Warren Controls 1800 User Manual
INSTALLATION, OPERATION
& MAINTENANCE INSTRUCTIONS
Series 18OO
Heavy Globe control valves
TABLE OF CONTENTS
Overview ....................................... Cover
Valve Information ................................ 2
Information Present on Valve ..........3-4
Body vs. Application ........................... 5
Dimensions & Weights .....................6-7
Installation ........................................8-9
Maintenance ...................................... 10
Packing Adjustment .......................... 10
Parts/Overhaul .................................. 10
Parts Kits ......................................11-13
Drawings ......................................14 -21
PRODUCT OVERVIEW
This document covers the installation, operation and maintenance
of the Series 1800 Heavy Globe Control Valves presented in the
“Series 1800 Product Specication”, including the 1840 Two-Way
Single Seat Unbalanced Valve, the 1843 Two-Way Single Seat
Cylinder Balanced Valve, the 1850 Three-Way Mixing/ Diverting
Valve, and the 1852 Three-Way Diverting/ Mixing Valve. Warren
Controls Series 1800 Heavy Globe Control Valves feature rugged
high capacity bodies of iron, steel, or stainless steel with a variety
of trim materials and port sizes. The equal percentage and linear
plugs in the 2-way valves and linear plugs in the 3-way valves
provide excellent modulating control of a wide variety of uids.
The Series 1800 is ideally suited where value and long life are
important objectives for applications including but not limited to
the Chemical, District Energy, Food & Beverage, General Service,
Marine, Power, and Rening industries with temperatures from
-20 to 800ºF, severe service, high pressure drops, and corrosive
uids.
GENERAL INFORMATION
The instructions given herein cover generally the operation and
maintenance of subject equipment. Should any questions arise
which may not be answered specically by these instructions,
they should be referred to Warren Controls Inc. for further detailed
information and technical assistance. This manual cannot possibly
cover every situation connected with the operation, adjustment,
inspection, test, overhaul and maintenance of the equipment
furnished. Every eort is made to prepare the text of this manual
so that engineering and design data is transformed into the most
easily understood wording. Warren Controls Inc., in furnishing this
equipment and this manual, must presume that the operation and
maintenance personnel assigned thereto have sucient technical
knowledge and experience to apply sound safety and operational
practices which may not be covered herein. In applications where
Warren Controls Inc. furnished equipment is to be integrated
with a process or other machinery, these instructions should be
thoroughly reviewed to determine the proper integration of the
equipment into the overall plant operational procedures. Warren
Controls does not assume responsibility for the selection, use, or
maintenance of any product. Responsibility for proper selection,
use, and maintenance of any Warren Controls product remains
solely with the purchaser and end-user
ACTUATORS AND ACCESSORIES
Series 1800 Heavy Globe Control Valves are available with
a variety of actuators and accessories. These actuators and
accessories have separate instructions. For complete control
valve installation, operation, and maintenance instructions see
also the instructions for the actuator and accessories in use.
VALVE IDENTIFICATION
To use these instructions it is necessary to identify the conguration of the valve. Factory assembled control valves have a
nameplate mounted on the actuator. The valve’s part number (P/N) is present on the plate. The part number represents the
conguration of the control valve. To identify the valve’s type, size, actuator, accessories, and other characteristics decode the
part number using conguration table. If the information is incomplete, incorrect, or not present contact the factory with the
valve serial number listed on the plate. (See Information Present on Control Valves section for location of part number, serial
number, and other important information on valve.)
VALVE BODY
Model
Valve
Type
Size
Body
Material
End
Connection
Trim Style Trim Material Trim Cv
Packing
Type
Bonnet
Construction
18H 2” - 4” Bodies
Diaphragm:
84” or 115”
Cylinder: 6”
or 8”
18J 6” - 12” Bodies
Diaphragm: 115”
Cylinder: 8” or
18K
1/2” - 1 1/2”
Bodies
Diaphragm: 84”
12”
40 2-Way,
Single Seat
43 2-Way
CageBalanced
50 3-Way
Mixing
52 3-Way
Diverting
050 1/2 inch
075 3/4 inch
100 1 inch
150 1-1/2 inch
200 2 inch
250 2-1/2 inch
300 3 inch
400 4 inch
600 6 inch
800 8 inch
010 10 inch
012 12 inch
ACTUATOR
Actuator
Action
Spring Range
Series
00 None
DIAPHRAGMS:
84 DL84
(84 Sq.In.)
