual relay reset button
on controller. Converts momentary
relay to latching.
C. Specifications
Emergency torque: 40 ft-lbs (55 Nm)
Motor speed: 1600 RPM
Charge current @ 115/230 VAC: 0.9 amp max
Charge current (solar) @ 12 VDC: 0.34 amp max
Battery Type: 12V, 8.0 amp-hr. High Rate
Battery backup power: Up to 5 days
Standard cable length: Gravity Mount: 7 ft.
Clamp Mount: 15 ft.
Valve: C.I. ** DWG's 110,113
Yoke: C.I.** DWG's 189,131
The C.I. (Chlorine Institute), Wash., DC torque
specified : Emergency Close 40-50 ft-lbs
**Compatible with C.I. and CGA (Compressed Gas
Association) No. 820, 820C Yokes.
l. Introduction
1/17 1.
For Clamp Mount For Gravity Mount

A. General
Halogen Valve System’s Terminator Actuator
provides an electric powered closure for a 150 lb.
chlorine cylinder or ton container valve. The valve
must be opened manually with a chlorine valve
wrench and process connections checked for leaks
prior to installing the actuator. During an emergency,
the actuator will close the cylinder or container valve
when triggered by a gas leak detector, remote switch,
or any combination of automatic or manual controls.
The Terminator Actuator is constructed of specific
materials selected for liquid or dry chlorine gas
service. Three Viton O-rings in the Xenoy plastic
alloy housing seal and protect the motor and drive
section against harsh environments. One is in the
bearing and two are between Xenoy surfaces.
Power for the Terminator Actuator is provided by a
12-volt battery and charger that are located within the
Gemini Controller. A microprocessor in the
controller insures the battery is always at optimal
charge. Battery condition and system status are
continuously monitored and displayed on the
controller’s panel. The controller uses 115/230 volt
AC for the charging circuit. In the event of a loss of
AC power, the battery will continue to provide system
power for up to five days. If during a prolonged AC
power outage the battery capacity falls to a critical
level, the controller will automatically initiate the valve
closing sequence to protect against an unguarded
system, followed by an output relay signal alerting
that a valve shutoff operation was performed.
The recommended installation includes a remote
mountable emergency shutoff switch. One switch is
provided per controller as a standard accessory. This
switch should be located within easy reach of
operating personnel, along the primary exit path from
the cylinder or ton container area. It is also recom-
mended that additional emergency shutoff switches
be located at all exits and also on an exterior wall for
access outside the confined chlorine area.
A. General
The controller enclosure and fittings (MAX-LOC®
cord grip), along with the actuator and cable are
NEMA 4X rated to insure durability in a chlorine
environment. It is recommended though that all
components be located indoors, or within a weather-
protected gas cabinet or shelter.
Installing the Terminator/Gemini system in
accordance with the following instructions and in
their order presented will insure a properly installed
system with minimal installation time.
1/17 2.
ll. Operation
NOTE
The Terminator Actuator is a CLOSE ONLY
device. Opening the valve must be
accomplished manually.
III. Installation
NOTE
For the typical chlorine valve that is open one
full turn, the actuator will close the valve many
times faster (in 3 seconds or less) than can be
done manually with a wrench.
Typical Dual Cylinder Installation

