USER MANUAL. FlowLogic SFL Flow Controller WARRANTY NOTICE

Transcription

1 USER MANUAL FlowLogic SFL Flow Controller SAFETY WARNING Users are required to read the entire User Manual before handling or using the product. WARRANTY NOTICE Failure to follow the instructions and procedures in this manual, or misuse of this equipment, will void its warranty. PART NUMBER: The information in this manual is current as of its publication date. Publication date: 9/30/2015 Copyright 2015 Sullair, LLC. All rights reserved. Subject to EAR, ECCN EAR99 and related export control restrictions.

2 Air Care Seminar Training Sullair Air Care Seminars are courses that provide hands-on instruction for the proper operation, maintenance, and servicing of Sullair products. Individual seminars on Stationary compressors and compressor electrical systems are offered at regular intervals throughout the year at Sullair s training facility located at Michigan City, Indiana. Instruction includes training on the function and installation of Sullair service parts, troubleshooting common faults and malfunctions, and actual equipment operation. These seminars are recommended for maintenance, contractor maintenance, and service personnel. For detailed course outlines, schedule, and cost information contact: Sullair Training Department SULLAIR or (ext. 5623) training@sullair.com - Or Write - Sullair, LLC 3700 E. Michigan Blvd. Michigan City, IN Attn: Service Training Department. Subject to EAR, ECCN EAR99 and related export control restrictions.

3 FlowLogic SFL Flow Controller User Manual Table of Contents Table of Contents Section 1: Safety General Personal protective equipment Pressure release Fire and explosion Moving parts Electrical shock Lifting Decals... 3 Section 2: Description General... 5 Section 3: Specifications General specifications... 7 Section 4: Installation Receiving & inspection Location Installation Installing dashboard remotely Sizing receiver storage Determining existing air storage Section 5: Operation Pressurization and start-up procedure Shutdown procedure isolation, and depressurization: Section 6: Troubleshooting Troubleshooting guide Subject to EAR, ECCN EAR99 and related export control restrictions. i

4 Table of Contents FlowLogic SFL Flow Controller User Manual Section 7: Parts List Procedure for ordering parts Valve service kit SFL-150, SFL-250, SFP-150, SFE Valve service kit SFL-500, SFP-250, SFE-250, SFP-500, SFE Valve service kit SFL Valve service kit SFL-1000, SFP-750, SFE-750, SFP-1000, SFE Valve service kit SFL-1500, SFL-1750, SFP-1500, SFE Valve service kit SFP-1750, SFE Valve service kit SFL-2600, SFL-3500, SFP-2600, SFE-2600, SFP-3500, SFE Valve service kit SFL-5500, SFP-5500, SFE Appendix A: System Diagrams...34 A.1 Piping and instrumentation SFL-150 to SFL A.2 Piping and instrumentation SFL A.3 Piping and instrumentation SFL-750 to SFL A.4 Piping and instrumentation SFL-2600 to SFL A.5 Identification SFL A.6 Identification SFL-150 with manual bypass...39 A.7 Identification SFL A.8 Identification SFL-250 with manual bypass...41 A.9 Identification SFL A.10 Identification SFL-500 with manual bypass...43 A.11 Identification SFL A.12 Identification SFL-750 with manual bypass...45 A.13 Identification SFL A.14 Identification SFL-1000 with manual bypass...47 A.15 Identification SFL A.16 Identification SFL-1500 with manual bypass...49 A.17 Identification SFL A.18 Identification SFL-1750 with manual bypass...51 A.19 Identification SFL A.20 Identification SFL-2600 with manual bypass...53 A.21 Identification SFL A.22 Identification SFL-3500 with manual bypass...55 A.23 Identification SFL A.24 Identification SFL-5500 with manual bypass...57 A.25 Identification, notes all models...58 ii Subject to EAR, ECCN EAR99 and related export control restrictions.

5 FlowLogic SFL Flow Controller User Manual 1: Safety Section 1 Safety NOTE Operator is required to read entire instruction manual. 1.1 General Sullair designs and manufactures all of its products so they can be operated safely. However, the responsibility for safe operation rests with those who use and maintain our products. The following safety precautions are offered as a guide, which, if conscientiously followed, will minimize the possibility of accidents throughout the useful life of this equipment. This Sullair FlowLogic Flow Pressure Controller should be operated only by those who have been trained and delegated to do so, and who have read and understand this Operator s Manual. Failure to follow these instructions, procedures and safety precautions in the manual may increase the possibility for injury. Never activate the FlowLogic Controller unless it is safe to do so. Do not attempt to operate the FlowLogic Controller with a known unsafe condition. Use bypass and isolation valving or other suitable means to render the unit inoperative. If needed, disconnect the power and lock out at the source. Be sure to tag the FlowLogic Controller inoperative so others may know of the unsafe conditions. Install, use and operate the FlowLogic Controller only in full compliance with all pertinent OSHA regulations and/ or any applicable Federal, State and Local codes, standards and regulations. Do not modify the FlowLogic Controller in any way without written factory approval. While not specifically applicable to all systems, most of the precautionary statements contained herein are applicable to most systems and the concepts behind these statements are generally applicable to all systems. Prior to installing or operating the FlowLogic Controller, owners, employees, and users should become familiar with, and comply with all applicable OSHA regulations, and/or any other applicable Federal, State and Local codes, standards and regulations relative to personal protection equipment. 1.2 Personal protective equipment Prior to installing or operating the FlowLogic Flow Pressure Controller, owners, employers, and users should become familiar with, and comply with, all applicable OSHA regulations and/or any applicable Federal, State and Local codes, standards, and regulations relative to personal protective equipment, such as eye and face protective equipment, respiratory protective equipment, equipment intended to protect the extremities, protective clothing, protective shields and barriers, pressure relief devices and electrical protective equipment, as well as noise exposure administrative and/or engineering controls and/or personal hearing protective equipment. 1.3 Pressure release A. Prior to installing the FlowLogic Flow Pressure Controller make sure that the equipment is suitable and rated to be installed at the maximum potential pressure in the compressed air system. B. Prior to inspecting or performing maintenance on the FlowLogic Pressure Controller after it has been rendered inoperative, locked out and tagged, be sure the control pressure and line pressure to the unit has been shut off, vented and the pressure gauges or transducers read zero (0). C. Do not allow the system to exceed the rated pressure during operation. Be sure that the high discharge pressure switches and safety relief valves in the system are properly set and in working condition Subject to EAR, ECCN EAR99 and related export control restrictions. 1

