RWF40

Compact Universal Controller

Flowrite
SKB/C/D
Valve Actuator

Flowrite VF 599 Series

Two-Way Valves

Differential Pressure Transmitter

with Three-Valve Manifold

RWF40 Modulating Feedwater Control Valve

Application Guide

Section 1 Overview
Introduction 1-1
The Siemens Differential Pressure Feedwater Control (DPFC) is an integrated system based on
a highly accurate Differential Pressure (DP) transducer(s) coupled to a RWF40 universal
controller. The RWF40 controls the Feedwater valve actuator directly (electro-hydraulic
actuator), or through an I to P converter (Pneumatic valve actuator). Many different actuators
and feedwater valves are offered to accommodate different feedwater pressures and flows.
The DPFC may be used on Firetube and Watertube Boilers, as well as Deareators. It can be set
up as a single or a dual element level control, depending upon which sensors are connected.
ModBus communications are also available via the RWF40, allowing the DPFC to interface with
a building management system or a HMI (touch screen). These features make the DPFC
extremely flexible, and ideally suited for use on most steam boilers and Deareators.
Figure 1-1.1 Typical Single Element DPFC

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Product Offering 1-2

RWF40 Universal Controller Options (All are 120VAC)
RWF40.001A97

Configurable analog output

2 Configurable analog inputs
Analog inputs forward or reverse scalable
Accuracy to 0.1 WC
Used for one or two element level control
Configurable High and Low alarm points

RWF40.002B97

Same features as above, plus:

RS-485 interface for ModBus communications.

Differential Pressure Transducer Options

7MF4433-NODISP

Industrial Grade DP Transducer

Used for :
Level Sensing (linear)
Flow Sensing (linear or square rt.)
Spanned 0 to 60 WC
2300 PSIG Max Operating Press.
Accuracy of 0.1% of span (0.06 WC)
Pushbutton, Laptop or HART configuration
HART Communications
IP65 (exceeds NEMA 4)
Explosion proof, if properly installed
Includes mounting hardware

7MF4433-DISP

Same features as above plus:

Viewable, multi-mode local display.

7MF4433-DISPR2

Same features as 7MF4433-DISP except:

Spanned 0 to 100 WC
Accuracy of 0.1% of span (0.1 WC)

Differential Pressure Transducer Accessories

7MF94115BA

3-Valve Manifold for DP Transducer

Billet Stainless Steel
NPT threaded connections
Includes mounting hardware, gaskets

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Differential Pressure Sensor Accessories (continued)

15965-659

Flanges for DP Transducer

Billet Stainless Steel
NPT threaded connections
Includes mounting hardware, gaskets

Electro-Hydraulic Feedwater Valve Actuators

SKD62UA

Valve actuator for use with VF599 Valves

Maximum Stroke
Adjustable Stroke
Direct or reverse acting
Adjustable opening characteristic
Opening Time : 30 sec
Closing Time : 15 sec
Spring return closing
225 lb Positioning Force
Analog Input, 4 to 20mA or 0 to 10 VDC
1000 Ohm signal can also be used
NPSM for conduit connectors

SKC62UA

Valve actuator for use with VF599 Valves

Same as SKD62UA, except :
1 Maximum Stroke
Opening Time : 120 sec
Closing Time : 20 sec
630 lb Positioning Force

SKB62UA

Valve actuator for use with VF599 Valves

Same as SKD62UA, except :
Opening Time : 120 sec
Closing Time : 15 sec
630 lb Positioning Force

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Electro-Hydraulic Feedwater Valve Actuator accessories

599-10048

Stem Reatainer Kit for use on valves up to 3 with

SKB/C actuators (10mm)

599-10049

Stem Reatainer Kit for use on valves, 4 to 6 with

SKB/C actuators (14mm)

599-10071

Weathershield for the SKD62UA Actuator

Makes the actuator NEMA 3R compliant
when mounted vertically.

599-10065

Weathershield for the SKC/B 62UA Actuators

Makes the actuator NEMA 3R compliant
when mounted vertically.

