Smith Meter® Model 210 Digital Electro
Contents
1.2. Figure 9 Cover Spring Removal Remove the stem assembly from the valve body On the underside of the stem note that the stem may have a flat machined surface This flat surface is dependent on valve size Some valve sizes have a nut where this flat would be Figures 10 and 11 Secure this flat surface or the lower stem nut in a vice as shown in Figure 12 Page 12 e MNO3010 Issue Rev 0 3 4 15 Model 210 Valve I O S Manual Service and Maintenance Figure 10 Stem Flat Surface Figure 12 Poppet Assembly Remove the stem nut with a socket or open ended wrench Issue Rev 0 3 4 15 MNO3010 Page 13 Model 210 Valve I O S Manual Service and Maintenance Figure 13 Stem Nut Removal Remove the lock washer back up plate and diaphragm washer Note the back up plate and diaphragm washer have a tight fit around the stem Ensure not to gall the threads of the stem while removing the back up plate Figure 14 Diaphragm O ring Remove the top diaphragm O ring diaphragm and lower diaphragm O ring and discard as these components should be replaced Figure 15 Diaphragm O ring Removal Page 14 MNO3010 Issue Rev 0 3 4 15 Model 210 Valve I O S Manual Service and Maintenance Figure 16 Diaphragm Removal Inspect the lower diaphragm washer for any defects If none are present the diaphragm washer can be left on the stem If there are visible defects i e shar
3. Slowly close the isolation needle valve upstream of the pressure pilot until stable no flow surging 210 Valve operation is obtained Using a pressure gauge check to be sure the pressure pilot is set to control at the desired pressure Adjust it as required Notes A If it is not possible to conduct Steps 9 10 and 11 with all load positions operating compromise by having as many load positions as possible operating Then throttle the flow ahead of the meter with a manual valve until the 210 Valve is not limiting flow i e not modulating This occurs when the flow rate is less than the high flow rate limit set into the controller by more than the flow control band width B The pump should be wired to remain on for at least five 5 seconds after E Stop is initiated to assist in valve closure C Ifthe ratio between the highest and the lowest 210 Valve inlet pressure at high flow ie one versus all positions operating from that pump is greater than 2 1 it may not be possible to obtain satisfactory valve performance under all operating conditions If the inlet pressure variation is extreme no compromise needle valve settings may be possible The system will then have to be changed either by adding pumping capacity adding a pressure reducing valve in the common line from the pump to the loading positions or by replacing the 210 Valves with air operated 215 Valves etc D If it becomes necessary to use the control loop nee
4. Step 4 With no other loading position from the pump open highest valve inlet pres sure preset a small volume and energize the valve solenoids as normally would be done to initiate flow Step 5 Slowly open the downstream needle valve until the main valve opens slowly but smoothly and maintains flow stability solenoids not clicking excessively Step 6 Allow a normal preset shutdown observing the valve closing speed and flow stability during the multi stage shutdown Step 7 If the shutdown speed and flow stability are acceptable go to the next step If either is unacceptable adjust the upstream needle valve further closed for slower valve shutdown and better flow stability or further open for faster valve shutdown Preset small batches each time repeating Steps 5 and 6 until satisfactory valve per formance is obtained Page 6 MNO3010 Issue Rev 0 3 4 15 Model 210 Valve I O S Manual Operation Step 8 Preset a small batch and after high flow is reached initiate an emergency stop E Stop Record the volume throughput after initiation of the E Stop and ob serve whether there was excessive line shock If line shock was excessive close the upstream solenoid isolation needle valve a little further to slow the valve closure rate Repeat this step until excessive line shock is eliminated Step 9 If possible with all other loading positions from the pump open lowest valve inlet pressure preset a small batch an