B. Gemini™ Controller
Installation of the controller should be performed
by a professional electrician in accordance with
applicable electrical codes.
Mount Controller
The Gemini controller
enclosure is gasket
sealed and rated for
installation in a
corrosive chemical
environment. The
controller should be
rigidly mounted to a
wall or other
permanent structure
within the length of the
electrical cable and
convenient to the
cylinder or ton valve
and the actuator storage bracket. Installation of the
controller should be performed by an electrician in
accordance with applicable electrical codes.
Maximum distance from actuator to controller must
not exceed 17 ft (5.2m). See Actuator Cable
Extension info on page 18.
The back of the
Gemini enclosure is
equipped with tapped
screw holes for
mounting tabs. The
tabs and attach
screws are taped to
the inside of the
enclosure door for
shipping. Attach tabs
to enclosure using
screws and tapped holes. Fasten the controller to a
wall or structure using the mounting tabs and proper
anchors for the material. The controller should be
mounted in a location which allows its status lights to
be easily viewed by operators when working on the
ton container or cylinder.
It is recommended that 115 / 230 VAC power to the
controller be supplied from a dedicated circuit with
disconnect switch. Wiring should be through rigid
PVC or liquid tight flexible PVC coated conduit.
Connections and terminations should only be made
in enclosures rated for the corrosive environment
encountered in chlorine facilities (NEMA 4X). All
controller entry fittings should be of the proper size
and type to insure the gas-tight integrity of the
enclosure is not broken at cable or conduit
entrances. Molex Woodhead MAX-LOC® or similar
fittings are preferred.
C. Actuator Storage Bracket
An actuator storage bracket is provided for each
actuator. Install bracket on a wall or other structure in
a location convenient to the cylinder or ton container
and within reach of the actuator cable. The bracket
helps prevent damage to the actuator and cable
when not in use and during tank or cylinder change.
D. Actuator Cable
The actuator is shipped
with an electrical cable
pre-wired to the actuator.
This cable cannot be
disconnected from the
actuator in the field. If
longer cable lengths are
necessary, see
acceptable method for
cable extension on page
18, and consult the factory.
Connect actuator cable to the
actuator terminal block inside the
Gemini Controller (see image and
drawing on page 11 and 13). For
proper polarity, the actuator wire
color must match the color
labeled on the terminal. Red =
positive, black = negative.
CAUTION
Do not connect AC power to the controller or
battery leads to battery terminals until instructed
to do so. All other connections should be
completed first. Connecting AC power to the
improper terminal block will damage the
controller.
Gravity Mount Actuator
Storage Bracket
Gemini Controller
Mounting Tabs
1/17 3.
Cable Entry Fittings
Clamp Mount Actuator
Storage Bracket

1/17 4.
E. Contact Closure Input Wiring
(Emergency Shutoff Switch, Gas Detector)
Connect wires from remote shutoff switch and/or gas
detector to the contact closure input terminal block
“TB1” shown on pages 11 and 13. Use 24 AWG
twisted and shielded wire, such as Belden 9501
or equivalent. Input can be configured for either
normally open or normally closed contacts via the
remote input jumper setting, JP1, on the controller
mainboard shown on page 11 and 13. The controller
default setting is normally open since the supplied
emergency shutoff switch is a normally open switch.
This default setting will cause all attached valves to
close any time the input circuit is closed via switch or
gas detector relay. See more info on pages 16 & 17.
F. Output Relay Wiring
The standard low voltage relay
output is rated at a maximum of
1 amp @ 24V AC/DC. After the
completion of an emergency
shutoff sequence, this relay will
close for approximately 3 seconds.
The relay can be wired as
Normally Open or Normally Closed
but cannot be configured as
latching.
Optional Relay Interface
Module (P/N 4500.05)
The optional
Relay
Interface
Module (RIM)
when ordered,
takes the place
of the standard
low voltage
relay. The
Relay Interface
Module provides a dry contact (K1) rated 5A @
250VAC. Relays K2 and K3 on the Relay Interface
Module are not factory configured for use but can be
in the field if required. Contact factory for instructions.
G. 115 / 230 VAC Power
After the controller is mounted and all I/O
connections are made, connect wires for 115 / 230
VAC power. Connect 115 / 230
VAC wires to the terminal block
labeled “115/230VAC”,
“WHT” (L2, low side), “GRN” (G,
ground) and “BLK” (L1, high
side). See drawing on page 13.
Conduit and fittings should be
rated NEMA 4X to maintain a
gas and liquid-tight seal for the
controller.
H. Battery
The battery is included, but not pre-
installed in the Gemini controller.
Install battery inside controller,
securing with yellow bracket.
1. Connect the Red controller wire
to the positive terminal of the
battery. Connect the Black
controller wire to the negative
terminal of the battery.
2. Press the microprocessor
RESET button on the mainboard
inside the controller to insure
initiation of the control program
(see board image on page 11 for
button location).
CAUTION
AC power must be OFF when connecting power
wires to controller. Do not apply AC power to
controller until battery has been connected.
CAUTION
Do not install unauthorized relays or other
devices inside the Gemini controller box. Doing
so may damage the controller and will void the
Warranty.
WARNING
i Battery MUST be connected for system to
operate.
i To protect system, always connect battery
first, then AC charging power. Always
disconnect AC charging power first, then
disconnect battery.
i
i
Do not connect battery leads until AC power
is also available. This will prevent excessive
discharge of the battery which could damage
the battery.
i
If the polarity of the battery connection is
accidentally reversed, the circuit board will
be damaged.
WARNING
Do not apply any source of power to Input
Terminal Block TB1. Applying power to this
terminal block will damage the system.
Terminal Block
L2 G L1