ASC1.6

0% stoke auxiliary switch

SPDT contacts
Rating: 24V, 4A resistive, 2A inductive

Feedwater Valves for use with Electro-Hydraulic Actuators

599-03xxx

to 2 Brass Feedwater Valves

Stainless Steel Caged Trim
Max. Leak-by : 0.01% of rated Cv
100 to 1 Rangeability

Complete listing in specifications,

Section 6

599-06xxx

2 to 6 Cass Iron Feedwater Valves

Stainless Steel Caged Trim
Max. Leak-by : 0.01% of rated Cv
100 to 1 Rangeability

Complete listing in specifications,

Section 6

Pneumatic Actuator, Feedwater Valve assemblies with positioning relay

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283-03xxx

Max inlet pressure to positioning relay : 60 PSIG

Max positioning relay outlet pressure : 30 PSIG
Max inlet pressure to Pneumatic Actuator :35 PSIG
1/8 NPT connections to positioning relay
Maximum Stroke
Adjustable spring preload

Complete listing in specifications,

Section 6

Penumatic Actuator, Feedwater Valve Actuator assembly accesories

545-208

Analog to Pneumatic Transducer

(4-20mA or 0-10VDC) to 3-15 PSIG

201-1000

Pressure Reducing Valve

142-279

2 Pressure Guage
0 -100 PSIG

908-051

Compressed Air Filter

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Typical DPFC systems 1-3

Typical Single Element DPFC

A typical single element DPFC system will include the following components:
RWF40.001A97

Universal Controller

7MF4433-DISP

Differential Pressure Transducer (for level)

7MF94115BA

Three Valve Manifold for DP Transducer

SK(D,C,B)62UA

Electro-Hydraulic Feedwater Valve Actuator

599-10048

Stem Retainer Kit Used to couple SKB/C actuators to 599-0x Feedwater

valves up to 3 (10mm)

599-10049

Stem Retainer Kit Used to couple SKB/C actuators to 599-0x Feedwater

valves from 4 to 6 (14mm)

599-03xxx

Feedwater Valve

Installer
Supplied

Condensate Pot Assembly (see sketch in section 2-2)

24 VAC transformer, 30 VA (20 W) to power actuator
Tubing and Tube Fittings
Conduit, Wire, Piping

Typical Two Element DPFC

A typical two element DPFC system will include the previously mentioned items plus the
following additional components:
7MF4433-DISP

Differential Pressure Transducer (for flow)

7MF94115BA

Three Valve Manifold for DP Transducer

Installer
Supplied

24 VAC transformer for second 4-20mA loop

Important Safety Notes 1 - 4

All activities (mounting, installation, service work. etc.) must be performed by qualified staff.
Ensure that all piping, tubing and pressure vessels (condensate pot) are in accordance with
local and national codes.
Before performing any work in the connection area of the RWF40, disconnect the unit from
the main supply (all-polar disconnection).
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Protection against electrical shock hazard on all connected electrical components must be
ensured through good wiring and grounding practices.
The system must be cool and depressurized before any work is performed on the water /
steam side of the control. Failure to do this could result in severe injury or death.
Condensation and the entry of water into the electronics compartment of any component
must be avoided.

Approvals 1- 5
Table 1- 5.1 Standards and certificates

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Section 2 Mounting
RWF40 Mounting 2-1
The RWF40 should be mounted inside an enclosure that will protect the RWF40 from dirt and
moisture. The unit is mounted through the face of an enclosure, and uses a lead screw on each
side of the casing to clamp the RWF40 to the panel face. It should be noted that the enclosure
cutout must be accurate, or the RWF40 will not mount correctly. Figure 2-1.1 Illustrates the
proper size cutout for the RWF40, and the overall dimensions of the RWF 40.
After the cutout has been made, RWF40 can be inserted through the cutout back first. The lead
screws can be clipped in either the top and bottom or the left and right sides. Figure 2-1.2
illustrates the lead screws clipped in the left and right sides. After this is done, tighten the lead
screws, clamping the RWF40 to the face of the enclosure. Figure 2-1.2 illustrates this
procedure, as well as RWF40 module removal.
Please see Section 6 for specifications.
Figure 2-1.1 RWF40 Enclosure Cutout and Overall Dimensions (Inches)

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Figure 2-1.2 RWF40 Enclosure Mounting, Module Removal

Differential Pressure Transducer Mounting 2-2

The Differential Pressure Transducer (DPT) can be used for two different types of sensing duty.
In a typical single element DPFC, the DPT functions as a level sensing device that can
accurately detect the difference in the level of two water columns. In a dual element DPFC, two
DPT are used, one to sense level and the other to sense differential pressure across a flow
element (orifice). This flow element is typically piped into the vessel outlet.
The DPT is supplied with hardware and brackets that permit many different mounting
orientations. The DPT is typically oriented right side up (transducer head above process
connections, process connections horizontal) but it may also be oriented so that the process
connections are vertical with the transducer head to the side. The DPT must not be oriented
upside down (transducer head below process connections). Acceptable orientations are shown
in Figure 2-2.1.
After the DPT has been mounted in one of the permissible mounting orientations, accessories
such as the 3-valve manifold or the flange kit may be mounted to the DPT. All necessary
hardware and gaskets are provided with the 3-valve manifold and the flange kit.