6 1: Safety FlowLogic SFL Flow Controller User Manual prior to making adjustments or initially starting the unit or damage and or personal injury could occur. D. Keep personnel out of line with and away from the points of compressed air discharge. E. Use air pressure less than 30 psig (2.1 bar) for cleaning purposes, and then only with effective chip guarding and personal protection equipment per OSHA standards. F. Secure all connections and tubing with suitable retaining devices to prevent accidental disconnection and expulsion or shorting. G. Vent all internal pressure prior to opening any line, fitting, hose, valve, drain plug, connection or other FlowLogic system component. To avoid hazardous expulsion of system components always verify that system pressure has been reduced to zero and proper bleed down time has been allowed for before attempting to remove pressurized components from the system. Also always be very attentive and careful when removing equipment and listen and feel for signs of escaping pressurized air to avoid hazardous expulsions. H. Do not engage in horseplay with compressed air as serious injury or death may result. 1.4 Fire and explosion A. Clean up spills of lubricant or other combustible substances immediately if they occur. B. Do not permit fluids to accumulate on, under or around the external or internal surface of the Flow- Logic Controller as fire may result. C. Disconnect and lock out all power at the source prior to attempting repairs or cleaning of the FlowLogic Flow Pressure Controller. D. Keep electrical wiring, including all terminals and pressure or other controls in good condition. Replace any wiring that has cracked, become cut, abraded or otherwise degraded. Replace terminals that are worn, discolored or corroded. Keep all terminals and pressure connections clean and tight. E. Keep grounded and/or conductive objects, such as tools, away from exposed live electrical parts such as terminals to avoid arcing which might serve as a source of ignition. F. Keep a suitable fully charged class BC or ABC fire extinguisher nearby when operating or servicing the FlowLogic Controller. G. Do not attempt to operate the FlowLogic Controller in any classification of hazardous environment unless the FlowLogic Controller has been specifically designed and manufactured for that duty. 1.5 Moving parts A. Wear snug fitting clothing and confine long hair when working around this equipment, especially when exposed to hot or moving parts. B. Disconnect and lock out all power at source and verify that all circuits are de-energized to minimize the possibility of accidental start-up or operation prior to attempting repairs. C. Keep a first aid kit handy. Seek medical attention promptly in case of injury. Do not ignore small cuts and bruises as they may lead to infection. 1.6 Electrical shock A. The FlowLogic Controller should be installed and maintained in full compliance with all applicable Federal, State and Local codes, standards and regulations, including those of the National Electric Code, and also including those relative to equipment grounding conductors, and only by personnel that are trained, qualified and delegated to do so. B. Keep all parts of the body and any hand-held tools or other conductive objects away from exposed live parts of the electrical system. Maintain dry footing, stand on insulating surfaces and do not contact any other part of the FlowLogic Controller when making adjustments or repairs to similar exposed parts of the electrical system. Make all such adjustments or repairs with one hand only, so as to minimize the possibility of creating a current path through the heart. C. Attempt repairs only in clean, dry, ventilated and welllit areas. D. Do not leave the FlowLogic Controller unattended with an open electrical enclosure. If it is necessary to do so, then disconnect, lock out and tag all power at source so others will not inadvertently restore power. E. Disconnect, lockout and tag all power at source prior to attempting repairs and prior to handling any ungrounded conductors. 2 Subject to EAR, ECCN EAR99 and related export control restrictions.

7 FlowLogic SFL Flow Controller User Manual 1.7 Lifting Do not attempt to lift if the FlowLogic Controller is more weight than you can safely handle by yourself during installation. Get assistance of either personnel or mechanical means as required. 1: Safety 1.8 Decals The FlowLogic Controller contains several decals, which contain necessary information for safe performance. These decals should never be removed. If a decal becomes damaged, contact your nearest Sullair Distributor or the Sullair factory Service Department for replacement parts. NOTE When ordering new decals, use part number printed on face when possible. For more information on decals, consult the decal drawings of this manual. Subject to EAR, ECCN EAR99 and related export control restrictions. 3

8 1: Safety FlowLogic SFL Flow Controller User Manual Notes: 4 Subject to EAR, ECCN EAR99 and related export control restrictions.

9 FlowLogic SFL Flow Controller User Manual 2: Description Section 2 Description 2.1 General Sullair s FlowLogic flow controller design can consistently deliver ±1% of its pressure set point. Most plant air systems have an ever-changing fluctuation of demand, and changes in plant air pressure. Peak air demands will draw from the air system, and tend to disrupt the air capacity. FlowLogic flow control systems are installed at the intermediate point of the compressed air system; downstream from the filtration, drying equipment and air receiver storage, and upstream from the main piping distribution system. The Sullair FlowLogic flow controller can show a direct compressed air system improvement when installed in conjunction with an adequate supply-side storage tank. The FlowLogic flow control constantly monitors air pressure as it is delivered to production, and releases air from the receiver storage as needed to maintain a continuous, stable air pressure supply. 1. Rotary screw compressor 5. Dry storage 2. Wet storage 6. Flow controller 3. Filter 7. Air out 4. Refrigerated dryer 8. Oil/water separator Figure 2-1: Sample FlowLogic installation Subject to EAR, ECCN EAR99 and related export control restrictions. 5

10 2: Description FlowLogic SFL Flow Controller User Manual Notes: 6 Subject to EAR, ECCN EAR99 and related export control restrictions.

11 FlowLogic SFL Flow Controller User Manual 3: Specifications Section 3 Specifications 3.1 General specifications Nominal flow ratings Maximum inlet temperature Maximum inlet pressure Outlet pressure range Pressure regulation Based on: psig ( bar) inlet pressure 100 F (38 C) inlet Temperature 100 F (38 C) ambient temperature 5psid (.3 bar) control pressure differential. 125 F (51.7 C) cfm ( m 3 /min): 200 psig (13.8 bar) cfm ( m 3 /min): 150 psig(10.3 bar) Consult factory for higher inlet pressures cfm ( m 3 /min): psig ( bar) cfm ( m 3 /min): psig ( bar) Consult factory for lower outlet pressures ±1% of setpoint within the design range Subject to EAR, ECCN EAR99 and related export control restrictions. 7

12 3: Specifications FlowLogic SFL Flow Controller User Manual Notes: 8 Subject to EAR, ECCN EAR99 and related export control restrictions.