1/17 5.
I. Status Lights
With the battery connected, the Armed/Ready panel
light should be flashing green for each Terminator
Actuator that is attached to the controller. If Armed/
Ready light is OFF and actuator is connected to
controller, attempt to reset controller by pressing and
holding the TEST B key until BATTERY STATUS
light turns OFF (+/- 6 seconds), then release.
Controller will reboot. This reset is required after
every emergency activation but is not required
after a test activation.
Apply 115 / 230 VAC power to the Gemini Controller.
With the battery and AC power connected, the amber
BATTERY CHARGER STATUS panel light will flash
slow or fast indicating the amount of charge current
being applied to the battery. A steady (solid) ON light
indicates battery is fully charged.
If the amber BATTERY STATUS panel light is
flashing after AC power is applied, the battery may
have discharged during storage or transit. It should
change to steady ON after a few minutes. Do not
proceed with the remainder of the installation
until BATTERY STATUS light is steady ON. If
required, see the troubleshooting section of this
manual for battery test or replacement procedures.
J. System Connection Check
The electrical system must be checked during
installation for proper polarity and status indication.
This is done by test running each actuator BEFORE
placing the actuator on a cylinder or tank valve.
TEST PROCEDURE:
1. Place actuator in the storage rack or hold in a
manner where drive bushing can be observed.
2. Depending on actuator being observed, press
either TEST A or TEST B key on Gemini panel
and observe rotation of bushing.
3. Confirm that the actuator shaft and drive
bushing rotate in the closing direction when
motor turns.
4. The actuator motor should run for about
3 seconds and then shut off automatically.
5. If the bushing does not turn, or turns in the
opening direction, DO NOT USE and contact
factory!
6. Repeat above TEST PROCEDURE for each
actuator.
7. When the system successfully passes the
polarity test, you may proceed to “Mounting to
a Cylinder Valve”, Section IV, or “Mounting to
a Ton Container Valve”, Section V, for further
testing of the system.
WARNING
Do not place actuator on valve until the
following test is complete!
IMPORTANT
The actuator cables and controls are connected
with proper polarity when the actuator motor
drives the shaft and bushing in the direction that
closes the valve (counter clockwise when
viewed from the bottom of the actuator).
NOTICE
Pushing the mainboard “RESET” button is
required whenever a new battery is installed or if
the battery connection is interrupted during
control system set-up.
WARNING
During test, drive busing will rotate. Keep clear
of drive bushing to prevent injury.

1/17 6.
Follow these procedures:
1. Make sure all piping connections are
in accordance with The Chlorine
Manual or local procedures. The CGA
820 yoke and adapter assembly is the
standard connection used to connect
process tubing to the cylinder valve
outlet. Always install a new gasket
between the valve face and the
CGA 820 yoke connection each
time the connection is made.
2. Tightening the yoke bolt (in picture) will
compress the
gasket and secure
the yoke rigidly to
the valve by
coupling the valve
outlet flange to the
process tubing or
piping with a CGA
820 connection.
3. After checking for leaks at the connections, and
with the valve opened no more than one (1) full
turn of the valve stem, the Terminator Actuator
can now be placed on the valve.
4. Remove the retention pin that
extends through the end of both
rods of the actuator.
5. Align the actuator shaft and
drive bushing with the valve
stem. With the actuator rods
parallel to the sides of the valve, let the actuator
slide down on the valve while rotating the drive
bushing by hand to
align the bushing
with the flats on the
valve stem (Fig. 1)
6. The drive bushing
should fully engage
the wrench flats on
the valve stem.
7. The Terminator Actuator mounting rods are
designed to straddle and loosely grasp the
valve on either side of the outlet as shown in
figure 2. The two rods on the actuator will fit
inside the standard
yoke and fit loosely
on either side of
the valve nozzle
after the drive
bushing is seated
as shown in
Figure 3.
8. Confirm proper
alignment of the
actuator and the
valve stem by
visually checking the actuator drive bushing and
valve shaft.
9. Reinstall the
retention pin.
When properly
installed, the pin
should slide just
under the valve
outlet and extend
through both rods.
With the pin in
place, the
Terminator
should not be able
to be lifted up and
off of the valve.
10. The Terminator
Actuator is
designed to fit
loosely and rest directly on the cylinder valve
stem. When activated, the actuator will make a
loud ratcheting noise and move around slightly
during the closing of the valve.
11. The Terminator Actuator weighs about 8
pounds. Gravity, along with a secure fit on the
cylinder valve, will keep the actuator in place
during activation. The retention pin provides
additional security.
12. Follow instructions for In-Service Testing in
Section VI, Page 8 - Placing System In
Operation.
lV. Mounting to a Cylinder Valve
Gravity Mount Model
Fig. 2
Fig. 1
Fig. 3