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Figure 2-2.1 DPT Overall Dimensions (mm and inches)

Figure 2-2.2 Acceptable DPT Orientations

When mounting and tubing the DPT for level sensing, a few important points must be observed.
These points are as follows:
1. The DPT must be mounted on cold legs (drip legs) so that the water that the DPT is
exposed to is less than 200 o F.

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2. The DPT must be mounted lower than the lowest measured level. This could be the bottom
of the vessel (possibly in a deareator), or this could be halfway up the side of a vessel (as is
done on a typical firetube boiler). The DPT can be mounted at any practical distance below
the vessel.
3. The reference leg (-) of the DPT must remain full and at a constant level during operation.
This is assured by using a Condensate Pot which is less than saturation temperature. The
reference leg and the Condensate Pot must be filled with clean water during the initial Startup. When used on steaming vessels (boilers and deaerators) the Condensate Pot will
remain completely full due to the steam condensing in the below saturation temperature
Condensate Pot.
4. The colder and larger the Condensate Pot, the better. For example, if the vessel is at
saturation at 100 PSIG steam pressure, the water in the vessel is about 338 oF. If the
Condensate Pot is distanced from the vessel (on a un-insulated pipe) the water in the
Condensate Pot will be less than 338 oF, and will have a much lower likelihood to flashing in
the event of rapid de-pressurization of the vessel. If the Condensate Pot is distanced
enough to be less than 212 oF, Condensate Pot flashing will never take place. Achieving a
temperature of 212 oF at the condensate pot is not always practical, so the effects of a rapid
de-pressurization event severe enough to cause Condensate Pot flashing can be minimized
by using a larger diameter, larger volume condensate pot.
5. Provisions should be made so that the DPT can be bled of air during start-up. This is
typically done by loosening the plugs on the DPT opposite the process connection when the
vessel is cold and under little or no pressure.
Figure 2-2.2 illustrates the preferred method of mounting a DPT and Condensate Pot to a
typical deaerator vessel. Figure 2-2.3 illustrates another acceptable method that can be used to
mount a DPT to a typical deaerator vessel. Figure 2-2.4 and 2-2.5 illustrate the preferred and
acceptable methods (respectively) for mounting a DPT and Condensate Pot to a typical firetube
boiler.
Figure 2-2.3 Preferred Mounting (Deaerator Vessel)

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Figure 2-2.4 Acceptable Mounting (Deaerator Vessel)

Figure 2-2.5 Preferred Mounting (Firetube Boiler)

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Figure 2-2.6 Acceptable Mounting (Firetube Boiler)

The difference between the preferred and the acceptable methods of mounting is the water
column. The water column with blowndown valve is preferred since it provides a container for
solids precipitation / separation, and also a means to flush these solids. This serves to keep the
working leg of the transducer more debris free. The water column also serves to dampen
turbulence that may be occurring in the vessel. Last but not least, the water column serves as
an additional thermal barrier for the Condensate Pot. Typically, water columns are constructed
from pressure rated 1 pipe.
The Condensate Pot is the most important part of the reference leg, and necessary for almost
all installations. This piece serves as a condensate reservoir that will not vary in level any great
degree even if condensate flashing (due to depressurization) takes place. As was previously
mentioned, the larger the Condensate Pot, the better. Specifically, it is best to make the
Condensate Pot internal diameter as large as practical, while maintaining a 6 to 10 inch overall
height. Figure 2-2.6 illustrates typical Condensate Pots.

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Figure 2-2.7 Typical Condensate Pots (dimensions in inches)

Connection of the Condensate Pot to the DPT is usually accomplished with 3/8 Stainless Steel
tubing, but other tubing / pipe of different material and / or larger diameter will also perform
adequately.
If a second DPT is used to measure the DP across an orifice (as would be done in a two
element DPFC) the second DPT should be mounted and tubing installed according to Figure 22.8. The DPT is installed below the steam flow orifice for thermal isolation. The two pieces of
tubing going to the DPT (or legs) will fill up with water as the steam is cooled and condensed in
the metal tubing. Care should be taken to ensure the water legs going to the DPT are installed
so that the accumulated water in each leg is equal in height.
Figure 2-2.8 DPT Mounting for Steam Flow Orifice