13 FlowLogic SFL Flow Controller User Manual 4: Installation Section 4 Installation 4.1 Receiving & inspection Inspect the FlowLogic SFL flow controller carefully upon arrival; any damage or concealed damage should be notified to the freight carrier immediately on the freight bill. Uncrate and inspect for concealed damage. File claims with the freight carrier immediately and notify your local Sullair distributor. 4.2 Location Locate the FlowLogic SFL flow controller in an area accessible for maintenance. The area should be clean, cool, and well-lighted. Ambient temperature should be between 50 F and 100 F (10 C and 38 C). The Flow- Logic SFL should have the minimum service clearance on all sides. See the installation drawings for specific clearance requirements. 4.3 Installation Sullair suggests that an in-line strainer be installed on the inlet side of the FlowLogic SFL controller to guard against contaminants and ensure proper operation. Condensate automatic drains are recommended to remove water from the FlowLogic SFL controller for proper operation. The FlowLogic SFL Controller unit has an IN and OUT with labels and/or directional flow arrows cast right into the Control Element. Orient the FlowLogic unit in accordance with compressed air system flow. The FlowLogic unit can be installed in any plane. The headers are capable of supporting the weight of the unit for either vertical or horizontal mounting. Do not support the unit from the flow control valves or the associated control piping. Make the following piping connections: Always use two wrenches when installing piping connections to prevent over-torque stress and damage to connection when tightening. Install a three (3) valve bypass around the FlowLogic Flow Controller to allow routine maintenance and insure that compressed air will always be available for plant use. The bypass can be supplied with the SFL unit as an option, or can be field installed using full line size service valves. As the primary design of the control valves are for precision control of positive flow conditions, backpressure caused by having higher pressure on the downstream side of the FlowLogic flow controller than the supply side should be avoided. Testing the installation See Section 5.1: Pressurization and start-up procedure on page Installing dashboard remotely Mount the dashboard where most convenient for the operator. The appropriately labeled connections are on the dashboard. Do not exceed 150 feet (45.7 meters) from the SFL header to the dashboard. Consult factory for greater distances. Pilot air tubing between the FlowLogic piping header and the dashboard is 1/4" OD and must be bubble tight. See the general arrangement drawing for dashboard pneumatic connections. Testing the installation See Section 5.1: Pressurization and start-up procedure on page 13. Subject to EAR, ECCN EAR99 and related export control restrictions. 9

14 4: Installation FlowLogic SFL Flow Controller User Manual Table 4-1: Minimum pipe sizing in compressor room Pressure psig bar cfm Pipe diameter and maximum flow ¾ 1 1½ 2 2½ m 3 / min cfm m 3 / min cfm m 3 / min cfm m 3 / min Note: Based on 60 ft/s (18 m/s) velocity. Standard steel pipe. Table 4-2: Minimum pipe sizing of plant piping system Pressure psig bar cfm cfm m 3 / min cfm Pipe diameter and maximum flow ¾ 1 1½ 2 2½ m 3 / min cfm m 3 / min cfm m 3 / min cfm m 3 / min cfm Note: Based on 0.5 psi (.03 bar) drop per 100 feet (30.5 meters). Standard steel pipe. m 3 / min cfm m 3 / min m 3 / min cfm cfm m 3 / min m 3 / min cfm cfm m 3 / min m 3 / min 10 Subject to EAR, ECCN EAR99 and related export control restrictions.

15 FlowLogic SFL Flow Controller User Manual 4: Installation Compressor Output plus Storage Capacity = System Flow of 150% for 30 Seconds 8000 (30,283) 7000 (26,498) 5 psid (0.3 bar) 10 psid (0.7 bar) 15 psid (1.0 bar) Receiver size gallons (liters) 6000 (22,712) 5000 (18,927) 4000 (15,142) 3000 (11,356) 2000 (7571) 2200 gal (8328 L) 20 psid (1.4 bar) 25 psid (1.7 bar) 30 psid (2.1 bar) 1000 (3785) (14.2) 1000 (28.3) 1500 (42.5) 2000 (56.6) 2500 (70.8) 3000 (85.0) 3500 (99.1) 4000 (113.3) Compressor capacity SCFM (m 3 /min) Figure 4-1: FlowLogic air receiver sizing chart 4.5 Sizing receiver storage For any flow controller to work properly, there needs to be adequate storage for the controller to draw from. Many factors go into optimally sizing storage including: Compressor start-up times The response time of compressor control strategies being used How long and how large are the transient event loads in the system? Can the start-up of a compressor be prevented with properly sized and controlled storage? How do you prevent unintended shutdown of a compressor? How will extraordinary event loads by addressed? The best way to optimize storage for a specific application is to conduct an assessment or audit of the system. This will identify typical operating conditions within the facility and ensure that storage is not under sized or oversized. If an assessment or audit is not practical when applying a FlowLogic Flow Pressure Controller, some rules of thumb can be used to approximate storage requirements. Figure 4-1 shows recommended storage sizing given total compressor capacity and operating differential between storage and the system. The lines are based upon having stored energy to support the total compressor output plus an additional 50% of total compressor output for 30 seconds. For example, if the total system compressor capacity is 1600 cfm (45.3 m 3 /min), air is stored at 100 psig (6.9 bar) nominally and the system is controlled to 80 psig (5.5 bar), 2200 gallons (8328 liters) of storage is required. Subject to EAR, ECCN EAR99 and related export control restrictions. 11

16 4: Installation FlowLogic SFL Flow Controller User Manual 1200 (34.0) 1100 (31.1) Useable air in storage based on receiver size and pressure differential 30 pisd (2.1 bar) Useable air storage SCF (m 3 ) 1000 (28.3) 900 (25.5) 800 (22.7) 700 (19.8) 600 (17.0) 500 (14.2) 400 (11.3) 300 (8.5) 200 (5.7) 100 (2.8) 25 psid (1.7 bar) 20 psid (1.4 bar) 15 psid (1.0 bar) 10 psid (0.7 bar) 5 psid (0.3 bar) (1514) 800 (3028) 1200 (4542) 1600 (6057) 2000 (7571) 2400 (9085) Receiver size gallons (liters) 2800 (10,599) 3200 (12,113) 3600 (13,627) 4000 (15,142) Figure 4-2: FlowLogic compressed air storage chart 4.6 Determining existing air storage If storage already exists in a system, Figure 4-2 can be used to determine the usable storage for a given pressure differential between storage and system pressure. Using the 2200 gallons (8328 liters) of storage and the 20 psi (1.4 bar) pressure differential from the previous example, the chart shows a usable storage of 400 cubic feet (11.3 cubic meters). 400 cubic feet (11.3 cubic meters) provides an additional 50% capacity of a 1600 cfm (45.3 m 3 /min) system for 30 seconds. 400 cf / 30 sec x 60 sec/min = 800 cfm or 11.3 m 3 / 30 sec x 60 sec/min = 22.7 m 3 /min 12 Subject to EAR, ECCN EAR99 and related export control restrictions.

