Emerson Digital Controller Valves 788 DVC Maintenance Instructions
Contents
1. 5 5 TROUBLESHOOTING ehh a Sg at ese ae dad a u eae 6 1 PARTS LIST d Aes Rega ie e ace alah eg Neo ite aba deste 7 1 TABLE OF CONTENTS i DANIEL MODEL 788DVC DIGITAL CONTROL VALVES DEC 2012 Figures 2 1 Closed POSIMOM sn s adus NEP REI QN Su us s 2 2 2 2 Control PS D PR Hace es 2 3 2 3 Open Position o Control uy anaku Ete bet e tuti bete d 2 4 3 1 Flow vs Pressure Dr Re Re 3 3 Dc DIMENSIONS idet soo de iut dotes Sanat te Se gy Sn 3 6 4 1 Typical Application Bottom Loading 4 4 4 2 Solenoid Actuation Adjustments 4 5 4 3 Control Valve Configuration new for DL8000 4 6 5 1 Using the Piston to Insert the Seat Ring into the 150 300 Ib Cylinder 5 3 5 2 Cylinder Assembly Removal sa Pat Ru nuire 5 4 5 3 Optom Assembly esie u e Se o ea pe Be e ce um a UN tre A 5 6 7 1 Valve Cylinder Assembly ed ess a eau sx due pea ad teh d ve 7 4 Tables 3 1 Solenoid Electrical Data 150 Ib MOPD 3 5 3 2 Maximum Working Pressure 42222 ERA EUR P a eC eb b Uo 3 5 3437 Dimensions ut taint t ed oed ue axe e s asua Date te dA aE kah dte nequi ns 3 7 5 Typical Opening Closing Speed2. 5 3 0 1 Troubleshooting 0095 swe tides a 6 2 T PAS we eget LR tle deba o dosi aed ok eee eae etal beh 7 2 li TABLE OF CONTENTS DANIEL MODEL 788DVC DIGITAL CONTROL VALVES DEC 2012 1 0 INTRODUCTION The Daniel Model 788DVC Digital Control Valve is a solenoid operated device designed to provide precise flow rate control and batch delivery of liquid products It is used in conjunction with an electronic batch control device such as the Daniel DL8000 The Model 788DVC valve is automatically controlled by the DanLoad for low flow start up high flow rate control low flow shut down and final shut off It also provides for maximum flow meter accuracy by maintaining a constant flow rate in applications with varying line pressure The Model 788DVC features an external pilot control loop that consists of a normally open solenoid pilot a normally closed solenoid pilot strainer and opening closing speed controls 1 1 Aggressive Products Some Daniel control valves have been equipped with an AP Aggressive Products cylinder assembly This cylinder assembly may be supplied as a direct replacement for existing units or may be supplied with the original order It is designed for all Daniel 2 3 4 and 6 150 300 Ib ANSI Series 700 Valves Spring loaded Teflon cup seals are utilized on the main body piston and low swell Nitrile O rings in static positions For specific instructions
3. Failure to comply with recommended could result in serious injury and or damage to the equipment e Lower the new cylinder assembly and cylinder head into the valve body Align the bolt holes in the cylinder head with the studs in the main valve body f Fasten the cylinder head into position using retaining nuts Tighten nuts alternating to opposite sides to assure a uniform seat g Return all tubing and or valve accessories to their original position 5 8 DISASSEMBLY AND REASSEMBLY DANIEL MODEL 788DVC DIGITAL CONTROL VALVES DEC 2012 6 0 TROUBLESHOOTING The most frequent problem encountered with any control valve is the accumulation of sediment rouge scale and other foreign material in the pilot or its supply system It is therefore good practice to periodically remove the pilot from the valve and inspect it for accumulation of these materials The strainer and needle valve in the pilot supply line should also be flushed periodically to avoid erratic control and slow response typical to obstructed flow If sub standard conditions persist after thoroughly cleaning the system examine the pilot for swollen o rings Periodic examination of all seal and o rings for nicks cuts and wear is recommended Reference Section 5 Cylinder Disassembly Reassembly TROUBLESHOOTING 6 1 DEC 2012 DANIEL MODEL 788DVC DIGITAL CONTROL VALVES Table 6 1 provides information for identifying and correcting operational problems you ma
4. N C 1 110 50 120 60 456800 612 456800 612 456800 612 456800 612 456800 612 220 50 240 60 456800 621 456800 621 456800 621 456800 621 456800 621 junction box a solenoid N O 110 50 120 60 456815 012 456815 012 456815 012 456815 012 456815 012 220 50 240 60 456815 022 456815 022 456815 022 456815 022 456815 022 E needle valve 460385 522 460385 522 460385 522 460385 522 460385 522 E strainer assembly 530245 530245 530245 530245 530245 indicator consult factory mounting screws consult factory cylinder assembly 520065 421 530065 421 640065 421 560065 421 580065 421 std Construction w Viton Dynamic O rings 12 cylinder head 1 520056 500 530056 500 540056 500 560056 500 580056 500 13 cylinder 1 520471 400 530471 400 540471 400 56047 1 400 580471 400 14 valve spring Std Med 5 10 psi 520029 530029 540029 560029 580029 light 4 6 psi 520031 530031 540031 560031 580031 heavy 10 30 psi 520059 530059 540059 560059 580059 15 piston 1 520084 600 150333 150333 150333 CF stainless steel 16 sealing ring 520026 500 152048 120 152048 120 152048 120 152048 120 retaining ring socket screw 151001 019 151001 019 151042 151042 151042 O ring Buna N 152073 152075 152078 157002 157005 O ring Viton 152073 022 152075 022 152078 022 157002 022 CF O ring EPR 152073 005 152075 005 152078 005 157002 005 CF O ring Buna N 152085 152100 152080 157003 157006 O ri