8X DL84XR
15 DL115
(115 Sq.In.)
5X DL115XR
CYLINDERS:
C2 6” Spring Fail
(for 18H)
C3 8” Spring Fail
(for 18H)
C4 8” Spring Fail
(for 18J)
C5
12” Spring
Fail
(for 18J)
FAILURE MODES:
MODE VALVE TYPE ACTUATOR ACTION
Closed 40/43 Reverse
Open 40/43 Direct
Upper Closed* 50/52 Direct
Upper Open 50/52 Reverse
*Standard
0 None
R Reverse
Stem
Fail Down
D Direct
Stem
Fail Up
0 None or
Cylinder
L Low
3-9psi R/D
F Full
3-15psi R/D
H High
9-15 psi R/D
X Xtra-High
DL115XR
W WCB
F CF8M
R Cast Iron
F 125/150 lb.
Flanged
G 250/300 lb.
Flanged
E Equal %
L Linear
Types
50/52
Linear only
ACCESSORIES
Handwheel Positioners, I/P’s & Limit Switches
0 None
R Reverse
D Direct
0000
None
POSITIONERS:
BxP_ BLX Pneumatic
BxE_ BLX ElectroPneumatic
BxI_ BLX ElectroPneu. Intrn. Safe
BxX_ BLX ElectroPneu. Exp. Proof
BxF_ BLX ElectroPneu. Fail Freeze
76P_ Moore760 Pneumatic
76E_ Moore760 Electro-Pneumatic
Siemens PS2 Electro-Pneumatic
P24_
P2H
Siemens
P2P_
P2F_
PX11 Mark 1 Series - 2 ea. SPDT
PX12 Mark 1 Series - 2 ea. SPDT w/2k Pot.
PX13 Mark 1 Series - 2 ea. SPDT w/4-20 Feedback
PX14 Mark 1 Series - 4 ea. SPDT
PX15 Mark 1 Series - 6 ea. SPDT
I/P’s Use with Diaphragm Only
MAP1 Type 500X I/P, 3-9 PSI
MAP2 Type 500X I/P, 9-15 PSI
MAP3 Type 500X I/P, 3-15 PSI
MAP4 Type 500X I/P, 1-17 PSI
MAP5 Type 500X I/P, 6-30 PSI
MAP6 Type 550X I/P, 0-30 PSI
MAP7 Type 550X I/P, 0-60 PSI - For 15 or 5X only
MAP9 Type 950X I/P, 3-15 EXP
PS2 2,3,4 Wire HART
Siemens PS2 PROFIBUS PA
Siemens
PS2 FOUND. FIELDBUS
PROXIMITY SWITCHES:
x digit spec.
F Full Range Signal,
3-15 PSI or 4-20mA
L Low of Split Range,
3-9 PSI or 4-12mA
H High of Split Range,
9-15 PSI or 12-20mA
0 No Additions
L w/Mech. Lmt Swtch’s
F w/4-20 Feedback
B w/Swtch’s &
Feedback
NOTE:
L,F,B not available
S 316 SS
6 Alloy 6
Wrapped
4th digit spec.
F Full Port
1 1st Port
2 2nd Port
3 3rd Port
Air Filter
Regulators
0 None
A
Type 300,
0-30 PSI,
B
Type 300,
0-60 PSI
C
Type 300,
0-120 PSI,
D
Type 350SS,
0-100 PSI
Reduction
Reduction
Reduction
T Teflon
G Graphite
ASCO
Solenoids
0 None
120 VAC COILS
A 8320G184
3-Way Brass
B 8320G202
3-Way SS
J 8342G1
4-Way Brass
K 8342G701
4-Way SS
L EF8320G184
3-Way EXP
M EF8320G202
3-Way EXP
V EF8342G1
4-Way
EXP
W
EF8342G701
4-Way EXP
24 Vdc COILS
Z 8320G184
3-Way Brass
S 450 Tmax
x 800F Tmax
w/Ext. Bonnet
Special
Options
0 None
S Special
or Set-up
T SS Tubing
G SS Tagging
B SS Tubing
and Tagging
Br.
