Model Series 63UL Differential Type Flow
Contents
1. Siemens Energy amp Automation INSTALLATION AND SERVICE INSTRUCTION SD63UL Rev 9 July 2006 Supersedes Rev 8 Model Series 63UL Differential Type Flow Controller INTRODUCTION The 63UL Controller is used in conjunction with an external needle valve to provide constant volume flow rates for either liquids or gases over a continuously adjustable flow range In gas service the 63U is used when the upstream pressure is constant to provide a constant mass flow rate i e standard volume units per time unit e g SCFM In gas systems where the downstream pressure is constant a 63D is used Constant upstream pressure is not needed for constant volume flow rates i e volume units per time unit e g CFM With liquids both mass and volumetric flow rates are held constant regardless of up or downstream pressures This instruction has eight major sections Introduction Installation Principle of Operation Capacity Operation Maintenance Warranty and Parts List Model Designation 63 B U L Constant Differential Flow Controller Body Construction B Brass Neoprene Diaphragm S Stainless Steel Kynar Diaphragm Used with Constant Upstream Pressure Very Low Flow Rates Specifications Note Series 63DL shown Series 63UL is similar Supply Pressure Minimum sesers At least 5 psig greater than the maximum downstream pressure of the needle valve controller combination MaXiM2. external needle valve clean Any change in the rate of flow for a given needle valve setting will probably be caused by partial clogging of the needle valve CAUTION A Before disassembling the instrument turn off supply air pressure to the instrument Failure to obtain minimum flows will probable be caused by solids on the controller valve plunger It will be necessary to disassemble the 63_U model controller to remove the plunger valve Refer to the Parts List for the model at hand for component location SD63UL Table 1 Flow Capacity Formulas Higher Range Low Flow Models 63BD and 635D Models 63BD L and 63SD L 63BU and 63SU 63BU L and 63SU L GAS FLOW CAPACITY SCCM 4000 AP xPd x530 SCCM 400 ar xPd x 530 SG T SG T SCCM 200 Pu a x530 SG T SCCM 8 AP Pu Pd Approximately 1 200 of maximum RvT Maximum CCM 47 oP Vic CCM 06 AP Rv For any liquid For any gos Critical flow exists when the ratio of upstream pressure Pu to Rangeability and minimum controllable flow of each size depend downstream pressure Pd is equal to or less than approximately upon the needle valve used the specific gravity of the fluid the 0 53 operating pressures and other factors The formulas permit calculation of maximum flows for both the Pd 3 aie lt 0 53 low flow and higher range models Because minimum flows Pu occur in a laminar pattern with the low flow models a separate formula
3. is furnished Rangeability is considerably higher on The actual ratio value for air is 0 528 it should be noted that it gases than on liquids varies slightly for other gases FLOW RANGE EXAMPLES SCCM Cubic centimeters per minute of gas at standard condi i o i a Conditions tions 70 F 14 7 psia Note 1 SCF 28 317 SCC 15 psig 29 7 psia at inlet of controller AP psi pressure drop across the controller valve total 10 psi drop across controller not including 3 psi needle drop minus 3 psi valve drop Pu psia pressure at inlet of controller allow 3 psi for drop 70 F process temperature across the needle valve if it is installed upstream me Fi Pd psia pressure at outlet of controller allow 3 psi for drop Max Flow mr more across the needle valve if it is installed downstream Higher range units Series 63 Pn psia pressure at outlet of needle valve On air 56 000 scc min 280 scc min gt a 3 mi Ti mi SG Specific gravity of the gas referred to air or specific Orcos 1 500 co min een gravity of the liquid referred to water at 4 C Low range units Series 63L s yE z On air 5 600 scc min scc min T Absolute temperature of the gas degrees F 460 On water 146 ce min 0 6 6e min Rv Ratio of viscosities of gas referred to air or Ratio of viscosities of liquid at operating temperature to water at 4c Kn Flow constant of needle valve SD63UL Product Support This section provid