5. Notice is used to address safety messages or practices not related to personal injury A Safety alert symbol This is a safety alert symbol It is used to alert you to potential physical injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death This page intentionally left blank Notice THE CONTENTS OF THIS PUBLICATION ARE PRESENTED FOR INFORMATIONAL PURPOSES ONLY AND WHILE EVERY EFFORT HAS BEEN MADE TO ENSURE THEIR ACCURACY THEY ARE NOT TO BE CONSTRUED AS WARRANTIES OR GUARANTEES EXPRESSED OR IMPLIED REGARDING THE PRODUCTS OR SERVICES DESCRIBED HEREIN OR THEIR USE OR APPLICABILITY ALL SALES ARE GOVERNED BY DANIEL S TERMS AND CONDITIONS WHICH ARE AVAILABLE UPON REQUEST WE RESERVE THE RIGHT TO MODIFY OR IMPROVE THE DESIGNS OR SPECIFICATIONS OF SUCH PRODUCTS AT ANY TIME DANIEL DOES NOT ASSUME RESPONSIBILITY FOR THE SELECTION USE OR MAINTENANCE OF ANY PRODUCT RESPONSIBILITY FOR PROPER SELECTION USE AND MAINTENANCE OF ANY DANIEL PRODUCT REMAINS SOLELY WITH THE PURCHASER AND END USER TO THE BEST OF DANIEL S KNOWLEDGE THE INFORMATION HEREIN IS COMPLETE AND ACCURATE DANIEL MAKES NO WARRANTIES EXPRESSED OR IMPLIED INCLUDING THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE WITH RESPECT TO THIS MANUAL AND IN NO EVENT SHALL DANIEL BE LIABLE FOR ANY INCIDENTAL PUNITIVE SPECIAL OR CONSEQUENTIAL DAMAGES INCLUDING BUT NOT LIMITED TO LOSS OF PRODUCTION LOSS OF
6. http www daniel com Read and understand all instructions and operating procedures for this product If you do not understand an instruction or do not feel comfortable following the instructions contact your Daniel representative for clarification or assistance Install this product as specified in the INSTALLATION section of this manual per applicable local and national codes Follow all instructions during the installation operation and maintenance of this product Connect the product to the proper pressure sources when and where applicable Ensure that all connections to pressure and electrical sources are secure prior to and during equipment operation Use only replacement parts specified by Daniel Unauthorized parts and procedures can affect this product s performance safety and invalidate the warranty Look a like substitutions may result in deadly fire explosion release of toxic substances or improper operation Save this instruction manual for future reference Safety signal words and symbols Pay special attention to the following signal words safety alert symbols and statements DANGER Indicates a hazardous situation which if not avoided will result in death or serious injury Warning indicates a hazardous situation which if not avoided could result in death or serious injury Caution indicates a hazardous situation which if not avoided could result in minor or moderate injury NOTICE
7. NO EVENT SHALL DANIEL S LIABILITY TO BUYER AND ORITS CUSTOMERS EXTEND TO INCLUDE INCIDENTAL CONSEQUENTIAL OR PUNITIVE DAMAGES THE TERM CONSEQUENTIAL DAMAGES SHALL INCLUDE BUT NOT BE LIMITED TO LOSS OF ANTICIPATED PROFITS REVENUE OR USE AND COSTS INCURRED INCLUDING WITHOUT LIMITATION FOR CAPITAL FUEL AND POWER AND CLAIMS OF BUYER S CUSTOMERS DANIEL MODEL 788DVC DIGITAL CONTROL VALVES DEC 2012 1 0 2 0 3 0 4 0 5 0 6 0 7 0 TABLE OF CONTENTS INTRODUCTION St dus SOLIS TE T qa DOE 1 1 1 1 Aggressive POE dina td ER DAN 1 1 12 Principle of Operation desis sc ees aoa ub doa Aves lod tecum s 1 2 THEORY OF ORERA TION roe DM EXP IEEE nota a 2 1 2 1 Operational Sequence ux evo ped ea 2 1 SPECIFICATIONS 42255 wep e wags Sin eb D d pe Su ele qu epe areca 3 1 INSTALLATION AND MAINTENANCE 4 1 4 1 Recommended Installation Instructions 4 1 42 General Considerations as Applied to the DL8000 4 2 CYLINDER DISASSEMBLY AND REASSEMBLY 5 1 5 1 Cylinder Assembly Removal 5 1 5 2 Cylinder Disassembly ted nS ates eee RE SA Tu aa Ed 5 2 5 3 Cylind r Reassembly aret mens eve 5 4 5 4 Cup Seal Replacement on Existing Option Board
8. PROFITS LOSS OF REVENUE OR USE AND COSTS INCURRED INCLUDING WITHOUT LIMITATION FOR CAPITAL FUEL AND POWER AND CLAIMS OF THIRD PARTIES PRODUCT NAMES USED HEREIN ARE FOR MANUFACTURER OR SUPPLIER IDENTIFICATION ONLY AND MAY BE TRADEMARKS REGISTERED TRADEMARKS OF THESE COMPANIES DANIEL AND THE DANIEL LOGO ARE REGISTERED TRADEMARKS OF DANIEL INDUSTRIES INC THE EMERSON LOGO IS A TRADEMARK AND SERVICE MARK OF EMERSON ELECTRIC CO COPYRIGHT 2012 BY DANIEL MEASUREMENT AND CONTROL INC HOUSTON TEXAS U S A All rights reserved No part of this work may be reproduced or copied in any form or by any means graphic electronic or mechanical without first receiving the written permission of Daniel Measurement and Control Inc Houston Texas U S A Warranty and limitation of liability 1 LIMITED WARRANTY Subject to the limitations contained in Section 2 herein Daniel Measurement amp Control Inc Daniel warrants that the licensed firmware embodied in the Goods will execute the programming instructions provided by Daniel and that the Goods manufactured by Daniel will be free from defects in materials or workmanship under normal use and care and Services will be performed by trained personnel using proper equipment and instrumentation for the particular Service provided The foregoing warranties will apply until the expiration of the applicable warranty period Goods are warranted for twelve 12 months from the date of initial in
9. to Z port P2 is closed X port P1 and Y port P3 pressures are balanced The main valve spring being the differential force closes the piston and keeps it seated Position Indicator Flow Inlet Pressure M Outlet Pressure Figure 2 1 Closed Position 2 2 THEORY OF OPERATION DANIEL MODEL 788DVC DIGITAL CONTROL VALVES DEC 2012 OPEN CONTROL POSITION The normally closed solenoid is closed The normally open solenoid is closed Y Port P3 to Z port P2 is closed X port P1 to Y port P3 is closed The product cannot flow to or from the top of the piston The piston is hydraulically locked in position until the electronic preset commands the valve to open or close as required to maintain the desired high flow rate or low flow rate A eee ee mansa E eee Strainer Flow Inlet Pressure EM Outlet Pressure EM Controlled Pressure Figure 2 2 Open Control Position THEORY OF OPERATION 2 3 DEC 2012 DANIEL MODEL 788DVC DIGITAL CONTROL VALVES OPEN POSITION no control The normally closed solenoid is open The normally open solenoid is closed Y port P3 is open to Z port P2 X port P1 is closed off by the normally open solenoid The pressure on the bottom of the piston P1 is greater than the pressure at P3 plus the spring force P1 minus P2 is equal to or greater than the spring force Therefore P1 pressure pushes the piston open No flow control is r