1/17 7.
The clamp mounting system for the
Terminator valve actuator is designed
for use with the Chlorine Institute
recommended CGA 820 yoke
connection assembly. Adapters are
available that allow the clamp mount
Terminator to also be used with direct
mount vacuum regulators that do not
employ the standard CGA 820 yoke
connection. Special adapters can also
be provided for unusual regulator or
tubing connection devices. Consult the
factory for engineering assistance.
A. Ton Containers On a Pressure Manifold
For chlorination systems using a pressure manifold
(feeding under pressure), the clamp mount Terminator
attaches directly to the CGA 820 yoke.
For pressure systems not using a CGA 820 yoke,
both yokes and yoke to pigtail adapters are available
from Halogen Valve Systems.
B. Ton Mounted Vacuum Regulators
Direct mount
vacuum regulators
(VR’s) are designed
to mount directly to
the ton container
valve and vary
widely in weight and
configuration from
one manufacturer to
another.
An auxiliary valve
adapter allows the
clamp mount
Terminator to be
used with most ton
container mounted
vacuum regulators
that do not employ the CGA 820 yoke connection.
Some direct mount vacuum regulators require the
use of a VR Extension, P/N. 6303.00. The
extension creates additional clearance between the
vacuum regulator and the actuator. Contact your
local Halogen Valve Systems representative or
factory for assistance with vacuum regulator
compatibility.
C. Ton Container Mounting Procedures
1. Make sure all piping connections are in
accordance with The Chlorine Manual or local
procedures. The CGA 820 yoke and adapter
assembly is the standard connection used to
connect process piping to the container valve
outlet. Always install a new gasket between
the valve face and the CGA 820 yoke
connection each time the connection is
made.
2. Tightening the yoke bolt will compress the
gasket and secure the yoke rigidly to the valve
thereby coupling the valve outlet flange to the
process tubing or pipe using the CGA 820
connection.
3. After checking for leaks at the connections, and
with the valve opened no more than one (1) full
turn of the valve stem, the Terminator
Actuator can now be placed on the valve.
4. The actuator mounting clamp arms are
designed to straddle and grasp the yoke firmly.
Align the actuator shaft and drive bushing with
the valve stem. With the actuator clamp arms
Auxiliary Valve Adapter
Halogen Part No. 2202.00
CGA 820 Open Style Yoke
Halogen Part No.5151.00
Yoke to Pigtail Adapter
Halogen Part No. 6888.00
WARNING
The yoke must be tightened adequately to the
valve to insure that the torque reaction from
the actuator closing does not unseat the lead
gasket.
V. Mounting to a Ton Container Valve