SS
Br.
SS
Opts
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2
INFORMATION PRESENT ON CONTROL VALVES
There is a great deal of information present on each control valve ranging in importance from the part number and serial
number to the color of the paint and casting numbers. This information is important for identifying the valve, installing it
correctly, and obtaining parts. Examples of the current factory nameplates and flow arrow plates used on Series 1800
control valves are shown here. The accompanying table identifies the information present and where to find it on the
control valve. There may also be other casting numbers and foundry marks present that do not provide useful information.
Customer specific tagging may also present. The plates used, and information present, on Warren Controls other product
lines or older valves may be different, contact the factory for details.
ACTUATOR NAMEPL ATES
DL84 DL115 & CL
FLOW ARROW PLATES
2-WAY FLOW
3-WAY MIXING 3-WAY DIVERTING
VBA NAME PL ATES
INDUSTRIAL VBA
3-WAY MIXING
AS DIVERTING
3-WAY DIVERTING
AS MIXING
Series 1800 IOM1800 A 1209
3
INFORMATION PRESENT ON CONTROL VALVE SERIES 1800
Part Number & Serial Number
Information Symbol(s) Location Notes
Part number
(Configuration)
P/N On
actuator
• On Actuator Nameplate attached to leg(s) of actuator.
Serial number S/N On
actuator
and
valve body
Flow Direction(s)
Information Symbol(s) Location Notes
Flow direction
through valve
Port locations
for 3-way valves
Input Signal & Supply
Information Symbol(s) Location Notes
Input signal SIG On
Supply pressure SUP or
Valve Attributes
Information Symbol(s) Location Notes
Maximum
temperature rating
of valve body
U upper
port,
L lower
port,
C common
port
SUPPLY
TMAX or
Tma x
On valve
body
On valve
body
actuator
On
actuator
On
actuator
and
valve body
• On Actuator Nameplate attached to leg(s) of actuator.
• Sales order number only stamped on top of valve body bonnet.*
* Number stamped using approximately 1/8 inch tall characters
• On Flow Arrow Plate attached to valve body bottom port
flange (1800 3-way) between the end connections.
•
Arrow cast on valve body between the end connections (1800 2-way).
• On Flow Arrow Plate attached to valve body bottom port
flange (1800 3-way) between the end connections.
• On Actuator Nameplate attached to leg(s) of actuator.
• On Actuator Nameplate attached to leg(s) of actuator.
• On Actuator Nameplate attached to leg(s) of actuator.
• On Industrial VBA Nameplate attached to valve body bonnet
flange between the end connections on side opposite flow arrow
plate.
Tri m Cv
(Flow coefficient)
Trim style
(Characteristic)
Trim material TRIM MATL On valve
Valve body
material
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4
Cv On valve
body
CHAR On valve
body
body
On valve
body
• On Industrial VBA Nameplate attached to valve body bonnet
flange between the end connections on side opposite flow arrow
plate.
• On Industrial VBA Nameplate attached to valve body bonnet
flange between the end connections on side opposite flow arrow
plate.
• On Industrial VBA Nameplate attached to valve body bonnet
flange between the end connections on side opposite flow arrow
plate.
• If the factory applied paint is black the valve body material is
iron. If WCB is cast on the valve, and or the factory applied paint
is gray, the valve body material is steel. If CF8M is cast on the
valve the valve body material is 316 stainless steel.
BODY STYLE VERSUS APPLICATION
Stem Down
The upper port opens
and the lower port closes
Upper PortLower Port
Common Port
Stem Up
The upper port closes
and the lower port opens
Upper Port Lower Port
Common Port
Flow
Stem Down
The upper port opens
and the lower port closes
Upper PortCommon Port
Lower Port
Flow
Flow
Flow
Stem Up
The upper port closes
and the lower port opens
Upper Port Common Port
Lower Port
Flow
Stem Down
The upper port opens
and the lower port closes
Upper PortCommon Port
Lower Port
Flow
Flow
Flow
Stem Up
The upper port closes
and the lower port opens
Upper Port Common Port
Lower Port
Flow
Stem Down
The upper port opens
and the lower port closes
Upper PortLower Port
Common Port
Flow
Flow
Stem Up
The upper port closes
and the lower port opens
Upper Port Lower Port
Common Port
Flow
Stem Down
The valve closes
Stem Up
The valve opens
Stem Down
The upper port opens
and the lower port closes
Upper PortCommon Port
Lower Port
Flow
Flow
Flow
Stem Up
The upper port closes
and the lower port opens
Upper Port Common Port
Lower Port
Flow
Flow
Flow
Stem Down
The valve closes
Stem Up
The valve opens
2-Way Valves (Control of Liquids, Gases, and Steam)
1840 Two-Way Single Seat Unbalanced Valve
The most commonly applied solution with ANSI Class IV shut-off.