10. 600 ANSI 250 F 1332 psig WP 600 ANSI 450 F 667 psig WP P N 16 29 to 66 C 16 bar WP P N 16 121 C 15 8 bar WP P N 16 232 C 13 7 psig WP P N 25 29 to 66 C 25 bar WP P N 25 121 C 24 7 bar WP P N 25 232 C 21 6 psig WP P N 40 29 to 66 C 40 bar WP P N 40 121 C 39 6 bar WP P N 40 232 C 34 4 bar WP P N 63 29 to 66 C 63 bar WP P N 63 121 C 62 4 bar WP P N 63 232 C 54 3 bar WP P N 100 29 to 66 C 100 bar WP P N 100 121 C 99 bar WP PIN 100 232 C 3 6 SPECIFICATIONS DANIEL MODEL 788DVC DIGITAL CONTROL VALVES DEC 2012 SOLENOID PILOT IN lt N A N O li p ea LO AN iii Pw MN pan No indicator With indicator Figure 3 2 Dimensions SPECIFICATIONS 3 7 DEC 2012 DANIEL MODEL 788DVC DIGITAL CONTROL VALVES Table 3 3 Dimensions see Figure 3 2 Valve B Size 150 ANSI ANSI any ANSI No With Indicator 260 mm 11 279 mm 330 mm gu de 432 mm ma 565 mm 3 8 SPECIFICATIONS DANIEL MODEL 788DVC DIGITAL CONTROL VALVES DEC 2012 4 0 INSTALLATION AND MAINTENANCE The most common application of the Daniel Model 788DVC Digital Control Valve is for truck loading of petroleum products The valve may be used with a variety of flow meter types including Coriolis and turbine meters as shown in Figure 4 1 In this installation the DL8000 is the primary batch and control device Reference Figure 4 2 and 4 3 for configuration information Flow m
11. 788DVC DIGITAL CONTROL VALVES DEC 2012 7 0 PARTS LIST Table 7 1 lists the replacement parts for 2 through 6 inch Model V2700 20 Series Control Valves The item numbers in the parts list Table 7 1 correspond with the sequence numbers in Figure 7 1 This section contains the necessary parts required to assemble any standard unit that is covered in this manual Recommended spare parts have been indicated using an asterisk before the item number All part numbers shown reflect standard materials of construction For other materials of construction special requirements or part numbers not listed consult the factory TRADEMARKS B Eve Daniel a division of Emerson Process Management Kalrez hn ose pais DEW RS E I du Pont de Nemours and Company TENON SoA See Oe aes E I du Pont de Nemours and Company VON Samed het E I du Pont de Nemours and Company When ordering replacement parts you must furnish the following information Valve serial number Part number if available Part description Quantity required To order replacement parts contact your Daniel sales representative PARTS LIST 7 1 DEC 2012 DANIEL MODEL 788DVC DIGITAL CONTROL VALVES Table 7 1 Parts List 2 3 4 6 8 Sizes Item Description Qty 2 inch 3 inch 4 inch 6 inch 8 inch valve body in line 1 521001 531001 541001 561001 581001 150 ANSI steel 2 solenoid
12. BLY AND REASSEMBLY DANIEL MODEL 788DVC DIGITAL CONTROL VALVES DEC 2012 5 4 2 To upgrade existing valves having the original option received prior to September 1992 the following parts have been supplied as a separate kit washers 29 Stat O Seals 30 one gasket 31 three O rings replaces existing O rings 3 and 4 of the same part numbers Reference Figure 7 1 for complete valve part numbers 5 4 3 To upgrade existing AP units supplied prior to September 1992 a Follow procedures described in Section 5 1 for general disassembly and Section 5 2 for Aggressive Products Cylinder disassembly b Replace O rings and install gasket Stat O Seal and washers as required reference Figure 7 1 Complete cylinder assembly by installing piston and all component parts through the top of the cylinder housing Do not attempt to install the piston through the seat area Attempts to assemble through the seat area will destroy the spring loaded Teflon cup seals d Secure cylinder assembly to cylinder heads using hand pressure or arbor press for ease of installation DISASSEMBLY AND REASSEMBLY 5 7 DEC 2012 DANIEL MODEL 788DVC DIGITAL CONTROL VALVES PERSONAL INJURY AND OR EQUIPMENT DAMAGE Caution is required when performing any disassembly procedure as the Cylinder head is bolted to a spring loaded cylinder assembly Service should only be performed by trained and qualified service personnel
13. E METER FLOW STRAIGHTENER Ha LS d STRAINER LI UE LINE J J GROUND LEVEL Figure 4 2 Typical Application Bottom Loading INSTALLATION AND MAINTENANCE 4 5 DEC 2012 DANIEL MODEL 788DVC DIGITAL CONTROL VALVES Normally Closed Pilot Normally Open Pilot Closing Speed Opening Speed Adjustment Adjustment Figure 4 3 Control Valve Configuration new for DL8000 46 INSTALLATION AND MAINTENANCE DANIEL MODEL 788DVC DIGITAL CONTROL VALVES DEC 2012 5 0 CYLINDER DISASSEMBLY AND REASSEMBLY The following tools will be needed to disassemble and reassemble your control valve socket wrench adjustable wrench T handle or extended Allen wrench arbor press may be needed for 4 and 6 inch valves retaining ring pliers Numbers in parentheses correspond with the item numbers in Table 7 1 and Figure 7 1 Read the entire recommended procedure for all installation operations and maintenance procedures before attempting to install or disassemble the valve Disassembly of this cylinder assembly is different from previous Daniel Control Valves and requires strict adherence to the procedures outlined in this manual EQUIPMENT DAMAGE Failure to read and comply with these procedures could result in damage to the equipment and compromise in the integrity of the operation 5 1 Cylinder Assembly Removal All Daniel Valves 1 Isolate the Control Valve from the system and bl