17 FlowLogic SFL Flow Controller User Manual 5: Operation Section 5 Operation 5.1 Pressurization and start-up procedure The following sequence is to be used during every startup: 1. Prior to start up, check for unusual pressure drops and piping restrictions to the Flow- Logic flow controller from air receiver storage, and from the OUT of the FlowLogic to the main plant system. During start up, relief valves in the air receiver storage tank system may open. Pressure operations, and the air compressor system fluctuations may change dramatically after the SFL unit is put on line resulting in consequential events. In most cases Air Compressor controls and set points may require adjustments. 2. Open the 3-valve bypass around the Flow- Logic Flow Controller. 3. Pressurize the system and check for leaks. 4. Turn the Adjustment Control Valve (ACV) to the full clockwise position; this will open the FlowLogic flow control valves. The Adjustment Control Valve will be mounted on the SFL dashboard, or it is mounted in the remote control panel if so equipped. 5. While leaving the isolation valves Open; Slowly Close the Bypass valve around the FlowLogic SFL Controller. 6. Turn the ACV counter clockwise slowly to dial in the desired discharge pressure. Turn the ACV adjustment in small pressure changes allowing the system to stabilize between adjustments. Failure to adjust the FlowLogic in this manner may result in a system pressure drawdown. The "AIR OUT" gauge displays discharge pressure of the SFL unit. Maximum inlet pressure is shown on the FlowLogic nameplate. Maximum regulating pressure is 5 psi below the lowest operating compressor inlet pressure. NOTE If the instrument air or adjustment control air pressure is disconnected the control valves will close. 5.2 Shutdown procedure isolation, and depressurization: If the SFL is being shut down for a weekend shift then the following should be completed: 1. Slowly isolate the SFL with the Manual bypass Open, and the inlet / outlet isolation valves closing. 2. Open the bypass valve to allow process flow to continue downstream, and then close the SFL outlet isolation valve. 3. At this time the SFL is isolated and can be depressurized for servicing. 4. Leave drain valves open while servicing. To restart; follow Section 5.1: Pressurization and start-up procedure. WARNING Always remove all pressure and disconnect all power before servicing unit. Subject to EAR, ECCN EAR99 and related export control restrictions. 13

18 5: Operation FlowLogic SFL Flow Controller User Manual Notes: 14 Subject to EAR, ECCN EAR99 and related export control restrictions.

19 FlowLogic SFL Flow Controller User Manual 6: Troubleshooting Section 6 Troubleshooting 6.1 Troubleshooting guide The following Troubleshooting Chart is based on both the data obtained from actual tests conducted at our factory and real applied situations. It contains symptoms and usual causes for the described problems. However, do not assume that these are the only problems that may occur. All available data concerning the trouble should be systematically analyzed before undertaking any repairs or component replacement procedures. Check for loose wiring. Check for damaged piping. Check for parts damaged by heat or an electrical short circuit, usually apparent by discoloration or a burnt odor. Should your problem persist after making the recommended check, consult your nearest Sullair representative or the Sullair. Table 6-1: Troubleshooting guide Symptom Probable cause Remedy Low plant or FlowLogic flow control pressure. High FlowLogic flow control, discharge pressure. Unstable FlowLogic flow control, discharge pressure. Verify the operations of all the air compressors in the system are operating correctly. The pneumatic control tubing is leaking or damaged Adjustment Control Valve (ACV) is defective. Controls have stuck in the Closed position. Bypass valve is Open. Adjustment Control Valve is defective. Controls have stuck in the OPEN position. The Inlet air pressure is within 2 to 4 psi of the discharge air pressure set point. The pneumatic control tubing is leaking or damaged. (This line should be bubble-tight.) Adjustment Control Valve is defective. Controls valves are contaminated, and/or the valve internals have been damaged over time. Make adjustments or repairs to the compressors. Repair the leak. Replace the Adjustment Control Valve, and inspect all of the valves. Check the control valves for contamination. Clean and perform Annual Service Kit if necessary. Make adjustments or repairs. Replace the Adjustment Control Valve, and inspect all of the valves. Check the control valves for contamination. Clean and perform Annual Service Kit if necessary. Make adjustments or repairs to the compressors. Repair the leak. Replace the Adjustment Control Valve, and inspect all of the valves. Perform Annual Service Kit. Subject to EAR, ECCN EAR99 and related export control restrictions. 15

20 6: Troubleshooting FlowLogic SFL Flow Controller User Manual Notes: 16 Subject to EAR, ECCN EAR99 and related export control restrictions.

21 FlowLogic SFL Flow Controller User Manual 7: Parts List Section 7 Parts List 7.1 Procedure for ordering parts You should order parts from the nearest authorized Sullair representative or the representative from whom the flow controller was purchased. If for any reason you cannot obtain parts in this manner, contact the factory directly at the address, phone number, or website listed below. Sullair North America Operations 3700 East Michigan Boulevard Michigan City, IN USA SULLAIR (USA only) (non-usa) The genuine Sullair service parts listed meet or exceed the demands of this flow controller. Use of replacement parts other than those approved by Sullair will void the Sullair warranties specific to this product and may lead to hazardous conditions over which Sullair has no control. Such conditions include, but are not limited to, bodily injury and flow controller failure. Subject to EAR, ECCN EAR99 and related export control restrictions. 17

22 7: Parts List FlowLogic SFL Flow Controller User Manual 7.2 Valve service kit SFL-150, SFL-250, SFP-150, SFE R00 18 Subject to EAR, ECCN EAR99 and related export control restrictions.

