FMC-2000 Pressure Immune Mechanical Flow Controller

INSTALLATION AND

OPERATION GUIDE

REVISION E Jan 2004

1737 Stebbins Drive, Suite 240B

Houston, TX 77043(Main) (713) 979-1020

(Fax) (713) 715-7442Web: www.flowmatrix.net

Email: info@flowmatrix.net

Table of Contents

Inspection and Unpacking …………………...............………. 1 Introduction ……………………………………...............………. 2 For Your Safety ……..............………………………………... 3 Specifications ……………………………...............……….… 5 Warranty and Intended Use ………………………..........…... 6 Returning Merchandise ………………………...............………. 7 Principles of Operation

General …..…………..…………......…………............ 8 Features ……………..…………………….……..…........ 9

Installation Mounting the Controller ..….......……..….…….......…... 10 Primary Gas Connections ………………...…………… 11 Filtering and Flow Monitoring …………………………… 13

Maintenance ………....…………......………….……............ 13 Troubleshooting ………....…………......………….……............ 14

Inspection and Unpacking Inspect the package for external damage. Your FMC-2000 was carefully packed

in a sturdy cardboard carton with foam cushions designed to withstand shipping

shock. Upon receipt, please inspect the package for possible external damage.

Should the package appear to be damaged, immediately contact the shipping

company.

Open the carton carefully from the top and inspect for any sign of concealed

shipping damage. In addition to contacting the shipping carrier please forward a

copy of any damage report to your distributor or directly to Flow Matrix.

Inside the package, you should find:

• (1) FMC-2000 Flow Controller

• (1) Installation and operations guide

• (1) Conformance and configuration certificate

• Optional Accessories: fittings &/or mounting bracket

COPYRIGHT NOTICE: Copyright 2003 Flow Matrix LLC. This work is protected under Title 17 of the US Code and is the sole property of Flow Matrix LLC. No part of this document may be copied or otherwise reproduced, or stored in any electronic information retrieval system, except as specifically permitted under US copyright law, without the prior written consent of Flow Matrix LLC.

Introduction

Thank you for purchasing the FMC-2000 mechanical flow controller. The FMC-2000 is a user friendly, mechanically operated flow controller. It has many features to offer the user, which will be described in this manual. We recommend that all personnel who use this device read this manual to become more familiar with its proper operation.

The FMC-2000 controller is designed for use with either liquid or gas streams, but each individual controller is set-up for either gas or liquid service (according to end-user specifications). Please follow the simple installation guidelines and operation instructions to ensure the best performance and to avoid damage to the controller or your system. Please always observe the best and safest practices in handling high-pressure liquids and gases. Severe injury or death can occur during the sudden release of high-pressure liquids or gases. Flow Matrix guarantees the safe containment and control of pressures up to 500 or 3000 psig of gas depending on the specification of controller ordered (please refer to the certificate of conformance or the product label). If unsure, please contact a Flow Matrix technical representative to assist in the safe installation of the controller. Do not use the FMC-2000 device as a pressure isolation valve. Always have a isolation valve rated to the system’s maximum operational pressure installed upstream of the FMC-2000 device to ensure shut-off integrity. For further detail regarding the installation, operation and maintenance of the FMC-2000, please contact the Flow Matrix Applications Engineering Department or go to our website for quick information.

If you have questions or comments, we would like to hear from you.

Customer Service Department

Flow Matrix LLC. 1737 Stebbins Drive, Suite 240BHouston, TX 77043(Main) (713) 979-1020 (Fax) (713) 715-7442 web: www.flowmatrix.net email: info@flowmatrix.net

Copyright 2003 Flow Matrix LLC.

Product Serial Number _________________

For your Safety

• PLEASE READ THIS MANUAL BEFORE ATTEMPTING INSTALLATION OR OPERATION! Attempting to operate the FMC-2000 without fully understanding its features and functions may result in unsafe conditions.

• Always use protective eye wear and observe proper safety procedures when working with pressurized gases.

• Do not use the FMC-2000 device as a pressure isolation valve. Always install an isolation valve that is rated to the system’s maximum operational pressure, upstream of the FMC-2000 device to ensure shut-off integrity.

• Please use device for specification in which it was originally configured. Please consult Flow Matrix to assure suitable configuration.

• Do not install the controller backwards. If high pressure is delivered to the outlet port of the controller without pressure to the inlet, severe damage can occur. Always double-check your inlet and outlet conditions before pressurizing your system.

• The standard device is not rated for oxygen service. Please consult with Flow Matrix to select and configure a device that has been cleaned and prepared for oxygen service.