14. EL 788DVC DIGITAL CONTROL VALVES DEC 2012 5 4 Replacement on Existing AP Option Piston If your Daniel Valve is being modified to accommodate applications requiring the use of aggressive products used in petroleum blending operations the following procedures should be followed in retrofitting your valve Retrofit 5 4 1 To Replace Existing Standard Cylinder Assemblies with the Current Daniel AP Option a Remove original cylinder assembly as shown in Section 5 1 The cylinder assembly will be supplied from the factory with or without an indicator specified on order Clean and inspect O ring sealing surfaces in the main valve body Apply a lightweight lubricant to these surfaces before installing the new cylinder assembly Lower the new cylinder assembly and cylinder head into the valve body Align the bolt holes in the cylinder head with the studs in the main valve body Fasten the cylinder head into position using retaining nuts Tighten nuts alternating to opposite sides to assure a uniform seat Return all tubing and or valve accessories to their original position The cup seals 27 should be protected at all times against damage or distortion of any kind Proper installation dictates that cup seals 27 be installed with the closed ends facing in DISASSEMBLY AND REASSEMBLY 5 5 DEC 2012 DANIEL MODEL 788DVC DIGITAL CONTROL VALVES Figure 5 3 Option Assembly 5 6 DISASSEM
15. Operating and Maintenance Instructions Part Number 3 9008 556 Revision D December 2012 Daniel Model 788 DVC digital control valves 2 3 4 6 and 8 sizes EMERSON DANIEL Process Management This page intentionally left blank Important safety instructions Daniel Measurement and Control Inc Daniel designs manufactures and tests products to function within specific conditions Because these products are sophisticated technical instruments it is important that the owner and operation personnel strictly adhere both to the information printed on the product nameplate and to all instructions provided in this manual prior to installation operation and maintenance Daniel also urges you to integrate this manual into your training and safety program BE SURE ALL PERSONNEL READ AND FOLLOW THE INSTRUCTIONS IN THIS MANUAL AND ALL NOTICES AND PRODUCT WARNINGS Installing operating or maintaining a Daniel Product improperly could lead to serious injury or death from explosion or exposure to dangerous substances To reduce this risk Comply with all information on the product in this manual and in any local and national codes that apply to the product Do not allow untrained personnel to work with this product Use Daniel parts and work procedures specified in this manual Product owners Purchasers Use the correct product for the environment and pressures present See technical data product specifi
16. avity of 0 8 or greater multiply the pressure drop shown times the actual specific gravity This results in the actual pressure drop For specific gravities less than 0 8 use 0 8 to get the corrected pressure drop curves B C and D only PRESSURE LOSS 16 1832 3662 5494 7324 9156 11004 12818 14648 16478 18312 20144 21976 23808 25640 27473 29304 33043 12 998 1895 2993 3890 4988 5985 6983 7980 8977 9976 10974 11972 12970 13968 14967 15964 18001 10 698 1397 2095 2793 3491 4190 4888 5586 6284 6982 7680 8378 9076 9774 10472 11170 12575 8 445 889 1334 1778 2223 2668 3112 3557 4002 4447 4892 5337 5782 6227 6672 7117 7988 6 238 475 713 950 1188 1425 1663 1900 2183 2376 2614 2852 3090 3328 3566 3802 4241 4 106 214 320 428 534 641 748 855 961 1067 1173 1279 1385 1491 1597 1703 1905 3 65 128 193 257 321 385 449 513 577 641 705 769 833 897 961 1025 1147 2 29 57 86 114 143 171 200 228 256 285 314 342 370 398 427 456 530 FLOW GALLONS PER MINUTE 3 6 9 12 15 18 21 24 27 30 33 36 39 42 45 48 51 FLOW FEET PER SECOND Figure 3 1 Flow vs Pressure Loss SPECIFICATIONS 3 3 DEC 2012 DANIEL MODEL 788DVC DIGITAL CONTROL VALVES Materials of Construction Main Valve Body steel ASTM 352 LCC Cylinder Head steel ASTM 352 LCC Main Valve Cylinder steel nickel coated steel Main Valve Piston Standard stainless steel Seat Ring st
17. cations for limitations If you are unsure discuss your needs with your Daniel representative Inform and train all personnel in the proper installation operation and maintenance of this product To ensure safe and proper performance only informed and trained personnel should install operate repair and maintain this product Verify that this is the correct instruction manual for your Daniel product If this is not the correct documentation contact Daniel at 1 713 827 6314 You may also download the correct manual from http www daniel com If you resell or transfer this product it is your responsibility to forward this instruction manual along with the product to the new owner or transferee ALWAYS READ AND FOLLOW THE INSTALLATION OPERATIONS MAINTENANCE AND TROUBLESHOOTING MANUAL S AND ALL PRODUCT WARNINGS AND INSTRUCTIONS Do not use this equipment for any purpose other than its intended service This may result in property damage and or serious personal injury or death Product operation personnel To prevent personal injury personnel must follow all instructions of this manual prior to and during operation of the product Follow all warnings cautions and notices marked and supplied with this product Verify that this is the correct instruction manual for your Daniel product If this is not the correct documentation contact Daniel at 1 713 827 6314 You may also download the correct manual from
