Operating and Maintenance Instructions Part N um ber- 3-9008-556 Revision D Decem ber 2012 DanielTM 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.
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. 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.
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.
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Notice THE CONTENTS OF THIS PUBLICATION ARE PRESENTED FOR INFORMATIONAL PURPOSES ONLY, AND W HILE EVERY EFFORT H AS BEEN MADE TO ENSURE THEIR ACCURACY, THEY ARE NOT TO BE CONSTRUED AS W ARRANTIES 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. W E RESERVE THE RIGHT TO MODIFY OR IMPROVE THE DESIGNS OR SPECIFICATIONS OF SUCH PRODUCTS AT ANY TIME.
Warranty and limitation of liability 1. LIM ITED W ARRANTY: Subject to the limitations contained in Section 2 herein, Daniel Measurement & Control, Inc.
DANIELTM MODEL 788DVC DIGITAL CONTROL VALVES D E C 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 . . . . . . . . . . . . . . . . . . . . . .
D E C 2012 DANIELTM MODEL 788DVC DIGITAL CONTROL VALVES Figures 2-1 2-2 2-3 3-1 3-2 4-1 4-2 4-3 5-1 5-2 5-3 7-1 Closed Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Open - Control Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Open Position (no control) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Flow vs Pressure Drop . . .
DANIELTM MODEL 788DVC DIGITAL CONTROL VALVES 1.0 D E C 2012 INTRODUCTION The DanielTM 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.
DANIELTM MODEL 788DVC DIGITAL CONTROL VALVES D E C 2012 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.
DANIELTM MODEL 788DVC DIGITAL CONTROL VALVES 2.0 D E C 2012 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.
D E C 2012 DANIELTM 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.
DANIELTM MODEL 788DVC DIGITAL CONTROL VALVES D E C 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.
D E C 2012 DANIELTM 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 required. Figure 2-3.
DANIELTM MODEL 788DVC DIGITAL CONTROL VALVES 3.0 D E C 2012 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 lb., 300 lb., or 600 lb. 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 lb.
DANIELTM MODEL 788DVC DIGITAL CONTROL VALVES D E C 2012 INMETRO Certification: Certificate Number: INMETRO Marking: NCC 12.1244 X Ex d nC IIB T3 Gc Ex d IIC T* Gb *See Tables 1 and 2 in the certificate for temperature range details. Special condition 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.
DANIELTM MODEL 788DVC DIGITAL CONTROL VALVES D E C 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 gravity of 0.8 or greater, multiply the pressure drop shown times the actual specific gravity.
D E C 2012 DANIELTM 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 steel 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/
DANIELTM MODEL 788DVC DIGITAL CONTROL VALVES D E C 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 lb. MOPD) Voltage* 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.
DANIELTM MODEL 788DVC DIGITAL CONTROL VALVES D E C 2012 Table 3-2.
DANIELTM MODEL 788DVC DIGITAL CONTROL VALVES D E C 2012 Figure 3-2.
DANIELTM MODEL 788DVC DIGITAL CONTROL VALVES D E C 2012 Table 3-3. Dimensions (see Figure 3-2) Valve Size A 150# ANSI A 300# ANSI B1 No Indicator B2 With Indicator C 2" 10-1/4" 10-1/2" 9" 11" 8.25" 260 mm 267 mm 229 mm 279 mm 210 mm 11" 11" 9" 12" 8-3/4" 279 mm 333 mm 229 mm 305 mm 222 mm 13" 13" 9" 12-1/2" 9" 330 mm 368 mm 229 mm 318 mm 229 mm 17" 17" 12" 15-3/4" 11" 432 mm 454 mm 305 mm 400 mm 279 mm 22.25" 22.25" 15" 17.5" 11.
DANIELTM MODEL 788DVC DIGITAL CONTROL VALVES 4.0 D E C 2012 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.
DANIELTM MODEL 788DVC DIGITAL CONTROL VALVES D E C 2012 EQUIPMENT DAMAGE 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. 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.
DANIELTM MODEL 788DVC DIGITAL CONTROL VALVES D E C 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.
D E C 2012 DANIELTM MODEL 788DVC DIGITAL CONTROL VALVES Figure 4-1.
DANIELTM MODEL 788DVC DIGITAL CONTROL VALVES D E C 2012 Figure 4-2.
D E C 2012 DANIELTM MODEL 788DVC DIGITAL CONTROL VALVES Figure 4-3.
DANIELTM MODEL 788DVC DIGITAL CONTROL VALVES 5.0 D E C 2012 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.
DANIELTM MODEL 788DVC DIGITAL CONTROL VALVES D E C 2012 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.
DANIELTM MODEL 788DVC DIGITAL CONTROL VALVES 6. Lift off the cylinder head by taking out the socket screws. 7. Remove and inspect all O-rings for nicks, cuts and wear. D E C 2012 Figure 5-1. Using the Piston to Insert the Seat Ring into the 150/300 lb. Cylinder Table 5-l. Typical Opening/Closing Speed Line Size Inches 2-3 4 6 8 Typical Dead Time Setting (Seconds) 0.015 0.015 0.030 0.
DANIELTM MODEL 788DVC DIGITAL CONTROL VALVES D E C 2012 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.
DANIELTM MODEL 788DVC DIGITAL CONTROL VALVES 5.4 D E C 2012 Cup-seal 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.
D E C 2012 DANIELTM MODEL 788DVC DIGITAL CONTROL VALVES Figure 5-3.
DANIELTM MODEL 788DVC DIGITAL CONTROL VALVES 5.4.2 D E C 2012 To upgrade existing valves having the original “AP” 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.
DANIELTM MODEL 788DVC DIGITAL CONTROL VALVES D E C 2012 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. 5-8 e. Lower the “new” cylinder assembly and cylinder head into the valve body.
DANIELTM MODEL 788DVC DIGITAL CONTROL VALVES 6.0 D E C 2012 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.
D E C 2012 DANIELTM MODEL 788DVC DIGITAL CONTROL VALVES Table 6-1 provides information for identifying and correcting operational problems you may 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 Valve will not open Upstream valve is closed. Open valve.
DANIELTM MODEL 788DVC DIGITAL CONTROL VALVES 7.0 D E C 2012 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.
DANIELTM MODEL 788DVC DIGITAL CONTROL VALVES D E C 2012 Table 7-1. Parts List - 2", 3", 4", 6", 8" Sizes Item Description Qty 2-inch 3-inch 4-inch 6-inch 8-inch 1 valve body - in line 150 ANSI steel 1 521001 531001 541001 561001 581001 2 solenoid (N.C.) 110/50, 120/60 220/50, 240/60 1 456800-612 456800-621 456800-612 456800-621 456800-612 456800-621 456800-612 456800-621 456800-612 456800-621 3 junction box 1 4 solenoid (N.O.
DANIELTM MODEL 788DVC DIGITAL CONTROL VALVES D E C 2012 Item Description Qty 2-inch 3-inch 4-inch 6-inch 8-inch 21 O-ring/Buna-N O-ring/Viton® O-ring/EPR 1 ------- 157079 157079-022 157079-005 150727 157078-022 157078-005 150727 157061-022 157061-005 CF CF CF 22 O-ring/Buna-N O-ring/Viton® O-ring/EPR 1 ------- 152067 152067-022 152067-055 152070 152070-022 152070-005 152070 152070-022 152070-005 CF CF CF 23 seal spacer 530028 ---- ---- ---- 24 O-ring/Buna-N O-ring/Viton® O-r
D E C 2012 DANIELTM MODEL 788DVC DIGITAL CONTROL VALVES Figure 7-1.
DanielTM 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.
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.
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