23 Subject to EAR, ECCN EAR99 and related export control restrictions Valve service kit SFL-150, SFL-250, SFP-150, SFE-150 Components Key Description 1 VALVE O-RING 2 PUSHNUT FASTENER 3 SUPPORT 4 DIAPHRAGM 5 HOLDER 6 O-RING 7 STEM O-RING 8 RETAINER X 1/16W 9 STEM 10 SCREW 11 VALVE 12 CAP 13 VALVE SPRING 14 CAP O- RING 15 HEAD 16 RETAINING RING 17 DOME 18 SPRING 19 PITOT TUBE - ALLEN PLUG Valve service kit for SFL-150, SFL-250, SFP-150,SFE-150* (P/N: ) Key / part number Description Qty per kit 1 RELUBED O-RING 1 4 DIAPHRAGM 1 11 VALVE 1 13 VALVE SPRING 1 14 O-RING 1 18 SPRING 1 FILTER ELEMENT POLYETHYLENE ADJUSTMENT CONTROL VALVE 1 Service kit notes *SOME COMPONENTS MAY NOT BE REQUIRED FOR CERTAIN MODELS FlowLogic SFL Flow Controller User Manual 7: Parts List

24 7: Parts List FlowLogic SFL Flow Controller User Manual 7.3 Valve service kit SFL-500, SFP-250, SFE-250, SFP-500, SFE R00 20 Subject to EAR, ECCN EAR99 and related export control restrictions.

25 Subject to EAR, ECCN EAR99 and related export control restrictions Valve service kit SFL-500, SFP-250, SFE-250, SFP-500, SFE-500 Components Key Description 1 VALVE O-RING 2 PUSHNUT FASTENER 3 SUPPORT 4 DIAPHRAGM 5 HOLDER 6 O-RING 7 STEM O-RING 8 RETAINER X 1/16W 9 STEM 10 SCREW 11 VALVE 12 CAP 13 VALVE SPRING 14 CAP O-RING 15 HEAD 16 RETAINING RING 17 DOME 18 SPRING 19 PITOT TUBE - ALLEN PLUG Valve service kit for SFL-500, SFP-250, SFE-250*, SFP-500, SFE-500* (P/N: ) Key / part number Description Qty per kit 1 RELUBED O-RING 2 4 DIAPHRAGM 2 11 VALVE 2 13 VALVE SPRING 2 14 O-RING 2 18 SPRING 2 FILTER ELEMENT POLYETHYLENE ADJUSTMENT CONTROL VALVE 1 Service kit notes *SOME COMPONENTS MAY NOT BE REQUIRED FOR CERTAIN MODELS FlowLogic SFL Flow Controller User Manual 7: Parts List

26 7: Parts List FlowLogic SFL Flow Controller User Manual 7.4 Valve service kit SFL R00 22 Subject to EAR, ECCN EAR99 and related export control restrictions.

27 Subject to EAR, ECCN EAR99 and related export control restrictions Valve service kit SFL-750 Components Valve service kit for SFL-750 (P/N: ) Key Description 1 VALVE O-RING 2 PUSHNUT FASTENER 3 SUPPORT 4 DIAPHRAGM 5 HOLDER 6 O-RING 7 STEM O-RING 8 RETAINER X 1/16W 9 STEM 10 SCREW 11 VALVE 12 CAP 13 VALVE SPRING 14 CAP O-RING 15 HEAD 16 RETAINING RING 17 DOME 18 SPRING 19 PITOT TUBE - ALLEN PLUG Key / part number Description Qty per kit 1 RELUBED O-RING 3 4 DIAPHRAGM 3 11 VALVE 3 13 VALVE SPRING 3 14 O-RING 3 18 SPRING 3 - FILTER ELEMENT POLYETHYLENE ADJUSTMENT CONTROL VALVE 1 FlowLogic SFL Flow Controller User Manual 7: Parts List

28 7: Parts List FlowLogic SFL Flow Controller User Manual 7.5 Valve service kit SFL-1000, SFP-750, SFE-750, SFP-1000, SFE R00 24 Subject to EAR, ECCN EAR99 and related export control restrictions.

29 Subject to EAR, ECCN EAR99 and related export control restrictions Valve service kit SFL-1000, SFP-750, SFE-750, SFP-1000, SFE-1000 Components Key Description 1 O-RING 2-1/8 ID x 1/8W 2 O-RING 1-1/4 ID x 1/8W 3 O-RING 5 ID x 1/8W 4 O-RING 3-7/8 ID x 3/16W 5 O-RING 1/4 ID x 1/8W 6 O-RING 1/4 ID x 1/16W 7 VALVE 8 VALVE SEAT 9 RETAINING RIN 10 VALVE STEM 11 VALVE SPRING 12 HEAD 13 DOME(TEFLON COATED) 14 PISTON 15 BIAS SPRING 16 CAP(TEFLON COATED) 17 ALLEN PLUG Valve service kit for SFL-1000, SFP-750, SFE-750, SFP-1000, SFE-1000 (P/N: ) Key / part number Description Qty per kit 1 O-RING 2-1/8 X 1/8 2 2 O-RING 1-1/4 X 1/8 2 3 O-RING 5 X 1/8 2 4 O-RING 3-7/8 X 3/ O-RING 1-1/4 X 1/8 2 6 O-RING 1-1/4 X 1/ POPPET VALVE 2 9 RETAINING RING EXT TOOTH 2 14 R200SR195 PISTON 2 FILTER ELEMENT POLYETHYLENE 1 REG CONSTANT BLEED I/R 1 Service kit notes KIT CONTAINS EXTRA QUANTITIES OF SOME PARTS. CERTAIN MODELS MAY NOT REQUIRE ALL ITEMS. FlowLogic SFL Flow Controller User Manual 7: Parts List

30 7: Parts List FlowLogic SFL Flow Controller User Manual 7.6 Valve service kit SFL-1500, SFL-1750, SFP-1500, SFE R00 26 Subject to EAR, ECCN EAR99 and related export control restrictions.