18. eed off pressure 2 Loosen and remove the tubing from the cylinder head 3 Remove the nuts securing the cylinder assembly within the valve body 4 Tighten the two jack screws provided in the cylinder head until the cylinder assembly has been freed from the valve body These screws should be tightened evenly to prevent damage to the cylinder O ring and binding the cylinder assembly 5 Remove the cylinder assembly from the valve body by pulling upward and evenly using both hands on smaller valves or a mechanical device for larger models 6 Remove the two jack screws from the cylinder head DISASSEMBLY AND REASSEMBLY 5 1 DEC 2012 DANIEL MODEL 788DVC DIGITAL CONTROL VALVES 5 2 Cylinder Disassembly Refer to Figure 5 2 PERSONAL INJURY AND OR EQUIPMENT DAMAGE Caution is required when performing any disassembly procedure as the Cylinder head is bolted to a spring loaded cylinder assembly Service should only be performed by trained and qualified service personnel Failure to comply with recommended could result in serious injury and or damage to the equipment 1 Position the cylinder assembly in an arbor press with the cylinder head 5 down Valves smaller than 6 may not require a press Larger units may require the use of a spindle or arbor press to facilitate removal of the piston assembly in which case the arbor should be resting against the cylinder head 2 Place a metal sleeve over the piston nose to protect t
19. eel nickel coated steel Seals steel O rings Standard Viton dynamic Buna N Optional EPR Kalrez Low Swell Nitrile Neoprene Viton A Viton GFLT Optional Visual position indicator Microswitch type indicator AP aggressive products option Pressure Temperature Ratings The maximum working pressure for the Model 700B Series Control Valve is based on temperature pressure rating of the ANSI B16 5 flanges The Table 3 2 lists the maximum working pressure of ASTM 352 LCC WCb at 100 F 3 4 SPECIFICATIONS DANIEL MODEL 788DVC DIGITAL CONTROL VALVES DEC 2012 Other Internal Parts stainless steel Pilot Valve Body and Trim stainless steel Tubing steel or stainless steel Table 3 1 Solenoid Electrical Data 150 Ib MOPD Current Inrush Current Holding 110 50 Vac 0 71 amps 0 37 amps 120 60 Vac 0 65 amps 0 34 amps 220 50 Vac 0 36 amps 0 19 amps 240 60 Vac 0 33 amps 0 17 amps DC voltage and 440 480 Vac upon request SPECIFICATIONS 3 5 DEC 2012 DANIEL MODEL 788DVC DIGITAL CONTROL VALVES Table 3 2 Maximum Working Pressure Pressure Temperature ASTM A352 LCC WCB 150 ANSI 20 to 100 F 285 psig WP 150 ANSI 150 F 272 psig WP 150 ANSI 250 F 245 psig WP 150 ANSI 450 F 185 psig WP 300 ANSI 20 to 100 F 740 psig WP 300 ANSI 150 F 707 psig WP 300 ANSI 250 F 665 psig WP 300 ANSI 450 F 334 psig WP 600 ANSI 20 to 100 F 1480 psig WP 600 ANSI 150 F 1415 psig WP
20. equired Solenoid N O Solenoid Needle Strainer Valve Flow EN z nlet Pressure LI Outlet Pressure Figure 2 3 Open Position no control 2 4 THEORY OF OPERATION DANIEL MODEL 788DVC DIGITAL CONTROL VALVES DEC 2012 3 0 SPECIFICATIONS PERSONAL INJURY AND OR EQUIPMENT DAMAGE Do not exceed specifications listed below Failure to heed this warning could result in serious injury and or damage to the equipment Pressure Class 150 1b 300 Ib or 600 Ib ANSI steel DIN PN 16 40 64 and 100 Safe Working Temperature Ranges Standard 20 F 29 C to 150 F 66 C Optional 20 F 29 C to 250 F 121 C Maximum Safe Working Pressure 150 Ib ANSI steel body 285 psi 1965 kPa 3001b ANSI steel body 740 psi 5100 kPa 600 Ib ANSI steel body 1480 psi 10 200 kPa DIN PN 16 16 bars DIN PN 25 25 bars DIN PN 40 10 bars DIN PN 64 64 bars DIN PN 100 100 bars Size 2 in 3 in 4 in 6 in 8 in Ratings UL and CSA Listed Class I Group C and D Div 1 Class Group E F and G Explosion Proof NEMA types 7C 7D 9E 9F and 9G 5 NEMA 4 Weather Proof ATEX 1120 Eexe Eexd SPECIFICATIONS 3 1 DEC 2012 DANIEL MODEL 788DVC DIGITAL CONTROL VALVES INMETRO Certification Certificate Number NCC 12 1244 X INMETRO Marking Ex d nC IIB T3 Gc Ex dIIC T Gb See Tables 1 and 2 in the certificate for temperature range details Special condi
21. for receipt installation and maintenance of Control Valves containing the AP Cylinder Assembly reference manual 3 9008 554 Also contained within this manual are complete instructions for retrofitting existing standard valves with the Option package If you have questions or need information not contained in this manual please contact your Daniel sales representative or the Daniel Measurement and Control service center nearest you INTRODUCTION 1 1 DEC 2012 DANIEL MODEL 788DVC DIGITAL CONTROL VALVES 1 2 Principle of Operation Operation of the Model 788DVC Digital Control Valve is based on a balanced piston principle When pressure on both sides of the main valve piston are equal a spring located on the top of the piston acts as a differential force and closed the main valve piston As pressure against the bottom of the piston increases and exceeds the pressure exerted against the top of the piston plus the force of the spring spring tension is overcome and the valve opens Solenoid pilots are digitally controlled full open or full closed and are used to determine the main valve piston position required for flow control Reference Figures 2 1 2 2 and 2 3 for valve opening closing positions Read the entire recommended procedure for all installation operations and maintenance procedures before attempting to install or disassemble the valve Disassembly of this cylinder assembly is different from previous Daniel Con