4. UM ossessi See the table below Needle Valve Model Open Closed 63BU 250 psig 50 psig 63BU L 250 psig 50 psig 63SU 500 psig 100 psig 63SU L 500 psig 50 psig Ambient Temperature Limits Models 63BU amp 63BU L 40 to 180 F 40 to 82 C Models 63SU amp 63SU L 40 to 250 F 40 to 120 C SD63UL INSTALLATION Shipping and Storage If the controller is to be stocked stored or shipped to another location prior to piping make sure that the factory installed plastic plugs are in the ports to prevent entry of moisture dirt or other contaminants Mounting Mounting dimensions and the locations and sizes of connections are shown on the installation drawing see Figure 1 The controller may be mounted in any position Install the needle valve and feedback connections as close to the controller as possible to minimize pressure drop between these points The supply to the controller must be filtered to remove any solids CAUTION When installing the constant upstream controller be sure the external needle valve is open see Figure 1 Failure to do this could result in applying a differential pressure across the diaphragm of the flow controller in excess of its rate limit thus causing the diaphragm to rupture Blow out all piping before connections are made to prevent the possibility of dirt or chips entering the controller Use pipe sealant sparingly and then only on the male thread
5. ause it to fail The requirements for a quality instrument air supply can be found in the Instrument Society of America s Quality Standard for Instrument Air ISA S7 3 Basically this standard calls for the following Particle Size Maximum particle size in the air stream at the instrument should be no larger than 3 microns 2 SD63UL Dew Point The dew point at line pressure should be at least 10 C 18 F below the minimum temperature to which any part of the instrument air system is exposed at any season of the year Under no circumstances should the dew point at line pressure exceed 2 C 35 6 F Oil Content Maximum total oil or hydrocarbon content exclusive of non condensable should not exceed 1 ppm under normal operating conditions o 1 3 16 9 32 DIA MOUNTING HOLES SUPPLY NEEDLE VALVE k I OUTPUT Note 378 1 All connections are 1 4 N P T 2 Unless otherwise specified needie valve and all piping supplied by customer Figure 1 Installation Dimensions PRINCIPLE OF OPERATION If the pressure drop across a restriction is held constant the volume flow through the restriction is constant refer to Figure 2 on the next page The needle valve a variable restriction can be set to an opening which will produce the desired flow rate The pressure drop AP across the needle valve is held constant by the flow controller as follows 1 The input pressure P1 is a
6. es the Internet site addresses e mail addresses telephone numbers and related information for customers to access Siemens product support When contacting Siemens for support e Please have complete product information at hand For hardware this information is provided on the product nameplate part number or model number serial number and or version For most software this information is given in the Help gt About screen e If there is a problem with product operation Is the problem intermittent or repeatable What symptoms have been observed What steps configuration changes loop modifications etc were performed before the problem occurred What status messages error messages or LED indications are displayed What troubleshooting steps have been performed Is the installation environment e g temperature humidity within the product s specified operating parameters For software does the PC meet or exceed the minimum requirements e g processor memory operating system e A copy of the product Service Instruction User s Manual or other technical literature should be at hand The Siemens public Internet site see the table has current revisions of technical literature in Portable Document Format for downloading e To send an instrument to Siemens for repair call Repair Service and request a Return Material Authorization RMA IMPORTANT An instrument must be thoroughly cleaned decontamina
7. m No Part No Description Req d 3 2938 1 O Ring 1 4 10746 10 Bottom Forging 1 wS 10917 24 Valve Seat 1 1518 5 Differential Spring 1 7 2881 9 Top Forging 1 10746 2 Diaphragm and Valve Assembly 1 9 1 4 Lockwasher 6 10 Screw 1 4 20 x 3 4 Lg Fil Hd 3 11 Screw 1 4 20 x 5 8 Lg Fil Hd 3 1 12 1145 19 Mounting Bracket IMPORTANT Service Parts Kits are available for servicing the instrument Contact Siemens for available kits refer to the Product Support section of this instruction Some parts in this Parts List may not be available for separate purchase Recommended on hand spare parts Always specify range serial number or other nameplate information when ordering spare parts SD63UL PARTS LIST Siemens Constant Differential Flow Controller for Small Flows Model 63SU L Part No 12041 23 2938 120 12046 9 12041 42 Screw Screw 1145 19 esti A a IA d za a 2 Description Protecting Ring seg Ring Bottom Forging Valve Seat Differential Spring Diaphragm and Valve Assembly Top Housing Assembly 1 4 Lockwasher 1 4 20 x 1 1 4 Lg Soc Hd 1 4 20 x 1 Lg Soc Hd Mounting Bracket o G LD O mta t iwi IMPORTANT Drawing 12046PL Rev 3 78 B M 12046S11 Service Parts Kits are available for servicing the instrument Contact Siemens for available kits refer to the Product Support section of this instruction Some parts in this Parts Lis