31 Subject to EAR, ECCN EAR99 and related export control restrictions Valve service kit SFL-1500, SFL-1750, SFP-1500, SFE-1500 Components Key Description 1 O-RING 2-1/8 ID X 1/8W 2 O-RING 1-1/4 ID X 1/8W 3 O-RING 5 ID X 1/8W 4 O-RING 3-7/8 ID X 3/16W 5 O-RING 1/4 ID X 1/8W 6 O-RING 1/4 ID X 1/16W 7 VALVE 8 VALVE SEAT 9 RETAINING RING 10 VALVE STEM 11 VALVE SPRING 12 HEAD 13 DOME(TEFLON COATED) 14 PISTON 15 BIAS SPRING 16 CAP(TEFLON COATED) 17 ALLEN PLUG Valve service kit for SFL-1500, SFL-1750, SFP-1500, SFE-1500 (P/N: ) Key / part number Description Qty per kit 1 O-RING 2-1/8 X 1/8 3 2 O-RING 1-1/4 X 1/8 3 3 O-RING 5 X 1/8 3 4 O-RING 3-7/8 X 3/ O-RING 1-1/4 X 1/8 3 6 O-RING 1-1/4 X 1/ POPPET VALVE 3 9 RETAINING RING EXT TOOTH 3 14 R200SR195 PISTON 3 FILTER ELEMENT POLYETHYLENE ADJUSTMENT CONTROL VALVE 1 Service kit notes SOME COMPONENTS MAY NOT BE REQUIRED FOR CERTAIN MODELS FlowLogic SFL Flow Controller User Manual 7: Parts List

32 7: Parts List FlowLogic SFL Flow Controller User Manual 7.7 Valve service kit SFP-1750, SFE R00 28 Subject to EAR, ECCN EAR99 and related export control restrictions.

33 Subject to EAR, ECCN EAR99 and related export control restrictions Valve service kit SFP-1750, SFE-1750 Components Key Description 1 BONNET 2 HOUSING 3 UPPER HOUSING 4 LOWER HOUSING 5 BODY 6 PLUG 7 BREATHER PLUG 8 SCREW (UPPER HOUSING) 9 CONNECTOR 10 TUBING (UPSTREAM) 11 ELL 12 SCREW (BONNET) 13 TUBING (BALANCING) 14 DIAPHRAGM RING 15 TEE 16 NIPPLE 17 TUBING (ACTUATING) 18 TUBING (DOWNSTREAM) 19 DIAPHRAGM PLUG 20 BALANCE DIAPHRAGM 21 SPACER 22 SEAT EXTENSION 23 NUT 24 PILOT DIAPHRAGM 25 PLATE 26 PILOT SEAT(SMALL) 27 PILOT SEAT(LARGE) 28 PILOT SEAT GASKET 29 PILOT PLUG 30 CONICAL SPRING 31 MOTOR VALVE DIAPHRAGM 32 DIAPHRAGM PLATE 33 ASSIST SPRING 34 LOWER HOUSING GASKET 35 STEM SEAL SPACER Key Description 36 BACK UP 37 O-RING 38 CHANNEL SEAL 39 SEAL RETAINER 40 STEM 41 SEAT DISC 42 SEAT 43 RATIO PLUG 44 LOCK NUT 45 O-RING Valve service kit for SFP-1750, SFE-1750 (P/N: ) Key / part number Description Qty per kit 14 DIAPH SPACER RING(5258) 2 20 DIAPH STABALIZING BUNA-N(110) 6 24 DIAPH W/SEAL POLY(5259p) 2 26 PILOT SEAT 3/16(113) 2 27 PILOT SEAT 1/4 IN(111) 2 28 GASKET PILOT SEAT(118) 2 29 PILOT PLUG 3/16 X 1/4 SS6(112) 2 30 SPRING HELICAL CONICAL(108) 2 31 DIAPH 2 GT/MT BUNA-N(128) 2 34 GASKET 2 G SERIES(196) 2 35 SPACER STEM SEAL RET 2IN GT S6(4557DS6) 2 36 BACK UP TEFLON 2(149T) 4 37 O-RING VITON(154V) 2 38 CHANNEL SEAL LWR HSNG 2 GT(4557C) 2 39 STEM SEAL RETAINER 2 GT S6(4557ES6) 2 42 SEAT 2 GT/MT HSN(164HSN) 2 44 NUT UNITORQUE 3/8-24 LOCKNUT(173) 2 45 O-RING BUNA-N(5225) ADJUSTMENT CONTROL VALVE 1 Service kit notes KIT CONTAINS EXTRA QUANTITIES OF SOME PARTS. CERTAIN MODELS MAY NOT REQUIRE ALL ITEMS. FlowLogic SFL Flow Controller User Manual 7: Parts List

34 7: Parts List FlowLogic SFL Flow Controller User Manual 7.8 Valve service kit SFL-2600, SFL-3500, SFP-2600, SFE-2600, SFP-3500, SFE R00 30 Subject to EAR, ECCN EAR99 and related export control restrictions.

35 Subject to EAR, ECCN EAR99 and related export control restrictions Valve service kit SFL-2600, SFL-3500, SFP-2600, SFE-2600, SFP-3500, SFE-3500 Components Key Description 1 BONNET 2 HOUSING 3 UPPER HOUSING 4 LOWER HOUSING 5 BODY 6 PLUG 7 BREATHER PLUG 8 SCREW (UPPER HOUSING) 9 CONNECTOR 10 TUBING (UPSTREAM) 11 ELL 12 SCREW (BONNET) 13 TUBING (BALANCING) 14 DIAPHRAGM RING 15 TEE 16 NIPPLE 17 TUBING (ACTUATING) 18 TUBING (DOWNSTREAM) 19 DIAPHRAGM PLUG 20 BALANCE DIAPHRAGM 21 SPACER 22 SEAT EXTENSION 23 NUT 24 PILOT DIAPHRAGM 25 PLATE 26 PILOT SEAT(SMALL) 27 PILOT SEAT(LARGE) 28 PILOT SEAT GASKET 29 PILOT PLUG 30 CONICAL SPRING 31 MOTOR VALVE DIAPHRAGM 32 DIAPHRAGM PLATE 33 ASSIST SPRING 34 LOWER HOUSING GASKET 35 STEM SEAL SPACER Key Description 36 BACK UP 37 O-RING 38 CHANNEL SEAL 39 SEAL RETAINER 40 STEM 41 SEAT DISC 42 SEAT 43 RATIO PLUG 44 LOCK NUT 45 O-RING Valve service kit for SFL-2600, SFL-3500, SFP-2600, SFE-2600, SFP-3500, SFE-3500 (P/N: ) Key / part number Description Qty per kit 14 DIAPH SPACER RING(5258) 2 20 DIAPH STABALIZING BUNA-N(110) 6 24 DIAPH W/SEAL POLY(5259p) 2 26 PILOT SEAT 3/16(113) 2 27 PILOT SEAT 1/4 IN(111) 2 28 GASKET PILOT SEAT(118) 2 29 PILOT PLUG 3/16 X 1/4 SS6(112) 2 30 SPRING HELICAL CONICAL(108) 2 31 DIAPH 3 G/M BUNA-N(129) 2 34 BODY GASKET 3 G-L & DA (197) 2 35 SPACER STEM SEAL RET 3IN GT S6(4561DS6) 2 36 BACK UP PILOT PISTON 4020 PUMP (809) 4 37 O-RING BUNA-N (807) 2 38 CHANNEL SEAL LWR HSNG 3 GT(4561C) 2 39 STEM SEAL RETAINER 3 GT S6(4561ES6) 2 42 SEAT 3 GT/MT HSN(165HSN) 2 44 NUT UNITORQUE 1/2-20 UTC ZN (906) 2 45 O-RING BUNA-N(5226) ADJUSTMENT CONTROL VALVE 1 Service kit notes KIT CONTAINS EXTRA QUANTITIES OF SOME PARTS. CERTAIN MODELS MAY NOT REQUIRE ALL ITEMS. FlowLogic SFL Flow Controller User Manual 7: Parts List