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Section 2

Feedwater Valve / Electro-Hydraulic Valve Actuator Mounting 2-3

The 599-03 series of feedwater valve features female NPT threads on both the inlet and outlet
of the valve. The valve body is brass, and features a stainless steel trim. The valve is typically
mounted by the inlet and outlet piping. The 599-06 series of feedwater valve features a flanged
connection on both the inlet and outlet of the valve. The valve body is cast iron, and also
features a stainless steel trim. This valve is also typically mounted by the inlet and outlet piping.
The electro-hydraulic actuators (SKB/C/D) are typically field mounted to an appropriately sized
application-specific feedwater valve. The 599-0x feedwater valves require different actuator
strokes and force depending upon their size and application. 599-0x valves from to 3 require
an actuator having of stroke, and above 3 require an actuator having a 1 stroke. The
force that is required is dependent upon the inlet pressure into the valve, and also if the valve is
a normally open or normally closed valve. Specific information concerning valve / actuator sizing
is included in Section 6.
For normally closed valves (typically used in feedwater applications) full downward travel of the
valve stem is full open. Full upward travel is full closed. For normally open valves, full downward
travel of the valve stem is full closed. Full upward travel is full open. A complete listing of all
valves with technical information is included in Section 6.
Field mounting of the electro-hydraulic actuators to the 599-0x series feedwater valves is a
relatively simple process. However, the SKD actuator mounts to feedwater valves differently
than the SKB and SKC actuators. Figure 2-3.1 details the overall dimensions of the the SKD
and the SKB/C actuators. Figure 2-3.2 and 2-3.3 detail the SKD and SKB/C mounting
procedures respectively. Both the SKD and the SKB/C can be mounted with the valve below the
actuator (vertically, knob up) and also with the valve beside the actuator (horizontally). The
valve actuator must not be mounted with the valve above the actuator (vertically, knob down).
Figure 2-3.1 SKB/C and SKD Overall Dimensions (inches and mm)

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Figure 2-3.2 Mounting SKD Actuator to 599-0x Feedwater valves

Place the Actuator in manual mode by rotating

the knob on the very top of the actuator clockwise
until the manual flag appears. This will also move
the valve stem retainer downwards.
Loosen the socket head screws on both the valve
stem retainer and the actuator yoke.

Slide the actuator down over the valve stem

and the valve bonnet.
Rotate the actuator to the desired position
about the valve stem.
Ensure that the raised area on the I.D. of the
valve stem retainer is aligned into the machined
groove in the valve stem.
Hold the valve stem retainer, tighten the socket
head screws. Ensure that the raised area on
the ID of the valve stem retainer stays in the
valve stem groove during the tightening
process.
Tighten the socket head screws on the actuator
yoke with a torque not exceeding 40 in-lb.
Place the actuator back in auto by rotating the
knob on the very top of the actuator
counterclockwise until the MAN flag retracts.

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Figure 2-3.3 Mounting SKB/C Actuator to 599-0x Feedwater valves

Remove the valve stem retainer and the valve

stem retainer nut from the packaging.
Slide the narrow end of the nut over the valve
stem.
The 10mm valve stem retainer is for use with
valves up to 3. The 14mm valve stem retainer
is for use with valves from 4 to 6.

Spread the valve stem retainer just enough to fit

it into the valve stem groove. Be very careful
not to break the valve stem retainer in half.

Gently close the valve stem retainer by hand.

When the nut is slid up the valve stem, the
valve stem retainer should fit inside the nut.

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Figure 2-3.3 Mounting SKB/C Actuator to 599-0x Feedwater valves

Loosen the two actuator retainer bolts, and

remove the actuator retainer. The actuator
retainer bolts have a 3/8 head.
Next, slide the valve actuator onto the
feedwater valve. Unlike the SKD, the SKC/B
series of actuator slides onto the valve bonnet
from the side.
Replace the actuator retainer and the actuator
retainer retaining bolts. Install the bolts finger
tight. At this time, the valve actuator can be
turned about the valve stem to the desired
position.
After the valve is in the desired position, tighten
the actuator retainer retaining bolts with a
torque not exceeding 40 in-lb.

Unfold the crank arm on top of the actuator.

Turn the crank clockwise. This will lower the
threaded nipple that the valve stem retainer nut
threads onto.
When in the correct position, the window will
show a 16 for a SKB and a 32 for a SKC.

Slide the valve stem retainer nut up the valve

stem. Take care to ensure the valve stem
retainer fits inside the nut and that the retainer
stays fully engaged with the valve stem groove.
Thread the valve stem retainer nut onto the
threaded nipple.
Tighten the valve stem retainer nut. This
requires a 24 mm open end wrench.
Turn the crank counterclockwise until numbers
no longer show in the window (About 8 rev. for
SKB, and about 16 rev. for SKC)
Fold the crank arm on top of the actuator.