22. he sense line during removal This can be fabricated from a pipe section and should have an internal diameter large enough to encircle the piston nose The length must be sufficient to accommodate complete spring compression with allowing the sense line to strike the press plunger 3 Using EXTREME CAUTION depress the piston against the spring until the rectangular ports are cleared Block the piston in the open position fully compressed by inserting a suitable wedge through the port opening Any wood nylon or non marring dowel or handle that will safely guarantee piston position can be used for this operation It is recommended that a brass or other soft metal bar be used for this operation 4 Remove the retaining ring sealing ring and O ring X Using EXTREME CAUTION depress the piston against the spring and remove the piston blocks CAREFULLY remove the piston from the cylinder body while maintaining pressure on the valve spring 5 2 DISASSEMBLY AND REASSEMBLY DANIEL MODEL 788DVC DIGITAL CONTROL VALVES DEC 2012 6 Lift off the cylinder head by taking out the socket screws Remove and inspect all O rings for nicks cuts and wear Piston 4 Seat Ring 3 Cylinder 1 Figure 5 1 Using the Piston to Insert the Seat Ring into the 150 300 Ib Cylinder Table 5 1 Typical Opening Closing Speed Typical Recommended Low Flow Set point Typical Typical Typical Typical Line Dead Opening Openi
23. ible from the system before start up 4 2 General Considerations as Applied to the DL8000 Upon completion of the preliminary installation of the Digital Control Valve a Start up Adjustment Procedure must be administered Reference DL8000 Preset Controller Instruction Manual P N D301244X012 42 0 INSTALLATION AND MAINTENANCE DANIEL MODEL 788DVC DIGITAL CONTROL VALVES DEC 2012 The Daniel valve may be installed with a flow direction horizontal or vertical up but should never be installed with flow direction vertical down When installed in a horizontal line the valve should be installed so that the cylinder head is at the top of the valve and not the bottom See below PERSONAL INJURY OR DEATH AND OR PROPERTY DAMAGE Use equipment for its intended purpose Use of this equipment for any purpose other than its intended purpose may result in property damage and or serious personal injury or death INSTALLATION AND MAINTENANCE 4 3 DEC 2012 DANIEL MODEL 788DVC DIGITAL CONTROL VALVES MODEL 788DVC DIGITAL CONTROL VALVE WITH EXPLOSION PROOF HOOK UP POSITIVE DISPLACEMENT Figure 4 1 Typical Application Top Loading 44 INSTALLATION AND MAINTENANCE DANIEL MODEL 788DVC DIGITAL CONTROL VALVES DEC 2012 MODEL 788DVC DIGITAL SWIVEL Y CONTROL VALVE WITH EXPLOSION PROOF CONNECTION MR LOADING ARM FLOW STRAIGHTENER DL 8000 N PRESET PARITY TURBIN
24. ng Closing Closing Size Time Speed Time Speed Time Inches Setting Turbine PD Meter Adjust Shut off Adjust Full Seconds ment to Full ment Open to Open Seconds Open Seconds 2 3 100 50 100 100 4 150 25 150 25 6 150 25 150 25 8 150 25 150 25 DISASSEMBLY AND REASSEMBLY 5 3 DEC 2012 DANIEL MODEL 788DVC DIGITAL CONTROL VALVES 5 3 Cylinder Reassembly Refer to Figure 5 2 1 Inspect all O rings for wear and damage and replace as required 2 If removed attach the cylinder head to the main cylinder body 3 Insert the valve spring into the cylinder housing 4 Inspect and position the piston into the cylinder housing 5 Insert the fabricated sleeve over the valve piston and spring assembly Once fully compressed block the spring following the procedure used in step 3 of the Disassembly procedure 6 Inspect and reposition the seat O ring 7 Replace seating and retaining ring Once the entire retaining ring is in its groove position a punch or screwdriver over the end of the ring and tap sharply This will seat the ring 8 Again using CAUTION apply pressure to the valve piston and remove the block Carefully relieve the tension on the spring until it is properly resting against the seat ring 9 Reinstall the cylinder assembly in the valve body being careful to properly seat O rings and secure in place using lock nuts Figure 5 2 Cylinder Assembly Removal 5 4 DISASSEMBLY AND REASSEMBLY DANIEL MOD
25. ng Viton 152085 022 152100 022 152080 022 157003 022 CF O ring EPR 152085 005 152100 022 152080 005 157003 005 CF 7 2 PARTS LIST DANIEL MODEL 788DVC DIGITAL CONTROL VALVES DEC 2012 Item Description Qty 2 inch 3 inch 4 inch 6 inch 8 inch O ring Buna N 157079 150727 150727 O ring Viton 157079 022 157078 022 157061 022 2 O ring EPR 157079 005 157078 005 157061 005 CF 22 O ring Buna N 1 152067 152070 152070 CF O ring Viton 152067 022 152070 022 152070 022 CF O ring EPR 152067 055 152070 005 152070 005 CF 23 seal spacer 530028 152079 022 152079 022 152079 005 O ring Buna N 152061 152095 152094 O ring Viton 152061 022 152095 022 152094 022 O ring EPR 152061 005 152095 005 152094 005 Recommended Spare Parts PARTS LIST 7 3 DEC 2012 DANIEL MODEL 788DVC DIGITAL CONTROL VALVES Figure 7 1 Valve Cylinder Assembly 7 4 PARTS LIST Daniel Measurement and Control Inc Returned Material Authorization Repair Form for Used Equipment Including Decontamination Cleaning Statement A Return Material Authorization RMA number must be obtained prior to returning any equipment for any reason Download the RMA form from the Support Services web page by selecting the link below http www2 emersonprocess com EN US BRANDS DANIEL SUPPORT SERVICES Pages Support Services aspx 1 Return Material Authorization RMA Number 2 Equipment to be re
26. rint name Title Date Company Phone Fax Emerson Process Management Daniel Measurement and Control Inc 11100 Brittmoore Park Drive Houston TX 77041 T 1 713 467 6000 F 1 713 827 4805 www emerson com Copyright 2012 Daniel Measurement and Control Inc and Daniel Measurement Services Inc Divisions of Emerson Process Management reserve the right to make changes to any of its products or services at any time without prior notification in order to improve that product or service and to supply the best product or service possible Daniel Measurement Services Inc offers both on call and contract maintenance service designed to provide single source responsibility for all Daniel products The sales and service offices of Daniel Measurement and Control Inc are located throughout the United States and in major countries overseas For the location of the sales or service office nearest you telephone the number below or visit the Daniel Measurement and Control Inc website T 1713 827 6314 F 1713 827 4805 www emerson com