Sizes: 6, 8, 10, 12 inch (See 5840 for smaller sizes)
Body:
WCB Steel or CF8M Stainless Steel 150LB Flange or
300LB Flange (6 thru 12)
Trim: EQ% or Linear, 316 Stainless Steel or Alloy 6
Packing: TFE V-Ring, Spring Loaded (+32 to 450°F)
Adjustable Graphite (+32 to 500°F)
Adjustable Graphite w/Extension Bonnet (+32to 800°F)
Temperature: +32 to 350°F (125 FLG)
Rangeability: 50:1
Stem Down
Flow direction is reversed when used with Cylinder Actuator Fail Closed.
ANSI B16.1 Iron 125LB Flange or 250LB Flange (6 thru 10)
+32 to 400°F (250 FLG)
+32 to 800°F (150 or 300 FLG)
Stem Up
Flow
The valve opens
Flow
The valve closes
3-Way Valves (Control of Liquids)
1850 Three-Way Mixing Valve
This valve has two inlets and one outlet, and is the simplest solution
for
mixing
applications the inlet pressures are near equal and control is possible from
5% to 95% of travel with inlet pressures up to 300 PSI. In the 1/2 through 2
inch sizes, the flow can be reversed for diverting if this port configuration is
desirable.
Sizes: 1/2, 3/4, 1, 1-1/2, 2, 2-1/2, 3, 4, 6, 8, 10, 12 inch
Body:
WCB Steel or CF8M Stainless Steel 150LB Flange or
300LB Flange (1/2 thru 12)
Trim: Linear, 316 Stainless Steel
Packing: TFE V-Ring, Spring Loaded ( +32 to 450°F)
Adjustable Graphite (+32 to 500°F)
Temperature: +32 to 350°F (125 FLG)
+32 to 400°F (250 FLG)
+32 to 800°F (150 or 300 FLG)
Rangeability: 30:1 (sizes 1/2 thru 2)
50:1 (sizes 2-1/2 thru 12)
or bypass applications with ANSI Class IVshut-off. In normal
ANSI B16.1 Iron 125LB Flange or 250LB Flange (8 thru 12)
Adjustable Graphite w/Extension Bonnet (+32 to
Stem Down
Upper PortCommon Port
Flow
Stem Up
Upper Port Common Port
Flow
800°F)
1843
Valve
A balanced valve that is an effective solution for higher pressures.
It requires less force to operate than unbalanced valves so smaller
Two-Way Single Seat Cylinder Balanced
actuators can be used. Its single seat o-ring seal design facilitates
ANSI Class IV shut-off. It is limited to cleaner fluids.
Sizes: 6, 8, 10, 12 inch (See 5843 for smaller sizes)
Body: ANSI B16.1 Iron 125LB Flange or 250LB Flange
WCB Steel or CF8M Stainless Steel 150LB Flange or
300LB Flange
Trim: EQ% or Linear, 316 Stainless Steel or Alloy 6
Packing: TFE V-Ring, Spring Loaded ( +32 to 450°F)
Adjustable Graphite ( +32 to 500°F)
O-Ring: Fluoraz 797
Temperature: +32 to 350°F (125 FLG)
+32 to 400°F (250 FLG)
+32 to 500°F (150 or 300 FLG)
Rangeability: 50:1
Stem Down
FlowFlow
The valve closes
Flow direction is reversed when used with Cylinder Actuator Fail Closed.