36 7: Parts List FlowLogic SFL Flow Controller User Manual 7.9 Valve service kit SFL-5500, SFP-5500, SFE R00 32 Subject to EAR, ECCN EAR99 and related export control restrictions.

37 Subject to EAR, ECCN EAR99 and related export control restrictions Valve service kit SFL-5500, SFP-5500, SFE-5500 Components Key 1 BONNET 2 HOUSING 3 UPPER HOUSING 4 LOWER HOUSING 5 BODY 6 PLUG 7 BREATHER PLUG 8 SCREW (UPPER HOUSING) 9 CONNECTOR 10 TUBING (UPSTREAM) 11 ELL 12 SCREW (BONNET) 13 TUBING (BALANCING) 14 DIAPHRAGM RING 15 TEE 16 NIPPLE 17 TUBING (ACTUATING) 18 TUBING (DOWNSTREAM) 19 DIAPHRAGM PLUG 20 BALANCE DIAPHRAGM 21 SPACER 22 SEAT EXTENSION 23 NUT 24 PILOT DIAPHRAGM 25 PLATE 26 PILOT SEAT(SMALL) 27 PILOT SEAT(LARGE) 28 PILOT SEAT GASKET 29 PILOT PLUG 30 CONICAL SPRING 31 MOTOR VALVE DIAPHRAGM 32 DIAPHRAGM PLATE 33 ASSIST SPRING 34 LOWER HOUSING GASKET 35 STEM SEAL SPACER Description Key 36 BACK UP 37 O-RING 38 CHANNEL SEAL 39 SEAL RETAINER 40 STEM 41 SEAT DISC 42 SEAT 43 RATIO PLUG 44 LOCK NUT 45 O-RING Valve service kit for SFL-5500, SFP-5500, SFE-5500 (P/N: ) Key / part number Description Qty per kit 14 DIAPH SPACER RING(5258) 2 20 DIAPH STABALIZING BUNA-N(110) 6 24 DIAPH W/SEAL POLY(5259p) 2 26 PILOT SEAT 3/16(113) 2 27 PILOT SEAT 1/4 IN(111) 2 28 GASKET PILOT SEAT(118) 2 29 PILOT PLUG 3/16 X 1/4 SS6(112) 2 30 SPRING HELICAL CONICAL(108) 2 31 DIAPH 4 GT/MT BUNA-N(130) 2 34 BODY GASKET GT & MT(198) 2 35 SPACER STEM SEAL RET 4IN GT S6(4566DS6) 2 36 BACK UP TEFLON 4(151T) 4 37 O-RING VITON(156V) 2 38 CHANNEL SEAL LWR HSNG 4 GT(4566C) 2 39 STEM SEAL RETAINER 4 GT S6(4566ES6) 2 42 SEAT 4 GT/MT HSN(166HSN) 2 44 NUT UNITORQUE 1/2-20 UTC ZN (906) O-RING BUNA-N(5227) ADJUSTMENT CONTROL VALVE 1 Service kit notes Description KIT CONTAINS EXTRA QUANTITIES OF SOME PARTS. CERTAIN MODELS MAY NOT REQUIRE ALL ITEMS. FlowLogic SFL Flow Controller User Manual 7: Parts List

38 A: System Diagrams FlowLogic SFL Flow Controller User Manual Appendix A: System Diagrams A.1 Piping and instrumentation SFL-150 to SFL R00 Drawing notes 1 VALVES SHOWN ARE REPRESENTATIVE OF ACTUAL VALVE. 2 THE PORTING LAYOUT WILL BE COMMON ON ALL VALVES. 34 Subject to EAR, ECCN EAR99 and related export control restrictions.

39 FlowLogic SFL Flow Controller User Manual A: System Diagrams A.2 Piping and instrumentation SFL R00 Drawing notes 1 VALVES SHOWN ARE REPRESENTATIVE OF ACTUAL VALVE. 2 THE PORTING LAYOUT WILL BE COMMON ON ALL VALVES. Subject to EAR, ECCN EAR99 and related export control restrictions. 35

40 A: System Diagrams FlowLogic SFL Flow Controller User Manual A.3 Piping and instrumentation SFL-750 to SFL R00 Drawing notes 1 VALVES SHOWN ARE REPRESENTATIVE OF ACTUAL VALVE. 2 THE PORTING LAYOUT WILL BE COMMON ON ALL VALVES. 36 Subject to EAR, ECCN EAR99 and related export control restrictions.

41 FlowLogic SFL Flow Controller User Manual A: System Diagrams A.4 Piping and instrumentation SFL-2600 to SFL R00 Drawing notes 1 VALVES SHOWN ARE REPRESENTATIVE OF ACTUAL VALVE. 2 THE PORTING LAYOUT WILL BE COMMON ON ALL VALVES. Subject to EAR, ECCN EAR99 and related export control restrictions. 37

42 A: System Diagrams FlowLogic SFL Flow Controller User Manual A.5 Identification SFL R00 (for drawing notes, see Section A.25: Identification, notes all models on page 58) 38 Subject to EAR, ECCN EAR99 and related export control restrictions.