5. this will remove the pipe nipple from the junction box Issue Rev 0 3 4 15 MNO3010 Page 9 Model 210 Valve I O S Manual Service and Maintenance Figure 3 Tubing Removal If the solenoids are to be disassembled inspect the solenoid elastomers for any chunking or missing elastomer pieces If abnormal wear is visible the solenoid should be rebuilt or replaced Figure 4 Solenoid Elastomer Damage Example Remove the junction box and junction box bracket Once the valve cover has clearance to be removed using an open ended wrench or socket remove all of the cover nuts Page 10 MNO3010 Issue Rev 0 3 4 15 Model 210 Valve I O S Manual Service and Maintenance Figure 5 Cover Disassembly Caution The cover spring s could cause the cover to release from the body unexpectedly However if the cover does not release from the body use two flat headed screw drivers to pry down against the body as shown below Ensure to only insert the tip of the screwdrivers underneath the rabbit and not to pry against the diaphragm Depending on valve size there could be two springs underneath the cover 2 and 3 valves have one spring while 4 and 6 valves have two springs Figure 6 Cover Removal Issue Rev 0 3 4 15 MNO3010 Page 11 Model 210 Valve I O S Manual Service and Maintenance Figure 8 Cover Removal Remove the spring s from the valve stem
6. Valve and Line Accessories Smith Meter Model 210 Digital Electro Hydraulic Set Stop Installation Operation Service Manual Bulletin MNO3010 Issue Rev 0 3 4 15 MIC Technologies Customer Support Contact Information Customer Service FMC Technologies Measurement Solutions Inc 1602 Wagner Avenue Erie Pennsylvania 16510 USA P 1 814 898 5000 F 1 814 899 8927 measurement solutions fmcti com www fmctechnologies com Model 210 Valve I O S Manual Table of Contents Table of Contents A A O ae a 4 RECIPE OF EQUIPMEN E Hinsosecndienatns Sieben toaeeuedt uke ai A a Ae 4 VASO Mo ele eee ees eee ae ce eee A EE EE 4 bes See e TTT TTT MOOT SERINE OR at IRN CREA Pe OCS NO PO IER 4 2 QOPESFatiO TTT 5 A E eo e EE an T 2 2 Stan Up amd Field ACIUSHMONL asa N ee eee A 7 gt TFOUDIESHOOTING GUIA TTT 8 4 Service and Maintenance ccccecececcecececececececeeeceeceeecucaeacaeaeneneauaeaeaueanaeeeneneneaeaeaueasanaeaeneaeaeaeauaaeanaeeeneneneauaeaueaeanaeneneneneananaaes 9 Al Service Maintenance Miera e i a a lS EA trae Be a A a Se Jina 9 4 2 Recommended Spare Components T 9 o o o A 9 4 4 Ree RTT COUSIN CS add See a al i a ed eee Sioa ia a oh Oso 9 A IAS O A A O O ON 9 5s Related Publications tc a a E ea Dada coo 24 Issue Rev 0 3 4 15 MNO3010 Page 3 Model 210 Valve I O S Manual General 1 General 1 1 1 2 1 3 The Smith Meter Model 210 Digital Control Valves
7. am pressure closes the valve During flow when the N O solenoid is energized while the N C solenoid is deener gized pressure is trapped in the cover causing the valve poppet to be hydraulically locked in a fixed open position Therefore a constant flow rate is maintained When operating conditions change causing a change in flow rate for that fixed valve open ing the flow controller e g microLoad or AccuLoad signals the appropriate sole noid to open or close momentarily changing the valve open position thereby read justing the flow rate to its set value When the set flow rate changes e g from low flow start to high flow limit or dur ing multi step valve shutdown the appropriate solenoids are signalled to open and or close until the flow rate adjusts to the new set value When the product delivered reaches a predetermined field adjustable first stage trip value in the controller valve closure is initiated The flow controller signals the 210 Valve to ramp down the flow in a multi step manner thus preventing line shock Issue Rev 0 3 4 15 MNO3010 Page 5 Model 210 Valve I O S Manual Operation 2 2 Flow Rate GPM First Stage Trip 900 600 Final Gallons aS Stage Trip First High Flow Rate 300 Second High Flow Rate Low Flow Start 2 000 Gallons to Be Delivered Field programmable Caution There must be sufficient pump capacity to achieve the flow rate set into the Ac