Stem Up
The valve opens
Flow
Lower Port
The upper port opens
and the lower port closes
Flow
Lower Port
The upper port closes
and the lower port opens
1852 Three-Way Diverting/Mixing Valve
Designed as a diverting valve with one inlet and two outlets with ANSI
Class II shut-off. However, flow can be reversed for mixing if this port
configuration is desirable. The difference between the upper port and lower
port pressure must not exceed 50PSID.
Sizes: 2-1/2, 3, 4, 6, 8, 10, 12 inch
Body:
WCB Steel or CF8M Stainless Steel 150LB Flange or
300LB Flange (2-1/2 thru 12)
Trim: Linear, 316 Stainless Steel or Alloy 6
Packing: TFE V-Ring, Spring Loaded (+32 to 450°F)
Adjustable Graphite (+32 to 500°F)
O-Ring: Fluoraz 797 (2-1/2 thru 4)
EPR (6 thru 12)
Temperature: +32 to 150°F (125 or 250 FLG, 8 thru 12)
+32 to 500°F (150 or 300 FLG, 2-1/2 thru 4)
+32 to 150°F (150 or 300 FLG, 6 thru 12)
Rangeability: 50:1
Upper PortLower Port
ANSI B16.1 Iron 125LB Flange or 250LB Flange (8 thru 12)
Stem Down
Common Port
The upper port opens
and the lower port closes
Stem Up
Upper Port Lower Port
Flow
Common Port
The upper port closes
and the lower port opens
Series 1800 IOM1800 A 1209
5
Body Pressure-Temperature Ratings:
Temperature
(F)
+32° To 100° 175 400 285 740 275 720
150° 175 400 272 710 255 670
175° 170 385 266 695 245 645
200° 165 370 260 680 235 620
225° 155 355 252 673 230 605
250° 150 340 245 667 225 590
275° 145 325 237 661 220 575
300° 140 310 230 655 215 560
325° 130 295 222 650 210 548
350° 125 280 215 645 205 537
375° - 265 207 640 200 526
400° - 250 200 635 195 515
450° - - 185 620 182 497
500° - - 170 605 170 480
550° - - 155 587 155 465
600° - - 140 570 140 450
650° - - 125 550 125 440
700° - - 110 530 110 435
750° - - 95 505 95 425
800° - - 80 410 80 420
Pressure ratings are PSIG
For applications below 32º consult factory
125 FLG
Iron
250 FLG
Iron
150 FLG
Steel
300 FLG
Steel
150 FLG
St Steel
300 FLG
St Steel
Trim Materials
316 Stainless Steel 100 PSID
Alloy 6 300 PSID
Flowing
Differential
Pressure Limit
DIMENSIONS & WEIGHTS
2-WAY
3-WAY
Valves shown with DL84 Actuator as typical.
For additional actuator information see Series 1800 Product Specification and the
Installation Operation and Maintenance Instructions for the actuator in use.
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6
DIMENSIONS & WEIGHTS
2-WAY
Dimension (IN) 1840 Valve Size (IN)
6 8 10 12
A
B 11-7/8 13-3/4 15-1/4 15-1/4
C
Weight (LB)
125 or 150FLG 17-3/4 21-3/8 26-1/2 29
250 or 300FLG 18-5/8 22-3/8 27-7/8 30-1/2
Standard 13-7/8 15-1/4 16-1/8 17
Extension Bonnet 17-5/8 CF CF CF
Standard 390 650 1160 CF
Extension Bonnet 400 CF CF CF
Dimension (IN) 1843 Valve Size (IN)
6 8 10 12
A
B 11-7/8 13-3/4 15-1/4 15-1/4
C 14-1/2 15-7/8 16-3/4 17-3/4
Weight (LB) 455 760 1360 CF
Face to face dimensions conform to ANSI/ISA S75.03
CF = Consult factory
Actual Shipping Weights May Vary
125 or 150FLG 17-3/4 21-3/8 26-1/2 29
250 or 300FLG 18-5/8 22-3/8 27-7/8 30-1/2
3-WAY
Dimension (IN) 1850 Valve Size (IN)
1/2 3/4 1 1-1/2 2 2-1/2 3 4 6 8 10 12
A
B
C
Weight (LB)
Dimension (IN) 1852 Valve Size (IN)
A
B
C 9-1/2 10-1/4 11 14-1/2 15-7/8 16-3/4 17-3/4
Weight (LB) 140 210 390 545 900 1600 CF
125 or 150FLG 7-1/4 7-1/4 7-1/4 8-3/4 10 10-7/8 11-3/4 13-7/8 17-3/4 21-3/8 26-1/2 29