• Install a particle filter upstream of the FMC-2000 if the gas being used could have particulate matter. This is necessary to prolong the life of the controller. Do not flow slurries or abrasives through the controller. Consult with Flow Matrix for proper particle filter.

• Do not use the FMC-2000 as an isolation valve for gas shut-off under high inlet pressure conditions. The device will maintain a 20-50 cc/min leak under shut-off condition for the high-pressure configuration to avoid internal damage. The low-pressure controllers can be configured with bubble tight shut-off.

• Safety Codes often require a pressure regulator installed directly on a high-pressure gas cylinder. Although the FMC-2000 can control flow of gases without the need for a constant inlet pressure supply, it should not be used in place of a pressure regulator to regulate pressure. The FMC-2000 is designed to regulate flow.

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Specifications: (For detailed specifications please consult conformance certificate)

Range See label on controller

Response Time < 100 msec

Stability of Setpoint 2.0% + 0.5% of setpoint

Temperature Range -40°F to 350°F (0°C to 300°C) (high temp above 212°F (100°C) needs special materials)

Temperature Effect 0.15% Full Scale / °C

Repeatability of Setpoint 0.30% of reading

Relative Humidity Up to 96% non-condensing

Attitude Sensitivity None

Inlet Pressure Sensitivity None

Outlet Pressure Sensitivity Depends on configuration, contact Flow Matrix

Media As listed on controller label

Wetted Materials Dependent on configuration (316SS, anodized 6061-T6 Al alloy, Brass, PCTFE, PEEK, PTFE, FKM, nitrile, EPDM, Perflouroelastomer all possible)

Standard Flow range

Body material Max. pressure

0-250 mL/min.

0-2 LPM

0-50 LPM

Aluminum

0-250 mL/min

0-2 LPM

0-50 LPM

500 psig

0-250 mL/min.

0-2 LPM

0-20 LPM

Brass or

316 SS

2500 psig

NOTE: See label on the controller for actual flow and pressure ranges. NOTE: Custom tailored flow and pressure ranges possible. Flow rates >= 100 slpm possible for gas applications.

Limited Warranty Flow Matrix, LLC. warrants this product to be free from defects in material and workmanship for a period of one year from the date of shipment from Flow Matrix or from an authorized Flow Matrix dealer.. Each device has been configured and fully tested before leaving our factory. The performance specifications and calibration are included in this warranty period provided the device has not been tampered with or the device misapplied. It is the responsibility of the customer to ensure the device is properly applied and the proper configuration has been selected. Gases under pressure may present hazards to the user and to equipment. It is the responsibility of the customer to ensure that operators are properly trained on the proper application, operation and service of this product before using. Our only obligation is to repair or replace any item found to be defective. The seller assumes no liability for consequential damages of any kind, and the buyer, by acceptance through purchase of this product, will assume all liability for the consequences of its use or misuse by the buyer, his employees, or others. ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING WITHOUT LIMITATION THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, ARE DISCLAIMED. Intended Use The FMC-2000 was designed to control the flow of gases or liquids within the operating limits stated on the identification label affixed to the body of the device. A properly configured and operating FMC-2000 is useful in controlling the flow of gases in many applications, and in some instances may be useful in enhancing the safety characteristic of a process. Before implementation, the user must fully understand the operation and limitations of this device as well as the application for its use. The responsibility for the proper application, choice of configuration, operation, installation, and maintenance of the FMC-2000 is the sole obligation of the purchasing party. The purchaser is required to ensure operators are properly trained in the use of this unit as well as in the possible hazards associated with its use or with the intended application. The purchaser must ensure that all of the proper warnings, labels, instruction manuals, lock outs, redundant components, hazard analysis, and system validation have been completed and provided to the trained operator before implementation of the FMC-2000 product.

Returning Merchandise

Before returning merchandise, please contact your dealer, or a Flow Matrix

customer service representative (if you purchased your FMC-2000 direct).

Request a Return Material Authorization Number (RMA). Products returned

without an RMA # will not be accepted. Flow Matrix reserves the right to charge a

fee to the customer for products returned under warranty claims if the devices

are tested and found to be free from defects (covered by the warranty).

It is mandatory that any equipment returned for servicing be purged and neutralized of any dangerous contents including but not limited to toxic, bacterially infectious, corrosive or radioactive substances. No work shall be performed on a returned product unless the customer has submitted a fully executed, signed SAFETY CERTIFICATE prior to shipping to Flow Matrix. Please obtain this form from our website (www.flowmatrix.net ).