8. nonconformity in the goods Buyer agrees that these remedies provide Buyer and its successors with a minimum adequate remedy and are their exclusive remedies whether Buyer s or its successors remedies are based on contract warranty tort including negligence strict liability indemnity or any other legal theory and whether arising out of warranties representations instructions installations or non conformities from any cause e Note The above does not apply to any software which may be furnished by Seller In such cases the attached Software License Addendum applies All product designations may be trademarks or product names of Siemens Energy amp Automation Inc or other supplier companies whose use by third parties for their own purposes could violate the rights of the owners Siemens Energy amp Automation Inc assumes no liability for errors or omissions in this document or for the application and use of information in this document The information herein is subject to change without notice Procedures in this document have been reviewed for compliance with applicable approval agency requirements and are considered sound practice Neither Siemens Energy amp Automation Inc nor these agencies are responsible for repairs made by the user SD63UL PARTS LIST Siemens Constant Differential Flow Controller for Small Flows Model 63BU L Drawing 10746PL Rev 3 78 B M 10746S6 SS SSN ie Ite
9. obligation to repair or replace shall be in effect for a period of one 1 year from initial operation of the goods but not more than eighteen 18 months from Seller s shipment of the goods provided Buyer has sent written notice within that period of time to Seller that the goods do not conform to the above warranty Repaired and replacement parts shall be warranted for the remainder of the original period of notification set forth above but in no event less than 12 months from repair or replacement At its expense Buyer shall remove and ship to Seller any such nonconforming items and shall reinstall the repaired or replaced parts Buyer shall grant Seller access to the goods at all reasonable times in order for Seller to determine any nonconformity in the goods Seller shall have the right of disposal of items replaced by it If Seller is unable or unwilling to repair or replace or if repair or replacement does not remedy the nonconformity Seller and Buyer shall negotiate an equitable adjustment in the contract price which may include a full refund of the contract price for the nonconforming goods c SELLER HEREBY DISCLAIMS ALL OTHER WARRANTIES EXPRESS OR IMPLIED EXCEPT THAT OF TITLE SPECIFICALLY IT DISCLAIMS THE IMPLIED WARRANTIES OF MERCHANTABILITY FITNESS FOR A PARTICULAR PURPOSE COURSE OF DEALING AND USAGE OF TRADE d Buyer and successors of Buyer are limited to the remedies specified in this article and shall have no others for a
10. pplied to the needle valve and to the top of the controller s diaphragm and forces the diaphragm and plunger down The differential spring and downstream pressure P2 force the diaphragm and plunger up The differential spring produces a upward force equal to that produced by a constant pressure K SD63UL 3 The controller is in balance when the force due to P1 equals the forces due to P2 and K i e P1 P2 K P2 P1 K and K P1 P2 Since the pressure drop AP across the needle valve equals P1 P2 and since P1 P2 equals K then the pressure drop AP must equal K therefore flow is constant Examples P1 P2 K P2 P1 K K P1 P2 1543 18 3 18 15 18 psig 15 psig 3 psig DIAPHRAGM Pi INPUT NEEDLE OUTPUT VALVE AAA ati PLUNGER Figure 2 Schematic CAPACITY The formulas for the calculation of maximum and minimum flow rated can be found in Table 1 The minimum controllable flow will depend on the leakage past the valve plunger in the controller It is therefore a function of the cleanliness of the valve and pressure drop across it as well as any inherent leakage In general for a standard flow controller the maximum controllable flow will be approximately 1 100 of the maximum flow OPERATION With the supply turned on adjust the needle valve to obtain the desired flow rate within the capacity of the controller MAINTENANCE The only maintenance normally required is to keep the valve plunger and