8. are hydraulically operated diaphragm controlled valves typically used in conjunction with either an AccuLoad or microLoad Receipt of Equipment When the equipment is received the outside packing case should be checked immediately for any shipping damage Carefully remove the unit from its packing case and inspect for damaged or missing parts If damage has occurred during shipment or parts are missing the local carrier should be notified immediately and a written report should be submitted to the Customer Service Department FMC Technologies Measurement Solutions Inc P O Box 10428 Erie Pennsylvania 16514 0428 Prior to installation the unit should be stored in its original packing case and protected from adverse weather conditions and abuse Standard explosion proof solenoids are UL listed and CSA certified for use in Class Groups C and D Division 1 Class Il Groups E F and G Division 1 hazardous locations Installation Ensure the valve is installed with flow in the correct direction The intended flow direction is indicated on the side of the valve body These products have been designed for petroleum applications where corrosion erosion is normally minimum The design of the pressure containing housings have adequate material allowance for typical petroleum applications Consult the factory for other applications or for the actual material allowances Electrical Wiring is covered in the appropriate controller manua
9. ces of the back up plate to remove any burrs Figure 22 Back up Plate Using a brass bristle brush dress the inner diameter of the back up plate to remove any burrs Figure 23 Back up Plate Issue Rev 0 3 4 15 MNO3010 Page 17 Model 210 Valve I O S Manual Service and Maintenance Figure 25 Lock Washer Secure the stem nut to the stem using a socket or open ended wrench Tighten until the lock washer engages and is flat against the surface of the back up plate Figure 26 Engaged Lock Washer Page 18 e MNO3010 Issue Rev 0 3 4 15 Model 210 Valve I O S Manual Service and Maintenance Remove the stem assembly from the vice and install the stem into the seat of the valve DO NOT slide the diaphragm over the studs at this point Figure 28 Stem Assembly Insert a pry bar into the inlet of the valve and lift up the bottom of the stem Lift the stem to ensure that the diaphragm does not fray against the threads of the studs while seating the diaphragm Gently slide the diaphragm stud holes over the studs Ensure not to fray or twist the inner diameter of the diaphragm stud holes Ensure this is done while the stem is lifted This may require additional assistance If the valve is installed in the piping manually hold the valve stem assembly so that the diaphragm uniformly slides over the studs Issue Rev 0 3 4 15 MNO3010 Page 19 Model 210 Valve I O S Manual Se
10. cuLoad or microLoad or the valve may close slowly resulting in a spill Figure 2 Typical Load Cycle When the preset quantity is nearly reached 1 2 gallons remaining a final trip point field adjustable in controller signals the valve to close completely assuring accurate delivery of the preset quantity Figure 2 shows a typical truck loading flow rate sequence Start up and Field Adjustments Upon initial system start up using the 210 Valve it is recommended that the follow ing steps be followed sequentially to insure a stable and properly operating system Step 1 First all air must be vented from the cover chamber of the main valve Other wise the valve may be unstable or sluggish This is done by pressurizing the system and loosening the highest vent plug in the valve cover until all air is expelled Valves installed in horizontal lines usually automatically expel all of the air from the cover chamber after just a few full actuations of the valve Step 2 Be certain the flow rate limit is properly set in the controller e g AccuLoad microLoad etc so the meter is protected from over speeding and the valve is modu lating i e controlling flow rate Step 3 Before energizing the solenoids to open the valve completely close the downstream solenoid control loop isolation needle valve This prevents the 210 Valve from opening Also adjust the upstream solenoid control loop isolation needle valve about 1 4 1 2 open
11. d run If opening speed is not acceptable open the downstream solenoid isolation needle valve a little further and observe nor mal valve opening and closing performance as done in Steps 6 and 7 See Note A Repeat this step until acceptable opening speed is obtained Step 10 If closing speed is unacceptable adjust the first stage trip value in the pre set counter to a value sufficient to assure reaching final step flow prior to the final stage trip on the preset counter See Note B Step 11 Conduct an E Stop test as in Step 8 If the volume throughput after initia tion of E Stop is greater than the volume left in the tank or compartment after a high level sensor initiates an E Stop typically