Crystallizer Valve — Quick Reference
← Crystallizer Wiring ⌂ FIELD MANUAL
← FIELD MANUAL CH.03 CRYSTALLIZER VALVE SYSTEM — QUICK REFERENCE REF-03-B 01 FILL VALVE SPRING-RETURN FAIL CLOSED ATO — Air-to-Open ZSO + ZSC feedback Butterfly type Controls dextrose IN 120VAC solenoid Lose air = closes 02 DROP VALVE GATE DOUBLE-ACTING AIR BOTH WAYS Port A=open B=close 5/2 solenoid valve No fail-safe position Controls crystals OUT Load cell mounted below 03 DIVERT VALVE 3W 3-WAY VALVE ROUTE A or B De-energized = Path A Energized = Path B Spring-return actuator Routes dextrose flow Rotary actuator type 05 CONTROL VALVE I/P MODULATING 4-20mA CONTROL I/P positioner 3-15 PSI output Feedback linkage Controls flow rate Globe or butterfly body 04 ISOLATION MANUAL BALL VALVE LOTO CAPABLE Full open in operation Close + lock for maint NEVER bypass LOTO Flanged, removable Quarterly cycle check // QUICK FIELD FACTS AIR PRESSURES Supply to solenoids 80–120 PSI Minimum to operate 20 PSI Positioner range 3–15 PSI Normal supply 30 PSI ELECTRICAL Solenoid supply 120VAC Good coil resistance 85–120 Ω Shorted coil under 10 Ω Open/burned coil infinite Ω DISCRETE SIGNALS ZSO — valve OPEN 120VAC ON ZSC — valve CLOSED 120VAC ON Mid-travel both Both OFF Both ON same time WIRING FAULT WESTLOCK CAM Type 1700 Series Switch type SPDT micro To adjust cam Loosen set screw Most common fault Cam slipped on stem PLANT Process temp 70–80°C Cycle time ~2 hrs Fouling risk HIGH Clean interval Monthly // FAULT LOOKUP — SYMPTOM → FIRST CHECK SYMPTOM MOST LIKELY CAUSE FIRST CHECK Sequence stuck at valve step ZSO or ZSC not confirming Watch HMI DI — check Westlock cam Valve won't open at all No 120VAC to solenoid or no air Solenoid LED lit? Then check air PSI Product dripping from discharge valve Worn gate seal or buildup Inspect sealing face, replace gasket Control valve hunting or oscillating Positioner gain or linkage loose Recalibrate positioner, check linkage Fill valve won't close end of cycle Spring worn or product in packing Manual override test, check spring Solenoid clicking, valve not switching Low air pressure or fouled spool Check supply PSI at valve body port All crystallizer valves same fault Air header pressure drop Check main air header gauge first Solenoid coil very hot or burned Shorted coil or wrong voltage Ohm test — under 10Ω = short, replace Both ZSO and ZSC showing ON Wiring short or backfeed Disconnect wires one at a time to isolate // INSTRUMENTATION FIELD MANUAL — CH.03 CRYSTALLIZER VALVE 03_Crystallizer_Valve/Crystallizer_Quick_Reference.svg
← Wiring & Troubleshooting // CH.03