Principle of Operation: General

VaryingPressureConditions

PreciseStable FlowControl

First Stage Regulation

Second Stage Regulation

Restrictor

Feed

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Pres

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Con

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Man

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The FMC-2000 Is a mechanical device that operates much like a two stage regulator that maintains a constant pressure differential across a fixed orifice (restrictor). The pressure differential is attained by a flow-rate balanced, dual-stage regulation system referenced to the down stream pressure. Balance is attained by a mechanical, pneumatic feedback, thereby making it immune to pressure transients both upstream and downstream of the controller.

The figure above depicts the method of increasing and decreasing the desired flow output for the FMC-2000 controller. Simply rotate the handle clockwise to increase flow and counter-clockwise to decrease flow.

Since the FMC-2000 device is a flow controller and not a pressure regulator, the device will operate at the outlet pressure dictated by the user’s system. If the tubing is small or there are restrictions such as valves, filters, etc., downstream of the controller, the FMC-2000 will self-compensate to keep the flow rate at a constant value. Essentially the device will regulate flow, not pressure. There may be time delays from when the backpressure changes to the time that the controller senses it and reacts. This time delay is dependent on flow rate and downstream volume of the system in which the controller is installed.

The FMC-2000 is a flow-controlling device and does not provide a metered output. It is designed for applications where the flow rate can be set to a known value, as determined by an external flow meter or other feedback device, and left to maintain the flow (volumetric flow) regardless of the inlet or outlet pressures subjected by a particular process.

Installation The figure below depicts the overall dimensions of the FMC-2000 controller. The standard device features ¼ inch female NPT input and output ports (optional Swagelok style tube fittings are shown below). Options include VCR style fittings installed into the inlet & outlet ports. The standard device features a panel-mounting nut. Machine a hole to clear the adjustment knob (1.25 “ diameter) & slide the controller through the hole (from the rear of the panel as shown in left diagram). The FMC-2000 features an “IN” and “OUT” stamped into the body housing to identify the proper connections. The controller can be installed in any orientation without affecting its operation.

Do not install the controller gas connections in reverse. If high pressure is fed to the outlet of the controller without any pressure to the inlet, severe damage can occur. Always double-check your inlet and outlet conditions before pressurizing your system. Flow Matrix LLC. does not warranty issues involving improper installation.

Primary Gas Connections Please note that not all FMC-2000 flow controllers have been configured to operate with liquids. Only clean gases are to be introduced into the instrument. If gases are contaminated they must be filtered to prevent the introduction of particulates into the working mechanisms. Prior to connecting gas lines, inspect all parts of the piping system including fer-rules and fittings for dust or other contaminant’s. Be sure to observe the direction of gas flow as indicated by the input and output ports. When using Swagelok type fittings, insert the tubing into the fittings until the ends of the tubes are fully inserted on to the inner shoulders of the fittings. Compression fittings are to be tightened according to the manufacturer’s instruc-tions. Avoid over tightening! Perform a thorough leak test of the entire system.

Do not install the controller backwards. If high pressure enters the outlet of the controller without pressure to the inlet, severe damage can occur. Always check your inlet and outlet before pressurizing. Flow Matrix LLC. does not warranty issues involving improper installation.

If the flow is shut-off downstream of the controller by a valve or other restriction, the pressure in the fluid line between the point of isolation and the FMC-2000 controller will equilibrate at the inlet (supply) pressure. Always shut-off the flow with a valve upstream of the controller or the entire system will be exposed to the inlet (source) pressure. This is because the FMC-2000 controller regulates the flow from the outlet pressure of the system. If the downstream pressure starts to rise because of a flow restriction or a shut-off valve, the controller will open more in an attempt to maintain the flow setting. Eventually, the outlet port pressure equals the inlet pressure. This effect will not damage the controller; however, it might damage other devices installed in the system downstream of the controller if the proper precautions are not taken. Most operational safety codes and other regulatory standards require a high-pressure valve on the gas cylinder as well as a high-pressure cylinder regulator. In this instance, the FMC-2000 does not replace the high-pressure regulator.

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Examples of Typical Installations

HighPressure

GasCylinder(2500 PSIMaximum)

FMC-2000(High PressureConfiguration)

Flowmeter(Optional)

High Pressure Cylinderor Isolation Valve(Rated to MaximumCylinder Pressure)

To Process

All components in the processpath must be compatible withthe highest amount of systembackpressure or processpressure.

If the flow is never shut off downstreamof the FMC-2000 Controller, then therewill be no need to use a pressureregulator upstream of the controller. TheFMC-2000 will step down the outletpressure below 150 psi while inoperation unless the processbackpressure exceeds 150 psi.