about twenty 20 gallons for a gasoline transport a decision must be made whether to speed up the valve closure and ac cept some line shock at high valve inlet pressure i e one load position operating or accept a slower than ideal valve closure on E Stop at low valve inlet pressure i e all load positions operating Step 12 If a modulating pressure pilot was supplied on the valve it should have been factory set for the specified control pressure e g 64A pilot set at 35 psi maxi mum valve outlet pressure or 23 BP pilot set at 15 psi minimum valve inlet pressure Open the isolation needle valve s on the pressure pilot loop causing the pressure pilot e g Model 64A to control the valve by adjusting manual valves in the system
12. dle valves for pilot isolation i e in order to repair or replace a pilot without draining down the system be sure to mark their control position precisely to permit easy resetting after the repair is complete Issue Rev 0 3 4 15 MNO3010 Page 7 Model 210 Valve I O S Manual Troubleshooting Guide 3 Troubleshooting Guide Problem Cause Remedy A 1 RCC Improper wiring Check wiring T Downstream Model 13 Valve on 210 Valve Open needle valve closed FE pct or miroLoad fuse town Replacotuse rr O O ioopen connection to ick Open ary breek couping Fr ct oF H Testo Jn trainer HH check Fa reset counter switch not wortng May check PF fic sotenia ated osea Testandreplace 2 improper or anaic mon flow A Fiia pressure H Ste sysem ness nahe aaae AccuLoad or microLoad Hi Flow setting Correct setting ace a a dB 77 AO Chewing Pec Jn soto seat open E Pb ni sotonona ateo close Testard repce E meter pio oeme AccuLoad or microLoad Hi Flow setting Correct setting incorrect TT Repostonandioer AA set tg C fe act o microLoad board defecive Testandreplace PJ king capiragm Replace diaphragm P improper switch setings on high ow Adust reset courtertip PT First trip too on Preset Counter Adjust Preset Counter tip po meem Rent Za se Goer aenn A Manual verge vale open ose valve PT ostream Hod 13 Neo Va dosed Open needle ake Jeno sotnoistaiedio open Testa
13. er that the specifications are currently in effect Otherwise the manufacturer assumes no responsibility for the use of specifications which may have been changed and are no longer in effect Contact information is subject to change For the most current contact information visit our website at www fmctechnologies com measurementsolutions and click on the Contact Us link in the left hand column Headquarters Operations The specifications contained herein are subject to change without notice and any user of said 500 North Sam Houston Parkway West Measurement Products and Equipment specifications should verify from the manufacturer that the specifications are currently in effect Suite 100 Houston TX 77067 USA Ellerbek Germany 49 4101 3040 Otherwise the manufacturer assumes no responsibility for the use of specifications which Phone 1 281 260 2190 Erie PA USA 1 814 898 5000 may have been changed and are no longer in effect PAK ELAB AGU ATS Contact information is subject to change For the most current contact information visit our website at www fmctechnologies com measurementsolutions and click on the Contact Us link in the left hand column www fmctechnologies com measurementsolutions Integrated Measurement Systems Corpus Christi TX USA 1 361 289 3400 Kongsberg Norway 47 32 286700 Printed in U S A 4 15 FMC Technologies Measurement Solutions Inc All rights reserved MN03010 Issue Rev 0 3 4 15
14. l MNO6150 microLoad net 1 MNO6037 AccuLoad II I MN06135 AccuLoad III I MNO6140 AccuLoad III SA 1 MNO6143 AccuLoad III N4 1 Page 4 MNO3010 Issue Rev 0 3 4 15 Model 210 Valve I O S Manual Operation 2 Operation 2 1 Principle The Smith Meter Model 210 Valve Figure 1 fundamentally consists of a Smith Meter 200 Series Valve with two solenoid controls A valve response control device typically a needle valve is located between each solenoid and its respective upstream or down stream port This device is used to fine tune the opening closing rates of the valve as well as provide control loop isolation for easier control loop service Adjustment of these devices controls the flow rate to and from the cover chamber permitting valve adjust ments based on product viscosity and pressures O N C Solenoid Solenoid 30A Closing f 0 Opening Speed Speed Control Control Figure 1 Model 210 Valve Schematic The normally open N O and normally closed N C solenoids located in the upstream and downstream portions of the control loop respectively control the op eration of the valve When both solenoids are energized high upstream pressure is blocked from reaching the main valve cover the pressure in the cover vents to down stream lower pressure and the valve opens Conversely when both solenoids are deenergized the downstream control loop is blocked and high upstre