1/17 8.
open and parallel to the sidebars of the yoke,
rotate the drive shaft by hand to align the
bushing with the flats of the valve stem and
place bushing over valve stem.
5. The spring-loaded drive bushing at the base of
the actuator shaft should fully engage the
wrench flats on the valve stem and the clamp
arms should straddle the sides of the yoke.
6. Tighten the clamp knob finger tight while
rocking the actuator slightly back and forth.
This will assist in parallel alignment of the
actuator with the sides of the yoke, and the
actuator shaft will be concentrically aligned
with the valve stem. The horizontal position
of the ton container valve requires careful
attention to the alignment of the actuator
with the valve stem.
7. The clamp knob is only required to be
finger tight. This will securely hold the
Terminator in place on the yoke and
allow no rocking movement.
8. Check visually for proper alignment of the
actuator and the valve. If alignment appears
to be incorrect, loosen the clamp knob
slightly and adjust the alignment of the
actuator then retighten the clamp knob.
A. Opening the Valve
Before opening any chlorine valve, make sure that
the yoke or regulator clamp is tightened firmly.
Never reuse a gasket that has been previously
compressed. It is recommended that all pressure
connections be made and tested as described in
The Chlorine Manual before operating the valve
actuator. This will insure that the valve can be
operated manually and that leak testing has been
completed prior to installing the actuator.
B. In-Service Testing
With the system pressurized and the flow of chlorine
established, the emergency shutoff system may be
tested under actual conditions. This test is
recommended each time the actuator is installed on
a new cylinder or ton container to insure actuator has
been correctly installed, and that the operating
condition of the valve will permit proper closing of it
by the Terminator/Gemini system.
Confirm that the Gemini controller panel lights are in
the following normal conditions:
If an Armed/Ready light is OFF but the actuator is
connected to controller, attempt to reset controller
by pressing and holding the TEST B key until the
BATTERY STATUS light turns OFF (+/- 6 seconds),
then release. The system will reboot after which all
status lights should indicate a normal condition.
This reset is required after every emergency
activation but is not required after a TEST key
activation.
If other lights are not properly indicating, see
TROUBLESHOOTING, Section XIII, on page 12.
With lights indicating a normal condition, depending
on the actuator you wish to test, press the TEST A
or TEST B key. The actuator will immediately
activate and close the valve. A loud ratcheting noise
from the actuator during closure is normal. The
Armed/Ready lights will rapidly flash alternately ON
and OFF for approximately 10 seconds then return
to slow, synchronized (if two actuators connected)
flashing when ready for another close cycle.
Remove actuator from valve, check that all process
connections are secure, reopen the valve no more
than one full (1) turn, and check for leaks.
The force required to reopen the valve should
confirm that the actuator applied enough torque
to completely seat the valve stem. If valve does
not appear to have been properly closed, do not
place actuator in service!
C. Corroded Valves
Cylinder or ton containers left in dispensing service
for extended periods may develop corrosion or
fouling of the valve body, packing, packing nut, and
stem. This can substantially increase the amount of
torque required to close the valve. In severe cases,
the increase in the torque required could exceed
the capacity of the actuator to close the valve.
LIGHT COLOR CONDITION
ARMED/READY GREEN FLASHING
BATTERY CHARGER STATUS AMBER STEADY ON
BATTERY STATUS AMBER STEADY ON
VI. Placing System In Operation
WARNING
If the valve cannot be readily operated both
manually and by the actuator, the cylinder or
container should not be placed in service under
any circumstances.

1/17 9.
To reduce the potential for fouling, implement the
following policies and procedures:
1. Test cycle the actuator system at least once per
month when in service.
2. Specify that the chlorine supplier provide only
cylinders or ton containers equipped with
Chlorine Institute approved Teflon valve packing.
This greatly reduces friction between the
packing and stem. In the past, graphite-
impregnated, split packing rings were the only
approved packing system for cylinder and
container valves. These require greater gland
nut tightness to seal, resulting in higher friction
between the valve stem and packing. Friction is
increased even more when the stem is corroded
or fouled. The solid, non-split Teflon packing
seals better, with less gland pressure, and
requires less force to open or close even if the
stem is corroded. New seal kits are available for
suppliers to convert existing valves to the new
Teflon packing at nominal cost.
3. Wet chlorine is the primary cause of corrosion of
the internal components of these valves. This
may be due to poor quality control during the
refilling of containers by the supplier.
Additionally, moisture and/or other contaminants
may not be fully evacuated from the chlorine
container before refilling. Moisture can also enter
the valve and cylinder through "suck-back" from
the dispensing piping or atmosphere. This
problem is the result of temperature changes or
other design deficiencies.
4. Consult with your supplier concerning their
refilling equipment and techniques as well as
valve reconditioning and repackaging. Detailed
procedures are covered in the Chlorine Institute
(C.I.) Pamphlet # 17, Cylinder and Ton
Container Procedure for Chlorine Packing, to
insure high quality, dry chlorine and contaminant
free valves that turn freely and easily (less than
10 ft-lb. of torque).
5. Consider the installation of equipment that
dispenses chlorine gas with a vacuum regulator.
This can eliminate "suck-back" and the intrusion
of atmospheric moisture. Your Halogen Valve
Systems representative can provide information
on devices engineered to dispense chlorine
while precluding the introduction of
contaminants.
A. Operational Testing
The system test sequence described in In-
Service Testing, (section B on page 8) should
be performed each time a tank or cylinder
change-out is done. For cylinders or ton
containers kept in extended service, this system
test should be performed at least once per
month, and preferably once a week. The battery
capacity is not appreciably affected by one or
even several test cycles of the actuator when
normal AC charging power is available.
B. Gas Detector & Emergency Shutoff Switch
Testing
If a leak detector senses chlorine gas from a leak
or from residual released during tank or cylinder
change-out and triggers the Gemini Controller to
close the chlorine valve, make sure that the room
is completely clear of chlorine gas before
resetting the Gemini Controller (RESET: Press
and hold TEST B key until BATTERY STATUS
light turns OFF, +/- 6 seconds, then release).
Otherwise, the gas sensor will still be detecting
residual chlorine in the room causing an
emergency close signal to be sent the Gemini
controller, immediately activating another
emergency close sequence.
Test Procedure
The testing or calibration of a gas leak detector,
emergency shutoff switch or any remote input to
the controller may be checked by the following
procedure. This procedure also provides a check
of the electrical continuity of the entire system.
1. Place actuators in storage brackets.
2. Expose the gas leak detector sensor to a
calibration gas, press an emergency close
switch, or activate any other input device you
wish to test.
3. After the controller receives an input signal,
each actuator should run for about 3
seconds, indicating that the controller
received the signal correctly.
4. The Armed/Ready lights will alternately
flash, then turn off until system is reset.
5. To reset controller, press and hold the TEST
B key until BATTERY STATUS light turns
OFF (+/- 6 seconds), then release. System
will reboot and all lights should then indicate
normally.
VII. Maintenance