CONSTANT FLOW APPLICATIONS (NO FLOWSHUT OFF DOWNSTREAM OF CONTROLLER)

HighPressure

GasCylinder(2500 PSIMaximum)

FMC-2000(High or Low

PressureConfiguration)

Flowmeter(Optional)

High Pressure Cylinderor Isolation Valve(Rated to MaximumCylinder Pressure)

To Process

All components in the processpath must be compatible withthe pressure that the pressureregulator is set at.

When the flow is shut off downstream ofthe FMC-2000 Controller, the pressurewill equilibrate to the value that thepressure regulator is set to (the pressureat the inlet of the FMC-2000). It will notdamage the FMC-2000 but it mightdamage other components in theprocess stream if the regulator is set toohigh.

FLOW APPLICATIONS WITH ON/OFF VALVESDOWNSTREAM

CylinderPressure

Regulator PG

Pressure Gauge

Filtering and Flow Monitoring

• Install a particle filter (100 micron) upstream of the FMC-2000 if the fluid being used could have particulate matter. This is necessary to prolong the life of the controller. Do not flow slurries or abrasives through the controller. Consult with Flow Matrix for proper filter selection.

• A good choice is an inline sintered metal filter that is rated for 100 microns. These are available from Flow Matrix. Make certain to install the filter in an accessible location for future servicing.

• The FMC-2000 is a flow-controlling device and does not provide a visual indication of flow output other than the scaling label on the stem of the device. It is designed for applications where the flow rate can be set to a known value, as determined by an external flow meter or other feedback device, and left to maintain the flow (volumetric flow) regardless of the inlet or outlet pressures subjected by a particular process.

Maintenance It is important that only clean, filtered fluids be put into the Flow Controller. Some models allow the use of liquid as noted directly on the controller label. The controller uses an orifice or specially designed restrictor as part of the controlling mechanism. In conditions when the sample media contains particulates or can crystallize, the orifice/restrictor may get clogged. Therefore, great care must be taken to avoid the introduction of any potential flow impediments.

CAUTION: IT IS MANDATORY THAT ANY DEVICE RETURNED FOR SERVICING BE COMPLETELY PURGED AND NEUTRALIZEDOF TOXIC, BACTERIOLOGICALLY INFECTED, CORROSIVE OR RADIOACTIVE CONTENTS. FULL DISCLOSURE OF RETURNED GOODS HAVING BEEN IN CONTACT WITH ANY POTENTIALLY HAZARDOUS SUBSTANCE MUST BE MADE TO FLOW MATRIX BEFORE RETURNING.

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Troubleshooting In most applications, the FMC-2000 will perform flawlessly. However, under certain instances where the device is subjected to conditions outside of the normal operating parameters (extremely high or low temperatures, out of range pressure, liquid service for those devices configured for gases, particulate entrainment,….) the flow controller may require servicing. We recommend this work be completed at one of our service centers or directly by Flow Matrix service department. A basic troubleshooting guide:

Symptom Cause Remedy

No flow or low flow output

The flow path is restricted or shut off

Check to ensure the tubing and controller ports are clear Is the controller knob fully shut? Is the controller output shutoff downstream? Is the supply pressure shutoff or in a vacuum? If using a valved rotameter downstream, is it open?

Flow output is not stable

The downstream pressure is in transition or there is insufficient pressure differential across the device.

The flow will recover as quickly as the pressure stabilizes Ensure there is sufficient pressure differential between the supply and load sides of the controller

Maximum flow rate not attainable

The controller was configured for another media Backpressure creates insufficient pressure differential across controller

Check the label to ensure you are using the correct media

Ensure the downstream flow is unrestricted

Features Fast Response Time: < 100 ms!

The Flow Matrix mechanical controller provides volumetric flow control that is

insensitive to inlet and outlet pressures. Traditional flow controllers operate in a very narrow spectrum of allowable inlet pressures. Unlike the Flow Matrix flow controller, typical flow control devices require independent pressure regulation and pressure measurement.

The Flow Matrix mechanical controller can be configured to operate over an entire spectrum of inlet pressures between 1 to 3000 psig.

The Flow Matrix mechanical controller can be configured to operate over a wide range of outlet flows from mL/m to LPM, liquid or gas.

Since no power is required, the Flow Matrix mechanical controller is

intrinsically safe and can be used with many flammable gases.

The controller is not sensitive to attitude or gravity effects. The controller design is fundamentally immune to temperature transients and

so will lend itself to process applications where these conditions may exist.

1737 Stebbins Drive, Suite 240B, Houston, TX 77043

Main: (713) 979-1020Fax: (713) 715-7442

Web: www.flowmatrix.net Email: info@flowmatrix.net