43 FlowLogic SFL Flow Controller User Manual A: System Diagrams A.6 Identification SFL-150 with manual bypass R01 (for drawing notes, see Section A.25: Identification, notes all models on page 58) Subject to EAR, ECCN EAR99 and related export control restrictions. 39

44 A: System Diagrams FlowLogic SFL Flow Controller User Manual A.7 Identification SFL R00 (for drawing notes, see Section A.25: Identification, notes all models on page 58) 40 Subject to EAR, ECCN EAR99 and related export control restrictions.

45 FlowLogic SFL Flow Controller User Manual A: System Diagrams A.8 Identification SFL-250 with manual bypass R01 (for drawing notes, see Section A.25: Identification, notes all models on page 58) Subject to EAR, ECCN EAR99 and related export control restrictions. 41

46 A: System Diagrams FlowLogic SFL Flow Controller User Manual A.9 Identification SFL R01 (for drawing notes, see Section A.25: Identification, notes all models on page 58) 42 Subject to EAR, ECCN EAR99 and related export control restrictions.

47 FlowLogic SFL Flow Controller User Manual A: System Diagrams A.10 Identification SFL-500 with manual bypass R01 (for drawing notes, see Section A.25: Identification, notes all models on page 58) Subject to EAR, ECCN EAR99 and related export control restrictions. 43

48 A: System Diagrams FlowLogic SFL Flow Controller User Manual A.11 Identification SFL R01 (for drawing notes, see Section A.25: Identification, notes all models on page 58) 44 Subject to EAR, ECCN EAR99 and related export control restrictions.

49 FlowLogic SFL Flow Controller User Manual A: System Diagrams A.12 Identification SFL-750 with manual bypass R01 (for drawing notes, see Section A.25: Identification, notes all models on page 58) Subject to EAR, ECCN EAR99 and related export control restrictions. 45

50 A: System Diagrams FlowLogic SFL Flow Controller User Manual A.13 Identification SFL R01 (for drawing notes, see Section A.25: Identification, notes all models on page 58) 46 Subject to EAR, ECCN EAR99 and related export control restrictions.

51 FlowLogic SFL Flow Controller User Manual A: System Diagrams A.14 Identification SFL-1000 with manual bypass R01 (for drawing notes, see Section A.25: Identification, notes all models on page 58) Subject to EAR, ECCN EAR99 and related export control restrictions. 47

52 A: System Diagrams FlowLogic SFL Flow Controller User Manual A.15 Identification SFL R01 (for drawing notes, see Section A.25: Identification, notes all models on page 58) 48 Subject to EAR, ECCN EAR99 and related export control restrictions.

53 FlowLogic SFL Flow Controller User Manual A: System Diagrams A.16 Identification SFL-1500 with manual bypass R01 (for drawing notes, see Section A.25: Identification, notes all models on page 58) Subject to EAR, ECCN EAR99 and related export control restrictions. 49

54 A: System Diagrams FlowLogic SFL Flow Controller User Manual A.17 Identification SFL R00 (for drawing notes, see Section A.25: Identification, notes all models on page 58) 50 Subject to EAR, ECCN EAR99 and related export control restrictions.

55 FlowLogic SFL Flow Controller User Manual A: System Diagrams A.18 Identification SFL-1750 with manual bypass R00 (for drawing notes, see Section A.25: Identification, notes all models on page 58) Subject to EAR, ECCN EAR99 and related export control restrictions. 51

56 A: System Diagrams FlowLogic SFL Flow Controller User Manual A.19 Identification SFL R01 (for drawing notes, see Section A.25: Identification, notes all models on page 58) 52 Subject to EAR, ECCN EAR99 and related export control restrictions.

57 FlowLogic SFL Flow Controller User Manual A: System Diagrams A.20 Identification SFL-2600 with manual bypass R00 (for drawing notes, see Section A.25: Identification, notes all models on page 58) Subject to EAR, ECCN EAR99 and related export control restrictions. 53

58 A: System Diagrams FlowLogic SFL Flow Controller User Manual A.21 Identification SFL R01 (for drawing notes, see Section A.25: Identification, notes all models on page 58) 54 Subject to EAR, ECCN EAR99 and related export control restrictions.

59 FlowLogic SFL Flow Controller User Manual A: System Diagrams A.22 Identification SFL-3500 with manual bypass R00 (for drawing notes, see Section A.25: Identification, notes all models on page 58) Subject to EAR, ECCN EAR99 and related export control restrictions. 55

60 A: System Diagrams FlowLogic SFL Flow Controller User Manual A.23 Identification SFL R01 (for drawing notes, see Section A.25: Identification, notes all models on page 58) 56 Subject to EAR, ECCN EAR99 and related export control restrictions.

61 FlowLogic SFL Flow Controller User Manual A: System Diagrams A.24 Identification SFL-5500 with manual bypass R00 (for drawing notes, see Section A.25: Identification, notes all models on page 58) Subject to EAR, ECCN EAR99 and related export control restrictions. 57

62 58 Subject to EAR, ECCN EAR99 and related export control restrictions. A.25 Identification, notes all models Drawing notes 1 AN INLINE STRAINER SHOULD BE INSTALLED ON THE INLET SIDE OF THE UNIT TO GUARD AGAINST CONTAMINANTS 2 THE HEADERS ARE CAPABLE OF SUPPORTING THE WEIGHT OF THE UNIT FOR EITHER VERTICAL OR HORIZONTAL MOUNTING. DO NOT SUPPORT FROM CONTROL VALVES OR CONTROL TUBING. 3 IF AN INTEGRAL BYPASS OPTION IS NOT ORDERED, THE INSTALLER SHOULD PROVIDE A MEANS TO BYPASS THE UNIT FOR SERVICING. 4 APPROPRIATE UPSTREAM DRY AIR RECEIVER STORAGE IS RECOMMENDED FOR PROPER FLOWLOGIC OPERATION. 5 DIMENSIONAL TOLERANCE: ± 1/4"(6.35MM) A: System Diagrams FlowLogic SFL Flow Controller User Manual

63 Subject to EAR, ECCN EAR99 and related export control restrictions.

64 Sullair, LLC 3700 East Michigan Boulevard Michigan City, IN USA SULLAIR (USA only) (non-usa) Information and specifications are subject to change without prior notice. Subject to EAR, ECCN EAR99 and related export control restrictions.