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If positive 0% stroke indication is desired, a limit switch can be added to the SKB/C/D. This
switch is an ASC1.6, and it features a SPDT design. This switch is mounted under the cover of
the SKB/C/D with small machine screws. The switch can be moved up and down slightly before
fully tightening the machine screws so that the activation point can be fine tuned.

Figure 2-3.4 Mounting ASC 1.6 switch to SKB\C and SKD

599 Series Feedwater Valve / Pneumatic Valve Actuator Mounting 2-4

Pneumatic feedwater valve actuators are typically factory mounted to an appropriately sized
application-specific feedwater valve so field assembly of the valve / actuator is not necessary.
The pneumatic feedwater valve actuator assembly also typically includes a positioning relay for
highly accurate control. Figure 2-4.2 shows a pneumatic valve actuator with a positioning relay.
The valve actuator can be mounted in any orientation, except upside down (with the actuator
diaphragm pointing to the floor)
The pneumatic feedwater valve actuator assembly may need adjustment in the field. Figure 24.1 details this adjustment procedure.

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Figure 2-4.1 Overall Dimensions (in inches) and Adjustment of 8 Pneumatic

Feedwater Valve Actuator (without positioning relay)

Normally closed feedwater valves:

To Increase the start to open pressure turn the
adjustment screw from the right to the left
To decrease the start to open pressure, turn the
adjustment screw from the left to the right.

Normally open feedwater valves:

To Increase the start to close pressure turn the
adjustment screw from the right to the left
To decrease the start to close pressure, turn
the adjustment screw from the left to the right.
As the pressure differential across the
feedwater valve increases, the span of the
Actuator spring will decrease.

Figure 2-4.2 Pneumatic Feedwater Valve Actuator (with positioning relay)

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The Pneumatic Feedwater Valve Actuator, when combined with the positioning relay offers
much improved control compared to the Pneumatic Feedwater Valve alone. The reason for this
is that the positioning relay is designed to achieve a given actuator position (actuator stroke) for
a given pneumatic signal. The positioning relay varies the air pressure to the diaphragm in the
feedwater valve actuator to achieve a certain actuator position which is monitored by the
feedback arm. The air pressure delivered to the actuator diaphragm can be greater or less than
the original pneumatic signal. The end result of the positioning relay is that the actuator and
therefore feewater valve position are largely unaffected by the differential pressure across the
feedwater valve.
If the positioning relay is not used, the differential pressure across the feedwater valve will
influence the actuator position, since the differential pressure causes pushing or pulling forces
on the valve stem. With these variable pushing or pulling forces present on the actuator stem, a
certain pneumatic signal will not always position the feedwater valve in the same place. For this
reason, the use of the positioning relay is recommended on deaerators (small to medium
variance in DP across the feedwater valve) and is highly recommended on boilers (medium to
large variance in DP across the feedwater valve).
The Pneumatic Valve Actuator, Feedwater valve, and Positioning relay are assembled and the
positioning relay calibrated prior to shipment. The positioning relay generally does not need to
be recalibrated in the field. However, if recalibration or replacement is necessary, calibration
instructions for the positioning relay can be found in a document entitled RL147 Positioning
Relay (Document Number 155-038P25).

Pneumatic Valve Actuator Mounting Accessories 2-5

A number of accessories are available to complete the installation of the pneumatic valve
actuator. These accessories include: Electric to Pneumatic Transducers, Pressure Regulators,
Compressed Air Filters, and Pressure Gauges.
In order to use a Pneumatic Valve Actuator with a RWF40, an Electric to Pneumatic Transducer
(AO-P) is necessary. The device takes a 4-20mA or a 0 to 10 Volt DC signal and converts this
electrical signal to a pneumatic (air pressure) signal. The electric input signal can be selected
via a jumper on the back of the AO-P. This jumper is shown in Figure 2-5.1. The AO-P also
features an auto / hand switch. This enables the pressure output of the AO-P to be manually
adjusted with a screwdriver when the AO-P is in hand mode.
The AO-P is available in both a panel mount and a remote mount. The dimensions of these two
different models are shown in Figure 2-5.2

Figure 2-5.1 Jumper Settings, Output of the Electric to Pneumatic Transducer (AO-P)

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Figure 2-5.2 AO-P Overall Dimensions (in inches and mm)

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Section 2