27. riting in advance by Daniel All costs of dismantling reinstallation and freight and the time and expenses of Daniel s personnel and representatives for site travel and diagnosis under this warranty clause shall be borne by Buyer unless accepted in writing by Daniel Goods repaired and parts replaced by Daniel during the warranty period shall be in warranty for the remainder of the original warranty period or ninety 90 days whichever is longer This limited warranty is the only warranty made by Daniel and can be amended only ina writing signed by Daniel THE WARRANTIES AND REMEDIES SET FORTH ABOVE ARE EXCLUSIVE THERE ARE NO REPRESENTATIONS OR WARRANTIES OF ANY KIND EXPRESS OR IMPLIED AS TO MERCHANTABILITY FITNESS FOR PARTICULAR PURPOSE OR ANY OTHER MATTER WITH RESPECT TO ANY OF THE GOODS OR SERVICES Buyer acknowledges and agrees that corrosion or erosion of materials is not covered by this warranty 2 LIMITATION OF REMEDY AND LIABILITY DANIEL SHALL NOT BE LIABLE FOR DAMAGES CAUSED BY DELAY IN PERFORMANCE THE REMEDIES OF BUYER SET FORTH IN THIS AGREEMENT ARE EXCLUSIVE IN NO EVENT REGARDLESS OF THE FORM OF THE CLAIM OR CAUSE OF ACTION WHETHER BASED IN CONTRACT INFRINGEMENT NEGLIGENCE STRICT LIABILITY OTHER TORT OR OTHERWISE SHALL DANIEL S LIABILITY TO BUYER AND OR ITS CUSTOMERS EXCEED THE PRICE TO BUYER OF THE SPECIFIC GOODS MANUFACTURED OR SERVICES PROVIDED BY DANIEL GIVING RISE TO THE CLAIM OR CAUSE OF ACTION BUYER AGREES THAT IN
28. stallation or eighteen 18 months from the date of shipment by Daniel whichever period expires first Consumables and Services are warranted for a period of 90 days from the date of shipment or completion of the Services Products purchased by Daniel from a third party for resale to Buyer Resale Products shall carry only the warranty extended by the original manufacturer Buyer agrees that Daniel has no liability for Resale Products beyond making a reasonable commercial effort to arrange for procurement and shipping of the Resale Products If Buyer discovers any warranty defects and notifies Daniel thereof in writing during the applicable warranty period Daniel shall at its option correct any errors that are found by Daniel in the firmware or Services or repair or replace F O B point of manufacture that portion of the Goods or firmware found by Daniel to be defective or refund the purchase price of the defective portion of the Goods Services Allreplacements or repairs necessitated by inadequate maintenance normal wear and usage unsuitable power sources or environmental conditions accident misuse improper installation modification repair use of unauthorized replacement parts storage or handling or any other cause not the fault of Daniel are not covered by this limited warranty and shall be at Buyer s expense Daniel shall not be obligated to pay any costs or charges incurred by Buyer or any other party except as may be agreed upon in w
29. tem generally consists of three pieces of equipment 1 a flowmeter 2 electronic preset with digital control and 3 a digital electric control valve The electronic preset is the device used to set the predetermined volume of liquid that is to be delivered by the valve 2 1 Operational Sequence With both solenoids de energized the main valve is closed as shown in Figure 2 1 The main valve can be infinitely positioned anywhere between 0 100 open by digital control of the solenoids With both solenoids energized as shown in Figure 2 3 the valve begins to open It will only open to the programmed flow rate set in the electronic preset Normally the electronic preset is programmed to digitally control low flow start up maximum flow rate low flow rate before shut off and no flow The electronic preset will automatically energize and de energize the solenoids to position the main valve to limit the required flow rate When the required flow rate is reached the solenoids will be as shown in Figure 2 2 This hydraulically locks the main valve piston in position Should flow increase the valve will close slightly to adjust to the required flow rate All of the positioning is done by digitally controlling the two solenoids as shown in Figure 2 1 2 2 and 2 3 THEORY OF OPERATION 2 1 DEC 2012 DANIEL MODEL 788DVC DIGITAL CONTROL VALVES CLOSED POSITION The normally closed solenoid is closed The normally open solenoid is open Y port P3
30. tion for safe use When the digital control valve is assembled with solenoid models 80174 80173 80143 80144 HP80143 8014G2 and F8003G1 the temperature of the process fluid must not be greater than 40 C Connections 2 through 6 ANSI flanged Valve Capacity uc RE RET Cv based on valve full open using water at 60 F 16 C For Valve Flow vs Pressure Loss see Figure 3 1 Consult manual 3 9008 550 Capacity Charts for valve sizing Flow vs Pressure Drop See Figure 3 1 Curve A Wide open valves with no spring resistance Applicable to pilot operated valves with Y and Z ports vented to sump atmosphere or pump station Curve B Light main valve spring Applies only to On Off valves rate of flow control valves and check valves with ANSI 150 to 300 Ib flanges Curve C Medium main valve spring Applies to all modulating control valves except rate of flow and valves using ANSI 600 Ib flanges Curve D Heavy main valve spring Applies to all valves using ANSI 600 Ib flanges 3 2 SPECIFICATIONS DANIEL MODEL 788DVC DIGITAL CONTROL VALVES DEC 2012 The main valve is full open when curves B C and D intersect Curve A After they intersect continue reading pressure drop curve from curve A In applications requiring a constant pressure drop over 40 psid a heavy main valve spring must be used Curves A B C and D are based on water specific gravity 1 0 For liquids having a specific gr