NOTE: This procedure is similar to In-Service
Testing outlined previously except that the
triggering signal originates with a leak detector or
emergency shutoff switch rather than the
controller panel TEST key. Since the actuators
are not on valves during this test, this procedure
may be repeated at 15 second intervals for
numerous sensor calibrations or input tests
without the need to reopen the cylinder or ton
container valve after each cycle. Additionally,
there will be no impact noise and the battery will
not discharge as quickly since there is less load
on the drive motor.
C. Battery
1. Operating Characteristics
Expected life of the system battery is 2 to 3
years under normal conditions. However, due to
differences in environmental factors and use,
the capacity reduction rate of each battery
varies. Because of this, it is recommended
that the battery be replaced annually with a
factory new battery to insure system
warranty and reliability of torque
application.
The BATTERY STATUS light flashes when the
Gemini microprocessor detects a voltage of less
than 12.5 volts across the battery. During
activation or system test, the BATTERY
STATUS light may flash intermittently. This is
due to the high current draw of the actuator
motor during the closing and seating of the
valve. As long as the BATTERY STATUS light
is on and steady, the battery has sufficient
charge.
A fully charged battery has the capacity to
power the actuator through ten cycles, under
load, in a five minute period. Thereafter, allow
five to ten minutes for cooling and recharging.
After a test cycle, be sure that the BATTERY
STATUS light is on and steady before
proceeding with the next test. Discharging
below about 9 volts can damage the battery. At
that point, the BATTERY STATUS light goes off
and the battery cannot be recharged and must
be replaced.
2. Storage
Spare batteries, when not supplied a sustaining
charge, have a shelf life of approximately one
year if stored in a cool, dry place. Periodic
recharging of spare batteries through a regular
service rotation will extend shelf life.
3. Battery Replacement
a) Disconnect AC
power.
b) Open controller door
and disconnect the
BLACK battery lead,
then the RED battery
lead from the battery
terminals.
c) Loosen the two
knurled thumb
screws on the
battery crossbar and
remove crossbar.
d) Remove the battery.
e) Place the new battery into the bracket with
terminals at bottom.
f) Reinstall the battery crossbar and tighten the
screws.
g) Connect the RED lead to the positive
terminal and BLACK lead to the negative
terminal of the battery. The Armed/Ready
lights should slowly flash continuously ON
and OFF for each connected actuator.
h) Reconnect AC power.
i) Push the red RESET
button on the mainboard
(see image and drawing on
pages 11 & 13 for button
location).
WARNING
If the BATTERY STATUS light is flashing, the
actuator may not operate even with charge
power connected. If the battery is fully
discharged, it will not recover regardless of
charging time. The battery must then be
replaced.
1/17 10.
NOTICE
Factory recommends annual
replacement of battery. Contact representative or
factory for replacement battery.
WARNING
FACTORY APPROVED BATTERY ONLY!
Use of non-approved battery may prohibit sys-
tem from operating correctly or damage system.