250 or 300FLG 7-1/2 7-5/8 7-3/4 9-1/4 10-1/2 11-1/2 12-1/2 14-1/2 18-5/8 22-3/8 27-7/8 30-1/2
125 or 150FLG 6-1/2 6-1/2 6-1/2 6-1/4 10 10-1/4 11-1/4 13-7/8 15-7/8 17-3/4 21-1/8 20-3/8
250 or 300FLG 6-5/8 6-3/4 6-3/4 6-1/2 10-1/4 10-5/8 11-5/8 14-1/8 16-1/4 18-1/4 21-3/4 21-1/8
Standard 5-1/2 5-1/2 5-1/2 6-1/8 8-1/8 8-7/8 9-5/8 10-3/8 13-7/8 15-1/4 16-1/8 17
Extension Bonnet CF CF CF CF CF CF 14-5/8 CF 17-5/8 CF CF CF
Standard CF CF CF CF CF 140 210 390 545 900 1600 CF
Extension Bonnet CF CF CF CF CF CF 215 CF 555 CF CF CF
2-1/2 3 4 6 8 10 12
125 or 150FLG 10-7/8 11-3/4 13-7/8 17-3/4 21-3/8 26-1/2 29
250 or 300FLG 11-1/2 12-1/2 14-1/2 18-5/8 22-3/8 27-7/8 30-1/2
125 or 150FLG 10-1/4 11-1/4 13-7/8 15-7/8 17-3/4 21-1/8 20-3/8
250 or 300FLG 10-5/8 11-5/8 14-1/8 16-1/4 18-1/4 21-3/4 21-1/8
Face to face dimensions conform to ANSI/ISA S75.03
CF = Consult factory
Actual Shipping Weights May Vary
Series 1800 IOM1800 A 1209
7
INSTALLATION
See also separate actuator and accessory
instructions for additional installation guidelines.
• Be sure that the flow medium, ambient temperature and the selected
location will not exceed the maximum temperature of the valve, actuator,
or accessories. Information can be found in the product specifications
and on the nameplate(s) regarding these limits (See Information Present
on Control Valves section for location of important information on valve).
• Follow good piping practices. Install a bypass around the valve. Install
stop valves in inlet and outlet piping to provide means to isolate valve.
• A straight run of pipe is recommended for 10 pipe diameters upstream
of the valve and 20 pipe diameters downstream of the valve.
• Protect valve and downstream equipment with a self-cleaning strainer.
•
Provide proper inlet and outlet drainage in steam service to prevent water hammer or possible erosion in equipment.
• Install gauges in inlet and outlet piping to provide means for checking adjustment and operation.
• For maximum efficiency and minimum wear install valve in vertical position with the stem pointing upward.
• Actuators mounted in any position other than vertical must be supported independent of the valve.
!
transportation. Immediately
notify your sales organization
of any damaged goods upon
receipt. Do not attempt to move
or disturb the valve further so
photos may be taken. If the
shipping container is noticeably
damaged refuse receipt, as
the shipping company should
be held liable until a shipping
representative is available to
take photos.
Check valve for any
damage due to
improper storage or
VERTICAL BELOW PIPING
Position is suitable for gases, but
NOT
for liquids or steam.
VERTICAL ABOVE PIPING IS
CORRECT MOUNTING POSITION.
All other positions reduce service life of equipment.
NEXT BEST POSITION
45º from vertical above piping on either side.
Valve must have an 8 Bolt Flange.
A non-vertical mounting position may be necessary
to protect actuator in high temperature applications,
but may reduce packing life.
WORST POSITION
DL84 Actuators mounted in any position other than
vertical
MUST
(Horizontal on either side).
be supported independent of the valve.
OPTION A:
Hanger Cable
DO NOT MOUNT DL115 ACTUATORS IN
!
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8
THE HORIZONTAL POSITION
OPTION B: L’s with U-BOLTS
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