31. trol Valves and requires strict adherence to the procedures outlined in this manual EQUIPMENT DAMAGE Failure to read and comply with these procedures could result in damage to the equipment and compromise in the integrity of the operation 1 2 INTRODUCTION DANIEL MODEL 788DVC DIGITAL CONTROL VALVES DEC 2012 2 0 THEORY OF OPERATION The Model 700B Series Control Valve operates on a balanced piston principle When pressures on both sides of the piston are equalized a spring located on top of the piston acts as a differential force and closes the piston When the pressure against the bottom of the piston exceeds the pressure plus the force of the spring exerted against the top of the piston spring tension is overcome and the valve opens See Figure 3 1 for more information These valves are normally closed N C and they will open when both solenoids are energized The valves are fail safe as they close upon loss of power They use the line product as the source of hydraulic power to open and close the main valve piston An electrical supply controlled by an electronic preset is the source of power for energizing the two solenoids These valves are used mainly for batching and they provide a means of reducing the rate of flow on on startup and before final shut off of a predetermined delivery This minimizes surges of pressure and line shock and assures 1 4 gallon shut off sizes 2 inch 8 inch of the preset volume The total sys
32. turned Model Number Serial Number 3 Reason for return Decontamination Cleaning Fluids Process A List each substance in which the equipment was exposed Attach additional documents if necessary Common CAS if Used for Hazardous EPA Waste Code Name available Waste 20 CFR 261 if used for hazardous waste Yes No 1 Yes No 1 Yes No 1 Yes No 1 Yes No Yes No Circle any hazards and or process fluid types that apply Infectious Radioactive Explosive Pyrophoric Poison Gas Cyanides Sulfides CorrosiveOxidizer Flammable Poison Carcinogen Peroxide Reactive Air Reactive Water Reactive Other list Other hazard category list Describe decontamination cleaning process Include MSDS description for substances used in decontamination and cleaning processes Attach additional documents if necessary Shipping Requirements Failure to comply with this procedure will result in the shipment being refused 1 Write the RMA number on the shipping package 2 Inside the package include one copy of this document and all required Material Safety Data Sheets MSDS 3 Outside of the package attach one copy of this document and all required Material Safety Data Sheets MSDS THIS EQUIPMENT BEING RETURNED FOR REPAIR HAS BEEN COMPLETELY DECONTAMINATED AND CLEANED ALL FOREIGN SUBSTANCES HAVE BEEN DOCUMENTED ABOVE AND MSDS SHEETS ARE ATTACHED By Signature P
33. ust be horizontal or vertical up but never vertical down 4 1 Recommended Installation Instructions As with all control valves it is most important that proper installation be accomplished if the valve is to operate as designed Preliminary set up should include the following steps 1 Evaluate the metering system in the process line to determine that criteria pertinent to digital valve control is met Minimum meter K factor 20 pulses unit Minimum meter pulse frequency low flow 50 Hz Minimum opening time shut off to full open 1 5 seconds Minimum closing time full open to shut off 1 5 seconds 2 Reference engineering drawings for proper in line sequence of all components 3 Check valve position The inlet flange has been marked and is to be in the upstream position 4 Verify all electrical connections against wiring diagrams and unit specifications Reference Figure 4 3 for Control Valve configuration INSTALLATION AND MAINTENANCE 4 1 DEC 2012 DANIEL MODEL 788DVC DIGITAL CONTROL VALVES It is recommended that the external pump control be turned to the OFF position when performing any electrical wiring installation and until initial control valve adjustments are made in the DL8000 EQUIPMENT DAMAGE Failure to comply with these procedures could result in damage to the equipment and compromise in the integrity of the operation 5 Flush the line of any and all contaminates 6 Bleed as much atr as poss
34. y experience with your control valve Please keep in mind this information is not exhaustive and that system abnormalities may result from causes other than valve error This information is provided to assist in general field repairs Table 6 1 Troubleshooting Condition Probable Cause Correction Pump is not operating Valve will not open Start pump and check for cavitation Downstream valve is closed Open valve Check coupler on bottom loading units and internal valve in truck Insufficient pressure Check pump Check bypass and strainer in line Swollen o rings Disassemble valve and replace o rings Check compatibility of o rings with product Pilot malfunction Consult pilot manual Valve opens too slowly Valve inlet pressure below normal Check strainer and pump for obstruction Swollen o rings Disassemble valve and replace o rings Check compatibility of o rings with product Pilot malfunction Consult pilot manual Valve will not close off tightly Bent indicator stem Replace indicator Foreign material lodged in main Disassemble valve and inspect piston valve piston seat Swollen o rings Disassemble valve and replace o rings Check compatibility of o rings with product Piston or seat o ring cut or Disassemble valve and replace if defective necessary Pilot malfunction Consult pilot manual 6 2 TROUBLESHOOTING DANIEL MODEL
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