15. ndrepiace Fo ne solencisfategtociose Testandreplace FE Final tt on Preset Counter Replace or repar smion pF actas or maload bard defecive Testandreplace a ae strainer clogged Check stainer fs Downstream system pressure too igh A 210Vaveleakng nasar ama See AccuLoad Installation Manual Bulletin MN06135 See Veeder Root Installation Operation Service Manual 251278 Bulletin 8 015 Page 8 MNO3010 Issue Rev 0 3 4 15 Model 210 Valve I O S Manual Service and Maintenance 4 Service and Maintenance 4 1 4 2 4 3 4 4 4 5 The intent of this section is to illustrate proper service and provide maintenance interval guidelines of Smith Meter 210 digital control valves Service Maintenance Intervals The preset or device that is controlling the solenoids may be equipped with a means to count the number of solenoid actuations In the event that this is possible the following is a maintenance schedule for both upstream and downstream solenoid e At 250 000 actuations inspect and replace components as needed e At 500 000 actuations rebuild the solenoids e At 750 000 actuations inspect and replace components as needed e At 1 000 000 actuations replace the solenoids Inside the main valve the elastomers diaphragm stem O rings and poppet seal should be visibly inspected for cracks breakout and deterioration every 3 to 5 years under normal load rack conditions This guideline can be used a
16. ng This will allow the tubing to be somewhat flexible and will make installation simpler Once all tubing is in place secure tubing with an open ended wrench Ensure not to over tighten as this could crush the tubing and create a leak path Figure 36 Tubing Installation Issue Rev 0 3 4 15 MNO3010 Page 23 Model 210 Valve I O S Manual Service and Maintenance Figure 37 Tubing Installation Re wire solenoid connections Ensure to reference proper preset controller or PLC manuals for this process Once the valve is completely assembled refer to the Start up and Field Adjustments section for proper valve tuning procedure Issue Rev 0 3 4 15 MNO3010 Page 24 Model 210 Valve I O S Manual Service and Maintenance 5 Related Publications The following literature can be obtained from FMC Technologies Measurement Solutions Literature Fulfillment at measurement fulfillment fmcti com or online at www fmctechnologies com mesurementsolutions When requesting literature from Literature Fulfillment please reference the appropriate bulletin number and title Model 210 Digital Electro Hydraulic Set Stop Specifications e ee eee Bulletin SS03009 Issue Rev 0 3 4 15 MNO3010 Page 25 Revisions included in MNO3010 Issue Rev 0 3 4 15 Total Revision The specifications contained herein are subject to change without notice and any user of said specifications should verify from the manufactur
17. p edges warpage etc the diaphragm washer should be replaced Use caution when installing the washer and ensure not to gall the threads Figure 17 Diaphragm Washer Place a new diaphragm O ring around the stem Gently roll the O ring down the stem until it mates with the diaphragm washer and apply a light coat of petroleum jelly to the O ring Place the new diaphragm on the stem Use caution while pulling the diaphragm down the threads as to not fray the diaphragm It is recommended to install the diaphragm so that the part number and elastomer markings are visible from the top Issue Rev 0 3 4 15 MNO3010 Page 15 Model 210 Valve I O S Manual Service and Maintenance Figure 18 Diaphragm Install a new diaphragm O ring Use caution while pulling the O ring down the threads of the stem Figure 19 Diaphragm O ring Apply a light coating of petroleum jelly to the top diaphragm O ring and the stem Figure 20 Petroleum Jelly Application Page 16 MNO3010 Issue Rev 0 3 4 15 Model 210 Valve I O S Manual Service and Maintenance Inspect the upper diaphragm washer for any defects If none are present install the diaphragm washer If there are visible defects i e sharp edges warpage etc the diaphragm washer should be replaced Use caution when installing the washer and ensure not to gall the threads Figure 21 Upper Diaphragm Washer Using a fine file dress the surfa