11. rew 1 4 20 x 1 Lg Socket Hd Steel W N P 9 1145 19 Mounting Bracket 1 IMPORTANT Service Parts Kits are available for servicing the instrument Contact Siemens for available kits refer to the Product Support section of this instruction Some parts in this Parts List may not be available for separate purchase Recommended on hand spare parts Always specify range serial number or other nameplate information when ordering spare parts 11
12. s A non hardening sealant is strongly recommended Connect the controller to a source of clean dry oil free instrument air See Instrument Air Requirements CAUTION Exceeding the specified ambient temperature limits can adversely affect performance and may cause damage to the controller Supply pressure in excess of that stated in the Specifications section may cause damage to the controller Instrument Air Requirements Connect the instrument to a source of clean dry oil free instrument air Failure to do so will increase the possibility of a malfunction or a deviation from specified performance CAUTION A Use of process fluids other than instrument air is not recommended No claim is made as to the suitability of this product for use with other process fluids such as hazardous gases except as listed on the appropriate certificate Non approved instruments are suitable for use with instrument air only Optional features and modifications such as tapped exhaust do not imply suitability for use with hazardous gases except as listed on the approval certificate There are many types of synthetic compressor lubricants Some may not be compatible with the materials used in construction of the instrument Wetting of these materials by such an oil mist or vapor etc may cause them to deteriorate This may ultimately result in failure of the positioner CAUTION A Synthetic compressor lubricants in the air stream at the instrument may c
13. t may not be available for separate purchase Recommended on hand spare parts Always specify range serial number or other nameplate information when ordering spare parts SD63UL PARTS LIST Siemens Constant Differential Flow Controller Model 63BU Drawing 2882PL Rev 3 78 B M 288289 Item No Part No Description Req d a 1518 5 Differential Spring 1 3 2882 18 Bottom Forging 1 4 2882 8 Valve and Diaphragm Assy 1 5 2881 9 Top Forging 1 6 Lockwasher 1 4 Neverslip Steel W N P 6 7 Screw 1 4 20 x 34 Lg Fil Hd Steel W N P 8 Screw 14 20 x 5 8 Lg Fil Hd Steel W N P 9 1145 19 Mounting Bracket IMPORTANT Service Parts Kits are available for servicing the instrument Contact Siemens for available kits refer to the Product Support section of this instruction Some parts in this Parts List may not be available for separate purchase Recommended on hand spare parts Always specify range serial number or other nameplate information when ordering spare parts 10 SD63UL PARTS LIST Siemens Constant Differential Flow Controller Model 63SU Drawing 12041PL Rev 3 78 B M 12041S10 Item No Part No Description Req d l 12041 23 Diaphragm Protecting Ring 1 a 3131 22 Differential Spring 1 3 12041 41 Bottom Forging 1 4 12041 33 Valve and Diaphragm Assy 1 5 12041 42 Top Housing Assy 1 6 Lockwasher 1 4 Steel W N P 6 i Screw 1 4 20 x 1 1 4 Lg Socket Hd Steel W N P 3 8 Sc
14. ted to remove any process materials hazardous materials or blood born pathogens prior to return for repair Read and complete the Siemens RMA form s For Product Support in the U S A Technical Support Telephone 1 800 569 2132 option 2 for Siemens and Moore Products Co brand instruments Fax 1 215 646 3547 E mail PITechSupp sea siemens com Hours of Operation 8 a m to 4 45 p m eastern time Monday through Friday except holidays Technical Publications http www sea siemens com ia under Customer Support Process Instrumentation in PDF click on Documentation amp Support Links Public Internet Site http www sea siemens com ia Repair Service 1 215 646 7400 extension 3187 For Product Support Outside of the U S A Visit the Siemens public Internet site see the above table for the URL locate Customer Support Process Instrumentation and click on the Contact Tech Support link to access the Global Support link SD63UL WARRANTY a Seller warrants that on the date of shipment the goods are of the kind and quality described herein and are free of non conformities in workmanship and material This warranty does not apply to goods delivered by Seller but manufactured by others b Buyer s exclusive remedy for a nonconformity in any item of the goods shall be the repair or the replacement at Seller s option of the item and any affected part of the goods Seller s
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