D. Microprocessor Circuit Board
All of the power management, display and diagnostic
elements of the Gemini controller are integrated on a
single circuit board mounted within the controller
enclosure. The actuator power fuse, located in the
upper right hand corner of the circuit board is the
only replaceable component on the circuit board.
Two spare 30 amp green blade type fuses are
included inside the controller. Additional fuses are
available from the factory as Part No. 4102.
The microprocessor program is stored in an EPROM
memory chip that is pre-programmed at the factory.
The board is not field repairable and if it malfunctions
it must be exchanged with a new or rebuilt factory
unit.
How to remove the circuit board for replacement
or repair:
1. Disconnect 115 / 230 VAC power at the source
external to the control enclosure.
2. Disconnect DC power supply input.
3. Disconnect the battery leads from battery, then
from board.
4. Disconnect the signal inputs, and optional relay
board if installed, from the circuit board.
5. Disconnect actuator cables from board.
6. Remove the single screw holding the board to the
center pin holder. Gently pull the circuit board
down and it will pop out of the pin holders.
Reverse the above 6 steps to install the new board.
Be sure that the terminal posts and cable
connections are secure in the terminal connectors.
OPERATIONAL TEST – IMPORTANT!
Verify wiring is in accordance with steps D thru I
on pages 3,4 and 5 and that system passes test
in step J on page 5 before placing system in
service.
Gemini Main Circuit Board
WARNING
Substitution of other fuses may result in damage
to the control circuitry and/or actuator failure and
may void warranty.
1/17 11.

Trouble Probable Cause Corrective Action
“ARMED/READY ” light
OFF
A. Reset required
B. Defective control
panel
C. Defective control
module
1. Press and hold “TEST B” key for 6 seconds. Required after
every emergency activation.
2. Check “BATTERY STATUS” light. If OFF, go to “BATTERY
STATUS” section below.
3. Check “BATTERY CHARGER STATUS ” light. If OFF,
check AC power to unit.
1. Press reset button on mainboard and hold while observing
controller panel LEDs. All four LEDs should be illuminated. If
one or more but not all are illuminated, replace controller
panel.
1. Press reset button on mainboard and hold while observing
controller panel LEDs. All four LEDs should be illuminated. If
none are illuminated, replace control module. Note: All LEDs
should be OFF for 0.75 seconds after the reset button is
released.
Actuator fails to operate
when “TEST A” or
“TEST B” key is pushed
(Battery OK)
A. Microprocessor
Stalled
B. Power fuse blown
C. Cable damaged or
bad connection
1. Push microprocessor “ RESET” button located on mainboard
(see image and drawing on pages 11 & 13)
1. Check the 30 amp, blade-type fuse (See page 11). Replace
with spare included with instructions.
2. Determine the cause of the blown fuse. Most likely cause of
blown fuse is a cross-connect or short in the cable.
1. Check cable terminations for proper polarity. Check for
damaged cable. Check for secure connections at cable
termination in control box. Return actuator and cable to
factory for service.
“BATTERY STATUS”
light FLASHING or OFF
A. FLASHING- Low
battery
B. OFF– Replace/
Recharge
1. Battery should recharge if “BATTERY CHARGER STATUS”
light is on or flashing. Light should eventually return to
steady on.
1. Replace battery (page 10). After removal from the
controller, verification of a bad battery can be accomplished
by checking the voltage across the terminals with a
voltmeter. Less than 12v indicates a defective battery.
Otherwise, proceed with the following checks of the
charging circuit.
2. Confirm AC power or solar cell power is available. Check
the charging circuit as follows:
a) “BATTERY CHARGER STATUS” light is on or flashing.
b) Check that battery cable connections are secure at the
circuit board terminals (refer to Maintenance Section for
access to circuit board).
c) Connect a DC voltmeter across the Red and Black
battery cables. Must be at least 13 volts DC. Otherwise,
replace circuit board (See Maintenance Section VII).
For the Gemini Controller
VIII. Troubleshooting
1/17 12.

For the Gemini Controller
IX. Typical Circuit Board Wiring
1/17 13.

1/17 14.
X. Optional Relay Interface Module Circuit Board
TB2, JS1*, JS2**
COM
N.O.
K2*, K1**
PIN 1
TB2 +V

For the Gemini Controller
XI. Optional Relay Interface Module Wiring
1/17 15.
BLUE
BROWN
BLUE
BRN
BLUE

1/17 16.
XII. Remote Input Circuit Wiring (N.O.)

XIII. Remote Input Circuit Wiring (N.C.)
1/17 17.