18. rvice and Maintenance Figure 29 Stem Assembly Installation While the stem is lifted if the valve has been removed from the piping install the spring s over the stem against the backup plate Figure 30 Stem Assembly Installation If the valve has one spring install the spring over the stem If the valve has two springs install the taller spring over the stem seating the spring flat against the backup plate noting the orientation of the starting coil of the spring Place the shorter spring over the taller spring seating the spring against the backup plate Ensure that the shorter spring is oriented 180 degrees out of phase from the taller spring as shown above Figure 31 Spring s Installation Page 20 MNO3010 Issue Rev 0 3 4 15 Model 210 Valve I O S Manual Service and Maintenance Figure 32 Cover Installation With the stem still lifted if the valve has been removed from the piping install every other nut until pressure can be relived from the cover While tightening the nuts tuck the excess of the diaphragm under the rabbit of the cover DO NOT cut the excess off This can be done by using a screwdriver or a thin flat device Ensure not to punc ture the diaphragm Figure 33 Cover Installation Issue Rev 0 3 4 15 MNO3010 Page 21 Model 210 Valve I O S Manual Service and Maintenance Figure 34 Cover Installation Continue tightening the cover nuts by hand
19. s a starting point for elastomer inspection however it is essential for every customer to determine a unique maintenance plan based on experience as every application and installation will vary Recommended Spare Components Reference the appropriate valve parts list for recommended spare parts Tools Required Open ended wrenches Standard sockets Crescent wrench Manual torque wrench Pry bar Two flat headed screwdriver Caution Prior to any service ensure that the line has been completely drained and power has been removed from the solenoids Use proper protective equipment i e safety glasses gloves etc while servicing the equipment Document Sequence This document will follow a sequential flow of a description of the action followed by a picture of the action 210 Valve Service It is highly recommended to service the valve while in the horizontal plane If the valve is in the vertical plane this could cause misalignment of some of the compo nents if proper care is not taken If the valve is removed from piping place on a flat surface and use wedges to ensure the valve does not roll while servicing If the valve is not removed from the piping some of these steps may difficult to accomplish Disconnect all wiring to solenoids Remove tubing from valve and set aside The tub ing can be reused if in good condition Remove solenoids by turning the solenoid and fitting assembly in the counter clockwise direction
20. until they require a wrench and the rabbit of the cover completely covers the valve body Install the remaining nuts by hand As the nuts are being tightened check for gap uniformity of the valve body and cover Once the nuts are snug using a manual torque wrench tighten the nuts per the sequence as shown in the table and diagrams below Table 1 10 bolt 12 bolt 2 Inch 8 bolt 3 Inch 8 bolt 4 Inch 10 bolt 6 Inch 12 bolt Nominal Bolt 5 16 18 7 16 14 5 8 11 Size Rounda Hand ighten to snug Hand tighten to snug _ Hand ghtentosmug Round Tighten to 10felbs Tighten to 25 fos Tighten to5febs FRound 3 Tighten to20fuibs Tightento 45 fos Tighten to 90febs Rounds na O T OOOO Table 1 Cover Nut Torque Valves and Sequence Page 22 MNO3010 Issue Rev 0 3 4 15 Model 210 Valve I O S Manual Service and Maintenance If the valve has been removed from the piping the valve can be rested on the inlet or outlet flange to allow proper leverage Figure 35 Torque Cover Nuts Install the junction box and junction box bracket and install solenoids Note the position of the longer studs These are to be used for the junction box installation If solenoid fittings were removed or replaced lightly dress fitting threads with Loctite 565 thread sealant Reinstall the valve tubing The tubing can be reused if in good condition Install tubing by loosely securing the tubing fitting to the solenoid fitti
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