Emerson Digital Controller Valves 788 DVC User Manual

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

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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 or product specifications 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 on, and supplied with, this product.

• 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:

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 is used to address safety messages or practices not related to personal injury.

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.

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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, W HICH 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 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 TRADEM ARKS 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.

BY DANIEL MEASUREMENT AND CONTROL, INC.

HOUSTON, TEXAS, U.S.A.

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, D aniel Measurement & 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 installation 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 Goo ds/Services. All replac ements or repairs necessitated by inadequate maintenance, normal wear and usage, unsuitab le 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 writing 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 in a 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 NO EVENT SHALL DANIEL’S LIABILITY TO BUYER AND/OR ITS 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

TABLE OF CONTENTS

1.0 INTRODUCTION ..................................................... 1-1

1.1 Aggressive Products.............................................. 1-1

1.2 Principle of Operation ............................................ 1-2

2.0 THEORY OF OPERATION ............................................. 2-1

2.1 Operational Sequence ............................................ 2-1

3.0 SPECIFICATIONS .................................................... 3-1

4.0 INSTALLATION AND MAINTENANCE.................................. 4-1

4.1 Recommended Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4.2 General Considerations as Applied to the DL8000 . . . . . . . . . . . . . . . . . . . . . . 4-2

5.0 CYLINDER DISASSEMBLY AND REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

5.1 Cylinder Assembly Removal ....................................... 5-1

5.2 Cylinder Disassembly ............................................ 5-2

5.3 Cylinder Reassembly ............................................. 5-4

5.4 Cup-Seal Replacement on Existing “AP” Option Board . . . . . . . . . . . . . . . . . . 5-5

6.0 TROUBLESHOOTING................................................. 6-1

7.0 PARTS LIST ......................................................... 7-1

TABLE OF CONTENTS i

DEC 2012 DANIEL MODEL 788DVC DIGITAL CONTROL VALVES

Figures

2-1 Closed Position ....................................................... 2-2

2-2 Open - Control Position ................................................. 2-3

2-3 Open Position (no control)............................................... 2-4

3-1 Flow vs Pressure Drop.................................................. 3-3

3-2 Dimensions .......................................................... 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 lb. Cylinder . . . . . . . . . . . . . 5-3

5-2 Cylinder Assembly Removal ............................................. 5-4

5-3 Option Assembly ...................................................... 5-6

7-1 Valve Cylinder Assembly ............................................... 7-4

Tables

3-1 Solenoid Electrical Data (150 lb. MOPD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

3-2 Maximum Working Pressure............................................. 3-5

3-3 Dimensions .......................................................... 3-7

5-1 Typical Opening/Closing Speed .......................................... 5-3

6-1 Troubleshooting ...................................................... 6-2

7-1 Parts List ............................................................ 7-2

TABLE OF CONTENTSii

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 lb. 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 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 “AP” 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.

EQUIPMENT DAMAGE

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.

Failure to read and comply with these procedures could result in damage to the equipment and compromise in the integrity of the operation.

INTRODUCTION1-2

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 system 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) 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.

Figure 2-1. Closed Position

THEORY OF OPERATION2-2

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.

Figure 2-2. Open - Control Position

THEORY OF OPERATION 2-3

+ 33 hidden pages

Emerson Digital Controller Valves 788 DVC User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual