Teledyne 200 Automobile Parts User Manual
Contents
1. 14 16 VDC 30 mA lt 1 Watt Power 24 Volt flow meter AS EE aa t 14 32 VDC lt 1 9 Watts Flow Signal inherently linear 0 5 00 VDC or 4 20 mA EE 316 SS Viton 82 18 Au Ni Braze KISS vga all LTL TATA T te v ATT Te vea Os JA e Trace Silver Solder 870 01071010 15 pin subminiature D 9 pin for 24 Volt EINS Swagelok others available Weight approx A keda dt ado aada aaa 1 8 lb 0 82 kg 1 3 Specifications HFC 202 Accuracy and Linearity eoe amp veda Sains 1 F S M E E MESSE SEE ASE E ASSESS 0 05 F S Std Pressure Rating 0 i cissecdicscascesescaauedsactadesteveeahacedeacesdossewuadeateecesasdabsdeaagetveveedauksddetnaceveadutasdedasegevaesetieds 500 psig High Pressure Options siuetidiiududaa kastan dla outdated at aatulu tada oh area laimata te Proof tested to 1500 psig Pressure koaalad 0 0067 psi 0 1000 psig 2 typical Control Valve DRY per customer order Teak Integrity aitama ede lt 1x10 Temperature Coefficient 3 E AR Zero 0 035 FS2. 5 1 3 SPECIFICATIONS HEC 202 gt ccccccscscsssesessececscscscscececssucecscsesesesvssusnsscscacecacsssusucacssassvavsvssnsaeasacacacaussasacatsesnavasees 5 1 4 OPTIONAL 4 20 MA CURRENT OUTPUT 6 1 5 OTHER ACCESSORIES c a weno ube abt ee ea ACA aa ed 6 1 3 1 Hastings Power Supplies o a a A EEEE a ANE ka 6 T 5 2 lt Interconnecting Cables 7 2 INSTALLATION AND OPERATION sisecsissssscsccscscssssossossosscsessesssessenessevds vossesbeas sbectsossiesessens cesoasicossbectesesesised ceesees 8 2 1 RECEIVING INSPECTION caade cubed cubeds 8 2 2 POWER REQUIREMENTS SG dad 8 23 OUTPUT SIGNAL Bead ER aes kahes aa 8 2 4 MECHANICAL CONNECTIONS Beis Ba 9 2 4 1 Standard Confiruration hati oie aiid aes 9 24 2 Conhigiiration AA 9 2 5 ELECTRICAL CONNECTIONS ak Sees a GG es BS 10 2 6 OPERATION a BEB AGRE ee ae eee Beets BAS 11 2 612 Operating Conditions nas nara keeks s nakas kehka ka k tu d Wk aio hia tee A Erkko ike nh hava nara 11 2 022
3. STT 12 2 6 3 High Pressure Operation hab AHAS id atin Baila Benes 12 2 64 Blending of Gases 12 27 OPERATION WITH EXTERNAL DEVICES rrvverenenenenenenenenenenenenenenenenenenenenenenenenenenenenenenenenene nene 12 2 7 1 Operation with a Hastings power 1 12 2 7 2 Operation with a Power Supply other than a 13 27 3 Operation with an external sensor Fig 2 2 isetsteeeneeeeresneetesteeveeneseneeneneenesneneeneseneene a 14 2 14 Response to Command Changes ee 14 2 8 RANGE CHANGING cad cb ees sake Bada eee a ee ca ade a obs RB eet ie aA Rr 15 2 9 VALVE OVERRIDE CONTROL snieni teea a a beeen ate 15 3 THEORY t os nsi e vov esed ocbsessesessevtieessestsassdesesossvateces sbecdsogsscadssusdesssessoasocesss 16 3 1 OVERALL FUNCTIONAL DESCRIPTION enevenenenenenenenenenenenenenenenenenenenenenenenenenenenenenenenenenenenenenenene 16 3 2 BOE fo O Se ge ec a a li 16 3 3 EDRECTRONICS nind cated a aaa ede Sha Nace ced eds oo ecb Sek oan ca Spec ceed a Last rel c
4. C 0 60 A a Span 0 05 RDG C 0 60 0 C and 760 Torr Power 15 Volt controller wreerree 14 16 VDC 60 mA 185 mA lt 3 Watts Power 24 Volt controller mewwererenneneeneerevevenenennenevereeveneneneneevevevennena 14 32 VDC lt 4 2 Watts Plow Signal res duets tedden saamatuses keda a aitad inherently linear 0 5 00 VDC or 4 20 mA Command Signal era n Ah ei al aes cee 0 5 00 VDC or 4 20 mA Wetted Material ccccccccssscccccssscccccssscecccssscecescssncccecesaaecesscaecesentaeccssntaeceesnacs 316 SS 302 SS Nickel Viton A a e sess 82 18 Au Ni Braze Trace Silver Solder Kalrez CONE e O siete 15 pin subminiature D 9 pin for 24 Volt eas in Swagelok others available Weishti APPrOx 1 8 lb 0 82 kg 1 Stated accuracy is for nitrogen or other gas specific calibration and using this gas only 2 Other materials are available Viton is the standard O ring option Specifications may vary for instruments with ranges greater than 10 slpm 140 072011 200 202 Series Page 5 of 24 1 4 Optional 4 20 MA Current Output An option to the standard 0 5 VDC output is the 4 20 mA current output that is proportional to flow
5. 15 Flow Signal Output is sourced from 15V Supply Setpoint Signal Input is Sunk to Signal Common POWER Skip Setpoint Signal for Flowmeters POWER D A M Digital Ammeter SUPPLY SUPPLY Flow Signal Output is sourced from 15V Supply Setpoint Signal Input is Sunk to Signal Common 1 5 Other Accessories 1 5 1 Hastings Power supplies Hastings Power Pod power supply display units are available in one and four channel versions They convert 100 115 or 230 VAC to the 15 VDC required to operate the flow meter and provide a digital indication of the flow rate Interface terminals for the retransmission of the flow meter analog output signal are located on the rear of the panel The Power Pod 100 and 400 models are built with controllers in mind but will work with meters as well The Model 40 is for flow meters only Throughout this manual when reference is made to a power supply it is assumed the customer is using a Hastings power supply Hastings PowerPod 100 and PowerPod 400 power supplies are CE marked but the Model 40 does not meet CE standards at this time The Model 40 and PowerPod 100 are not compatible with 4 20 mA analog signals With the PowerPod 400 individual channels input signals as well as their commands become 4 20 mA compatible when selected The PowerPod 400 also sports a Totalizer feature More information about the Power Pods can be found on the Hastings web site http www teledyne hi com products powerpod
6. 78 slpm 3 9 slpm 20 1 2 7 Operation with External Devices 2 7 1 Operation with a Hastings power supply There are two controls for each flow controller connected to a Hastings power supply A switch labeled OPEN AUTO CLOSED valve override THPS 400 only and a potentiometer labeled COMMAND For normal operation the valve override switch will be in the AUTO position The CLOSE position removes all power from the valve shutting off flow regardless of the command pot setting The OPEN position applies full available valve voltage to the valve causing it to open regardless of the command pot setting The OPEN position is useful for purging systems It is recommended that the valve override switch not be left in this position for extended periods of time with no flow through the controller as a small positive zero shift may be observed 140 072011 200 202 Series Page 12 of 24 The COMMAND pot adjusts the Analog command signal sent to the flow controller The setting for each controller connected to the power supply can be observed Depending on how the power supply was set up the display could indicate in flow units or percent of full scale Hastings Power Supply Feature Guide Feature Model 40 Power Pod 100 Power Pod 400 Digital Readout v A A 15 Volts v v Analog Outputs v A A Controller Analog Control Front Panel
7. The 4 20 mA signal is produced from the 0 5 VDC output of the flow meter The current loop output is useful for remote applications where pickup noise could substantially affect the stability of the voltage output or long cable runs where cable resistance would cause a voltage signal to decay The current loop signal replaces the voltage output on pin 6 of the DA 15 connector pin 2 of DE 9 24 Volt The current loop is sourced internally from the 15 VDC supply and must be returned to the signal supply common after pin 5 15 VDC or pin 8 24 VDC passing through the monitoring circuitry to complete the loop The load must be between 0 and 600 Ohm The 4 20 mA I O option can accept a current input for flow controllers The 0 5 VDC command signal on pin 14 pin 3 for 24 Volts can be replaced by a 4 20mA command signal The loop presents an impedance of 50 Ohms and is returned to the signal common On the 24 Volt units the signal common will need to be tied to the power supply common external to the flow controller to complete the loop since the signal common is galvanically isolated internally from the supply common This line must be current limited lt 50 mA to prevent short circuit currents from damaging the receiving circuit in the flow controller 24 Volt Supply FLOW 15 Volt Supply FLOW CONTROLLER VALVE RETURN 2 D A M Digital Ammeter Ode 15
8. CLOSE This setup will be adequate for most purposes but there will be a small delay for capacitors to charge between switch operation and control override 2 6 Operation The standard instrument output is a 0 5 VDC out and the signal is proportional to the flow i e 0 Volts zero flow and 5 Volts 100 of rated flow The 4 20 mA option is also proportional to flow 4 mA zero flow and 20 mA 100 of rated flow It is suggested that all connections be checked for leaks after installation This can be done by pressurizing the instrument do not exceed 500 psig unless the instrument is specifically rated for higher pressures and applying a diluted soap solution to the connections 2 6 1 Operating Conditions For proper operation the combination of ambient temperature and gas temperature must be such that the flow meter temperature remains between 0 and 60 C The most accurate measurement of flow will be obtained if the flow meter is zeroed at operating temperature as temperature shifts result in some zero offset The HFM 201 HFC 203 series is intended for use in non condensing environments only Condensate or any other liquids which enter the flow meter may destroy its electronic components 140 072011 200 202 Series Page 11 of 24 2 6 2 Zero Check Turn the power supply on if not already energized Allow for a 1 hour warm up Stop all flow through the instrument and wait 2 minutes Caution Do not assume that all metering valves c
9. MODULAR SENSOR The HFM 200 HFC 202 series incorporates a removable replaceable sensor module Field repairs to units can be achieved with a minimum of production line downtime e METER SETTLING TIME Changes in flow rate for the HFM 200 are detected in less than 2 seconds when using the fast response circuitry e LOW TEMPERATURE DRIFT The temperature coefficient of span for the HFM 200 HFC 202 series is typically less than 0 05 of full scale C from 15 45 C The temperature coefficient of zero is typically less than 0 1 of reading C from 0 50 C e CURRENT LOOP The 4 20 mA option gives the user the advantages of a current loop output to minimize environmental noise pickup 140 072011 200 202 Series Page 4 of 24 1 2 Specifications HFM 200 Accuracy and Linean gh elastics Nelda edie eee 1 F S Repeatability AT 0 05 F S Standard Pressure Rating laen aktus eesi 500 psig 0 0067 psi 0 1000 psig N2 typical Proof tested to 1500 psig Leak Integrity ess ea ead a dase se eee idea ein I seid aa eso san lt 1x10 Temperature Goeth Zero 0 035 FS C 0 60 C Span 0 05 RDG C 0 60 SUD E east ah SURN 0 C and 760 Torr Power 15 Volt flow meter
10. gt being 100 of rated or full flow Pin 14 of the DA 15 1 5VD0_Ref Ext_h 15 Volt Pin 3 of the DE 9 24 Volt is the command Ai input This should be a 0 5 VDC or 4 20 mA 4 Power Common _ signal and must be free of spikes or other electrical Saitoh Ove noise as these will generate false flow commands that ower Input the controller would attempt to adjust flow Pin 15 of 9 Case Ground _ the DA 15 15 Volt Pin 1 ofthe DE 9 24 Volt is a regulated 5 00VDC output reference that is normally adjusted to 5 01 VDC so that the user can achieve full scale command set point The reference is designed to provide the command signal for pin 14 by connecting one end of a potentiometer to the voltage reference and the other end to ground The center lead would then be connected to setpoint input PINOUTS If a valve override switch is not desired the unit is ready for use at this time If the override switch is desired connect the center pin of a single pole three position switch with the center off position to pin 8 of the DA 15 15 Volt Pin 6 of the DE 9 24 Volt Connect a voltage source gt 10 VDC to one end of the switch and negative voltage to the other end This will result in the valve being full open when the positive is supplied to the override pin off when the negative voltage is supplied and auto control when there is no connection to the valve override pin OPEN AUTO
11. jack in the board If it does not read approximately 22 VDC then replace regulator U2 U3 on 24 Volt board SYMPTOM Sensor has proper resistance readings but little or no output with flow CAUSE Plugged sensor ACTION Shut off gas supply and power supply Remove cover and PC board from unit Remove sensor assembly and examine If sensor has evidence of plugging clean or replace as applicable SYMPTOM Flow controller oscillates CAUSE Flow controller not adjusted for the dynamics of the flow system ACTION Check upstream and downstream pressures The gas supply regulator should not have excessive lockup when flow shuts off Also ensure that there is not a large drop in pressure between the regulator and the instrument due to line resistance Oscillations can also be caused if a large flow restriction is pneumatically close to the downstream end of the flow controller The differential pressure across the unit must be between 10 50 psig SYMPTOM Little or no flow even with Valve Override OPEN enabled 140 072011 200 202 Series Page 19 of 24 CAUSE Plugged orifice ACTION Verify the presence of a 10 50 psig pressure across the instrument If present shut off gas supply and power supply Remove orifice per Section 4 9 Examine orifice If plugged clean or replace as applicable Reassemble valve SYMPTOM Flow meter reads other than 0 00 VDC with no flow or there is a small flow when flow meter reads 0 00 VDC CAUSE ZERO pot
12. series htm 140 072011 200 202 Series Page 6 of 24 1 5 2 Interconnecting Cables Cables are available from Hastings in various lengths to connect from the 15 pin D connector on the back of the Power Pod directly to any ofthe 200 series and 300 series flow instruments including digital versions More information about the available cables can be found in the Power Pod 400 bulletin on the Hastings web site http www teledyne hi com pdfs bulletins htm 140 072011 200 202 Series Page 7 of 24 2 Installation and Operation This section contains the steps necessary to install a new flow meter controller into operation as quickly and easily as possible Please read the following thoroughly before attempting to install the instrument 2 1 Receiving Inspection Carefully unpack the Hastings HFM 200 HFC 202 series instrument and any accessories that have also been ordered Inspect for any obvious signs of damage to the shipment Immediately advise the carrier who delivered the shipment if any damage is suspected Check each component shipped with the packing list Insure that all parts are present 1 Flowmeter power supply cables etc Optional equipment or accessories will be listed separately on the packing list There may also be one or more OPT options on the packing list These normally refer to special ranges or special gas calibrations They may also refer to special helium leak tests or high pressure tests In most cases the
13. Override Totalizer 4 20 mA Ratio Control Alarms Multi Channel Display Conversion Factors A Communications RS232 RS232 RS485 2 7 2 Operation with a Power Supply other than a Hastings The flow controller must be connected to the power source as specified in section 2 6 In general a 0 5 VDC command signal proportional to the intended flow 0 Volts zero flow 5 Volts 100 of rated flow must be applied to pin 14 of DA 15 15 Volt Pin 3 of the DE 9 24 Volt connector A0 5 VDC signal proportional to the flow rate through the instrument will be present on pin 6 of the DA 15 15 Volt Pin 2 of the DE 9 24 Volt connector The control mode is selected via pin 8 of the DA 15 15 Volt Pin 6 of the DE 9 24 Volt connector Apply gt 10 Volts for full open lt 0 Volts for closed and allow the override to float for flow proportional to the command voltage Refer to your power supply manual for the specifics of implementing these parameters 140 072011 200 202 Series Page 13 of 24 2 7 3 Operation with an external sensor Fig 2 2 In some instances it might be desirable to use an external sensor to provide process information to the control circuitry Fig 2 2 in the flow controller For example you might want to control the pressure in a vacuum system by adjusting the MA rate at which the system is backfilled with a gas The new enhanced HFC series of flow controllers have provi
14. PC board fails it is easily removed from the instrument and replaced with a spare to minimize instrument downtime Replacement of the PC board will require the instrument to be recalibrated per Section 4 3 1 Unplug the power cable from the top of the transducer Remove the two jackscrews next to the D connector and the two screws on the sides of the cover Lift off the cover and unplug the four wire sensor plug and the two wire valve plug noting their orientation prior to removal Remove the screw that holds the PC board to the sensor Troubleshoot or replace as applicable Installation is the reverse of the above procedure Recalibrate if any components were changed or if any potentiometers were adjusted 4 6 Sensor Replacement If the sensor fails or becomes plugged it can be removed Remove the cover and the PC board per Section 4 5 above Remove the three bolts holding the sensor to the instrument base Remove the sensor from the base noting the two O rings Parker 2 005 V884 75 between the sensor and the base If the sensor is plugged it can be cleaned by running a fine wire approximately 0 008 diameter through the tube If sensor needs replacement obtain another from the factory and install it Ensure that O rings are clean and intact Install O rings on seating surface then carefully place sensor over O rings and tighten down the three screws evenly Replacement of sensor will require recalibration per Section 4 3 1 4 7 Orif
15. Revision H Document Number 140 022009 2 February 2009 Revision J Document Number 140 102009 October 2009 Revision K Document Number 140 102009 2 22 October 2009 Revision L Document Number 140 082010 August 2010 Revision M Document Number 140 072011 July 2011 a Visit www teledyne hi com for WEEE disposal guidance The instruments described in this manual are available with multiple pin outs CAUTION A Ensure that all electrical connections are correct The instruments described in this manual are designed for INDOOR use only The instruments described in this manual are designed for Class 2 installations CAUTION in accordance with IPC standards Hastings Instruments reserves the right to change or modify the design of its equipment without any obligation to provide notification of change or intent to change 140 072011 200 202 Series Page 2 of 24 Table of Contents 1 GENERAL INFORMATION icssescedcssscoscsscccssscavossasecsossontesse seetsssusocsevsesccs sscbecstevenasosssecessten eced evi s vees kuva ed s ss uusi 4 1 1 FRATURES AR 4 12 SPECIFICATIONS 200 AAS En
16. TELEDYNE HASTINGS INSTRUMENTS INSTRUCTION MANUAL 200 202 SERIES FLOWMETERS CONTROLLERS TELEDYNE TELEDYNE HASTINGS HASTINGS ELEDYNE HASTINGS INSTRUMENTS ISO 9001 A Teledyne Technologies Company CERTIFIED Manual Print History The print history shown below lists the printing dates of all revisions and addenda created for this manual The revision level letter increases alphabetically as the manual undergoes subsequent updates Addenda which are released between revisions contain important change information that the user should incorporate immediately into the manual Addenda are numbered sequentially When a new revision is created all addenda associated with the previous revision of the manual are incorporated into the new revision of the manual Each new revision includes a revised copy of this print history page Revision A Document Number 140 0999 3 332 September 1999 Revision B Document Number 140 1199 2 November 1999 Revision C Document Number 140 102002 October 2002 Revision D Document Number 140 082005 August 2005 Revision E Document Number 140 112007 November 2007 Revision F Document Number 140 062008 June 2008 Revision G Document Number 140 082008 22 August 2008
17. When flow occurs through the tubing heat is transferred from the tube to the gas on the inlet Figure 3 2 side and from the gas back to the tube on the outlet side creating an asymmetrical temperature distribution see Figure 3 2 The thermocouples sense this decrease and increase in the capillary tube temperature and produce a millivolt output 5 FL signal proportional to that change 2 FLOW MA 2 N 5 F TUPE AT E i TEMPE 4 For a constant power input the differential thermocouple output is a function of the mass flow rate and the heat capacity L 2 C L 2 of the gas Since the heat LENGHT OF TUBE capacity of many gases is 140 072011 200 202 Series Page 16 of 24 relatively constant over wide ranges of temperature and pressure the flow meter may be calibrated directly in mass units for those gases Changes in gas composition usually only require application of a simple multiplier to the air calibration to account for the difference in heat capacity and thus the flow meter is capable of measuring a wide variety of gases The HFM sensor measures approximately 10 sccm full scale flow 3 3 Electronics The Hastings HFM 200 HFC 202 series uses a thermal flow sensor to measure through a capillary tube which is a fixed percentage of the total flow through the instrument This sensor develops an output signal proportional to flow which is approximately 1 mV full scale
18. ane vean jalale juua 17 3 4 SHUNT t DA Sus Bat aces but bas oie a Be de aE SA te as a 17 3 5 N AEVESS fede sadu aca ach en ated te ates ee Be 18 4 MAINTENANC Eisissscsscstssssecsosdececseensicesevessocsccnsesds sdesscenseossctecsosessecsssuctaossbectoossvecdossseacsesusvecsebedseesesssicssuceasovsceasecdese 19 4 1 AUTHORIZED MAINTENANCE cccccccccecececececececececececscecececececscececesececscecscacacececesecasecesscausessassusessesaseusseseeeeeeenanaes 19 4 2 TROUBLESHOOTING ccccccccscveveccscsevevcsevevesecssevevesevevesesesevevcsesevesesssaveseeasevesecesevevesesevesesssesevesesevesesesevevesevevesesevis 19 4 3 DALI aa a a a TD 20 4 3 1 Calibration Procedure Figure 4 1 ccesccssesssesssesseeeeceseceseceseceseceaecnaecnaecaeecaeeeaecaeecaeeeaeeeneseneeceeeeaeenaeenaeeaes 20 4 3 2 Miscellaneous adjustments aah ba LD ja ia keV a ks a 21 4 4 END CAP REMOVAL inerevenenenenenenenenenenenenenenenenenenenenenenenenenenenenenenenenenenenenenenenenenenenenenenenesenenenenene 21 4 5 PRINTED CIRCUIT BOARD REPLACEMENT erevenenenenenenenenenenenenenenenenenenenenenenenenenenenenenenenenenenenene 21 4 6 SENSOR REPLACEMENT 21 ORIFICE CHANGES enenenenenenenenenenenenenenenenenenenenenenenenenenenenenenenenenenenenenenenenenenenenenenenenenenenen
19. ations upstream or downstream that involve conical shapes or optimized expansion nozzles will reduce the length of tubing required for flow straightening but the actual length necessary will be a function of that geometrical shape Testing of that configuration will be necessary for each application The same is true for screen meshes or flow straighteners 2 5 Electrical Connections If a power supply from Hastings Instruments is used with a 15 Volt version of the HFM 200 HFC 202 installation consists of connecting the HFM 200 HFC 202 series cable HAF 8AM from the D connector on the rear of the power supply to the D connector on the top of the flow meter Ifa different power supply is used follow the instructions below when connecting the flow meter Bipolar 15 Volt Power Supply to Bipolar Connections FLO 15VOLT 200 SERIES PINOUT DIAGRAM ET POINT BIPOLAR WER OLTACE PLY z z os FLOWMETE CONTROLLE 4 2 eturr External Input oint 140 072011 200 202 Series Connecting the HFM 200 HFC 202 series flow meters with anything other the prescribed cables and power supplies discussed above can severely damage the instrument and void the warranty The figure to the left shows the schematic layout for connecting the instrument to an appropriate 15 Volt power supply The power su
20. d for the command voltage 2 3 Output Signal The standard output of the flow meter is a 0 5 VDC signal proportional to the flow rate In the Hastings power supplies the output is routed to the display and is also available at the terminals on the rear panel If a Hastings supply is not used the output is available on pin 6 of the DA 15 connector pin 2 of the DE 9 for 24 Volt and is referenced to pin 5 pin 8 for 24 Volt It is recommended that the load resistance be no less that 2kQ If the optional 4 20 mA output is used the load impedance must be selected in accordance with Section 1 3 140 072011 200 202 Series Page 8 of 24 2 4 Mechanical Connections 2 4 1 Standard Configuration The flow meter may be mounted in any position as long as the direction of gas flow through the instrument follows the arrow marked on the bottom of the flow meter case label The preferred orientation is with the inlet and outlet fittings in a horizontal plane Gf operating with a dense gas or at high pressures the instrument must be installed horizontally When mounted in a different orientation the instrument should be re zeroed at zero flow with the system pressurized to the expected operating pressure The smallest of the internal passageways in the HFM 200 HFC 202 series is the diameter of the sensor tube which is 0 0125 0 31 mm so the instrument requires adequate filtering of the gas supply to prevent blockage or clogging of the tube The p
21. d the selling price of the product if Hastings Instruments determines in good faith that it is defective in materials or workmanship during the warranty period Defective instruments should be returned to Hastings Instruments shipment prepaid together with a written statement of the problem and a Return Material Authorization RMA number Please consult the factory for your RMA number before returning any product for repair Collect freight will not be accepted 5 2 Non Warranty Repair Policy Any product returned for a non warranty repair must be accompanied by a purchase order RMA form and a written description of the problem with the instrument If the repair cost is higher you will be contacted for authorization before we proceed with any repairs If you then choose not to have the product repaired a minimum will be charged to cover the processing and inspection Please consult the factory for your RMA number before returning any product repair TELEDYNE HASTINGS INSTRUMENTS 804 NEWCOMBE AVENUE HAMPTON VIRGINIA 23669 U S A ATTENTION REPAIR DEPARTMENT TELEPHONE 757 723 6531 TOLL FREE 1 800 950 2468 FAX 757 723 3925 E MAIL hastings_instruments teledyne com INTERNET ADDRESS http www teledyne hi com Repair Forms may be obtained from the Information Reguest section of the Hastings Instruments web site 140 072011 200 202 Series Page 24 of 24
22. djustable for ranges from 0 10 sccm to 0 250 sccm see FLOW Figure 3 4 The medium range shunt consists of a corrugated A Fi 33 stainless steel ribbon wound into a SHUNT TOUTE coil and fused Itis adjustable from 0 0 25 slm to 0 25 slm ranges Figure 3 4 2H 140 072011 200 202 Series Page 17 of 24 3 5 Valve The control valve is an automatic metering solenoid valve While most solenoids operate in either the fully open or fully closed state the automatic metering solenoid valve is designed to control flow see Figure 3 5 A spring connected to the plunger assembly holds a magnetic plunger tightly against an orifice to shut off flow The magnetic plunger is surrounded by an electrical coil which when energized with electrical current lifts the plunger off the orifice and allows flow to pass between the orifice and the plunger seat Controlling the current through the coil controls the distance between the orifice and the plunger seat effectively controlling the flow through the valve This current is controlled by a feedback loop that matches the transducer output with the command voltage Figure 3 5 140 072011 200 202 Series Page 18 of 24 4 Maintenance This section contains service and calibration information Some portions of the instrument are delicate Use extreme care when servicing the flow controller 4 1 Authorized Maintenance With prope
23. ed at minimum inlet pressure NOTE Perform this step only if a calibrated flow reference is available Set command to 100 Adjust SPAN R18 on 15 Volt R2 for 24 Volt pot until the flow reference reads full scale flow 5 000 VDC Record flow meter and flow reference outputs for flow rates of 20 40 60 80 and 100 Page 20 of 24 4 3 2 Miscellaneous adjustments Periodically during normal operation the ZERO should be checked and adjusted when reguired Ifthe instrument is not shutting completely off when the Valve Override CLOSE function is active or a command of zero flow has been given then the orifice may require approximately 1 8 turn clockwise 4 4 End Cap Removal The end cap on the inlet side must be removed to gain access to the filter or shunt assembly First shut off the supply of gas to the instrument Disconnect the Swagelok fitting on the inlet and outlet sides of the transducer and remove it from the system plumbing Remove the four hex bolts holding the end cap to the instrument see Figure 4 1 Carefully remove the end cap filter wave spring if present and shunt noting their order and proper orientation The shunt can be severely damaged if dropped Examine the filter and shunt If either is dirty or blocked clean or replace as applicable Reassembly is the reverse of the removal procedure Recalibration of the HFC is necessary 4 5 Printed Circuit Board Replacement In the unlikely event that the
24. enenenenenene 21 HBC 202 Orit iGe ts alatasa tama lid alu naa a e RE at 22 5 WARRANTY AND REPAIR 24 5 1 WARRANTY REPAIR POLICY ses 24 5 2 NON WARRANTY REPAIR POLICY 24 140 072011 200 202 Series Page 3 of 24 The Hastings HFM 200 mass flow meter and HFC 202 flow controller are designed to accurately measure and control mass flow over the range of 10 sccm to 30 slm without corrections or compensations for gas pressure and temperature with an accuracy of better than 1 FS Hastings mass flow instruments do not reguire any periodic maintenance under normal operating conditions with clean gases No damage will occur from the use of moderate overpressures 500 psi 3 45MPa or overflows Instruments are normally calibrated with the appropriate standard calibration gas nitrogen then a correction factor is used to adjust the output for the intended gas 1 1 Features e LINEAR BY DESIGN The HFM 200 HFC 202 series is inherently linear no linearization circuitry is employed Should recalibration in the field be desired a calibration standard is required the customer needs to simply set the zero and span points There will be no appreciable linearity change of the instrument when the flowing gas is changed e
25. entiometer is out of adjustment ACTION Shut off all flow Adjust ZERO potentiometer until output reads 0 00 VDC SYMPTOM Flow meter out of calibration and nonlinear CAUSE Leaks in gas inlet or outlet fittings ACTION Check all fittings for leaks by placing soap solution on all fittings between gas supply and final destination of gas Check flow meter for leaks Replace O rings if required or recalibrate as necessary 4 3 ADJUSTMENTS 5 1 2 3 4 5 6 140 072011 200 202 Series 4 3 1 Calibration Procedure Figure 4 1 NOTE Steps 5 and 6 adjusting the SPAN pot and performing a calibration run will require the use of a calibration reference Connect power cable to D connector as specified in Section 2 7 Allow instrument to warm up for 30 minutes with 10 flow and instrument in AUTO position After the warm up period set the flow to zero and insure that indeed there is zero flow Wait for 2 minutes 77 SPAN AC ZE Set ZERO R13 on 15 Volt R20 for 24 Volt potentiometer PV for 0 000 VDC output F Turn on gas supply to inlet of instrument Use the Valve Override CLOSE feature or if Valve Override is unavailable give the controller a command of zero Adjust S Figure 4 1 the orifice underneath the controller to obtain zero flow If KA LE the Valve Override feature was used to close the valve set it oo to AUTO Ensure that full range flow can still be obtain
26. ice Changes The orifice may require replacement if a large flow range change is desired if changing to a gas that has a specific gravity significantly different than the original gas if a large change in the differential pressures across the valve is desired or in the event that a small orifice becomes plugged Replacement orifices can be acquired from the factory The diameter of the orifice can be calculated using the following procedure 1 Orifice Changes del A Determine the minimum expected upstream pressure P in absolute pressure units add TN atmospheric pressure 14 7 psia the maximum Le 2 008 VITON expected downstream pressure Pd in absolute pressure i P units for full flow conditions pr 140 072011 200 202 Series Page 21 of 24 B If P gt 2P4 use formula 1 otherwise use formula 2 C Use a consistent set of units for pressure flow and density i e all lengths masses times in the same units cm ft kg sec etc 1 liter minute 1 667 x 10 m sec 1 gm liter 1 kg m 1 psia 6895 kg m sec 1 Pa 1 kg m sec D This formula provides approximate results that tend to be undersized because it neglects pressure drops internal to the flow controller compressible gas effects and temperature effects Multiply the result by 1 5 to get the expected minimum orifice size that can reliab
27. ly pass the desired flows at the expected pressures Where Formula 1 Formula 2 y n Orifice Diameter Flowrate in standard volumetric unit slm sccm scfh Po Standard Pressure 760 Torr 101 325 kpa P Upstream pressure in absolute units use minimum expected value Pa Downstream pressure in absolute units use maximum expected value Y Ratio of specific heats 1 2 for monatomic gases 1 4 otherwise Ao Density of gas standard pressure and temperature of flow unit Pi 3 1415 O Specific gravity of gas ratio of gas density to density of air Choose the available orifice with the closest diameter that is larger than the calculated diameter Orifice diameters inches available are 0 001 0 002 0 003 0 007 0 014 0 032 0 042 0 052 0 070 Contact factory to order new orifice As an example if the maximum controlled flow will be 10 slm of air with an upstream pressure of 50 psig and exhausting to atmospheric pressure the minimum orifice diameter calculated from the previous equation would be 0 0225 inches The next larger orifice that has a diameter of 0 032 inches should be installed 4 7 1 HFC 202 Orifice To change the orifice in the HFC 202 series turn the instrument upside down and turn the orifice counterclockwise with a 9 64 Allen wrench until it stops coming out Then grasp the exposed orifice end and pull it straight out See Figure 4 2 Prior to reinstallation of the o
28. magnitude This signal is amplified by the meter circuitry until it is 0 5 00 VDC This 5 Volt output is sent back to the power supply and to the flow meter circuitry if applicable At the power supply the 5 Volt output is sent to the terminals on the back and to the decoding circuitry in the display which converts it to a 3 digit output The controller circuitry utilizes the command and the flow voltages as input signals The 0 5VDC command signal is subtracted from the 0 5VDC flow signal creating an error signal This signal is amplified and causes the solenoid valve to move The amount and direction of the movement is dependent upon the value and the sign ofthe error signal and tends to minimize the error signal 3 4 Shunt Measurement of flow rates higher than the 10 sccm full scale is achieved by dividing the flow with a fixed ratio shunting arrangement as is illustrated in Figure 3 3 This is accomplished by placing the measuring capillary tube parallel with one or more dimensionally similar channels called a laminar flow element LFE Therefore the sensor only needs to heat the gas METER passing through the capillary tube i resulting low power requirements while retaining all the mass measuring characteristics The HFM 200 HFC 202 series A has two possible shunts The low EDE NS range shunt consists of tubes inserted into a cylindrical base This shunt is a
29. ompletely shut off the flow Even a slight leakage will cause an indication on the meter and an apparent zero shift For the standard 0 5 VDC output adjust the zero potentiometer located on the lower outlet side of the flow meter until the meter indicates zero For the optional 4 20 mA output adjust the zero potentiometer so that the meter indicates slightly more than 4 mA 1 e 4 03 to 4 05 mA This slight positive adjustment ensures that the 4 20 mA current loop transmitter is not in the cut off region The error induced by this adjustment is approximately 0 3 of full scale This zero should be checked periodically during normal operation Zero adjustment is required if there is a change in ambient temperature or vertical orientation of the flow meter controller 2 6 3 High Pressure Operation When operating at high pressure the increased density of gas will cause natural convection to flow through the sensor tube if the instrument is not mounted in a level position This natural convection flow will be proportional to the system pressure This will be seen as a shift in the zero flow output that is directly proportional to the system pressure 2 6 4 Blending of Gases In the blending of two gases it is possible to maintain a fixed ratio of one gas to another In this case the output of one flow controller is used as the reference voltage for the set point potentiometer of a second flow controller The set point potentiometer then provide
30. pply used must be meet the power requirements delineated in section 2 2 Power Requirements above If a bipolar supply is required the voltages must be referenced to a common ground Connect 15 VDC to pin 9 of the DA 15 connector and 15 VDC to pin 11 Pins 5 and 12 are both commons and they must be connected together and to the ground connection at the power supply Do not connect them together at the flow controller as the resulting crosstalk could result in flow instabilities Page 10 of 24 24 Volt Connections Refer to the diagram to the right when connecting 24 Vsti 24 200 SERIES PINOUT DIAGRAM Volt units SET INT Connect the positive lead of the power supply to pin SUPPLY 7 of the DE 9 connector and negative lead to pin 4 gt FA The supply input is diode protected such that reversing E the input polarity will not damage the instrument The power supply is galvanically isolated from all other lad ink pins General Connection Notes CONTROLLE OUTPUT Pin 7 of the DA 15 15 Volt Pin 9 of the DE 9 24 Volt is the case ground Tt should be connected to the cable shield if available and to the AC ground to the GN en power supply MODE Common is isolated Pin 6 of the DA 15 15 Volt Pin 2 of the DE 9 24 from the signal commor Volt is the output signal from the flow controller This output will be 0 5 VDC 4 20 mA 5 VDC 20 mA
31. process variable equal to the desired setpoint The 5 Volt reference is not available in this configuration External Variable Normal 2 7 4 Response to Command Changes The response of the control circuit to changes to the command signal is set at the factory for fast stable response If excessive overshoot is present the response can be slowed removing the jumper labeled JP4 located in the center of PC 828 for the 15 Volt units or by removing the top jumper of JP6 for the 24 Volt boards located to the right of the sensor connector The fastest response to command changes is obtained when JP4 P6 is covered by the jumper This setup allows large overshoot and undershoot in the actual flow rate while the control circuit is establishing control at the new command point A slower response to command changes is obtained when JP4 JP6 is not covered by a jumper This setup results in no overshoot or undershoot in the actual flow rate as the 140 072011 200 202 Series Page 14 of 24 controller circuit establishes control at the new command point This jumper does not affect the system gain and will not dampen out oscillations To adjust the response you need a means of producing a step change in the command voltage from 10 of full scale to 100 of full scale Follow the steps outlined below 1 Cover the pins of JP4 JP6 with a jumper see fig 2 2 amp fig 2 3 2 Set the command voltage to 10 of full scale Allow the flow
32. r care in installation and use the flow controller will require little or no maintenance If maintenance does become necessary most of the instrument can be cleaned or repaired in the field Some procedures may require recalibration Do not attempt these procedures unless facilities are available Entry into the sensor or tampering with the printed circuit board will void the warranty Do not perform repairs on these assemblies while unit is still under warranty 4 2 Troubleshooting SYMPTOM Override CLOSE function is enabled but flow remains or 0 00 VDC is commanded and flow remains CAUSE Orifice out of adjustment or faulty op amp ACTION Check the valve voltage between pins 2 amp 12 on the 15 pin D connector for 15 Volt units and Pins 5 amp 8 on the DE 9 connector for 24 Volts If the voltage is less than 3 00 VDC then turn the orifice clockwise until flow stops SYMPTOM Output of unit is proportional to flow but extremely small and not correctable by span pot CAUSE Sensor is not being heated ACTION Unplug connector J1 Check the following resistance The resistance between pins 2 amp 3 of the sensor should be approximately 2500 Ohms see Figure 3 1 on page 8 The resistance between pins 1 amp 4 should be approximately 2 3 Ohms The resistance between pins 2 amp 3 and the base of the sensor should be essentially infinite If not replace the sensor unit If sensor reads O K check the voltage output on pins 2 amp 3 of the
33. ressure regulator and the plumbing upstream must be of sufficient size to minimize changes in the upstream pressure When switching from full flow to zero flow the inlet pressure of the instrument should rise to no more that 30 above the inlet pressure at full flow In general high capacity regulators and large internal diameter plumbing help to make the system more stable The pressure drop between the regulator and the instrument due to line resistance should be minimized The differential pressure across a meter should be less than 6 of H O at maximum flow Controllers may have much higher differential pressures depending upon the size of the installed orifice There are two 8 32 threaded holes located on the bottom of the base that can be used to secure it toa mounting bracket if desired screws provided Other holes for special mounting can be added to the end cap as desired The standard inlet and outlet fittings for the 200 202 are 0 25 and 0 125 Swagelok optional VCR or VCO fittings The O rings for the end cap and the sensor are Viton optional Kalrez or Neoprene It is suggested that all connections be checked for leaks after installation This can be done by pressurizing the instrument do not exceed 500 psig unless the Flowmeter is specifically rated for higher pressures and applying a diluted soap solution to the flow connections 2 4 2 LFE Configuration The installation of a Laminar Flow Element LFE in a flow circui
34. rifice inspect the two O rings mounted on it for damage Replace if cut or gouged 140 072011 200 202 Series Page 22 of 24 Lubricate the O rings slightly with a silicone based grease and the threads with anti galling compound Push the orifice into its hole and screw it in until it is flush with the instrument base Apply pressure to the inlet side of the instrument Enable the Valve Override CLOSE function or unplug the instrument Screw the orifice in a few more turns until the flow through the instrument stops then turn it an additional 1 4 turn clockwise 140 072011 200 202 Series Page 23 of 24 5 Warranty and Repair 5 1 Warranty Repair Policy Hastings Instruments warrants this product for a period of one year from the date of shipment to be free from defects in material and workmanship This warranty does not apply to defects or failures resulting from unauthorized modification misuse or mishandling of the product This warranty does not apply to batteries or other expendable parts or to damage caused by leaking batteries or any similar occurrence This warranty does not apply to any instrument which has had a tamper seal removed or broken This warranty is in lieu of all other warranties expressed or implied including any implied warranty as to fitness for a particular use Hastings Instruments shall not be liable for any indirect or consequential damages Hastings Instruments will at its option repair replace or refun
35. s a control signal that is proportional to the output signal of the first flow controller and hence controls the flow rate of the second gas as a percentage of the flow rate of the first gas EXAMPLE Flow controller A has 0 100 slpm range with a 5 00 Volt output at full scale Flow controller B has 0 10 slpm range with a 5 00 Volt output at full scale If flow controller A is set at 80 slpm its output voltage would be 4 00 Volts 80 slpm 100 slpm x 5 00 Volts 4 00 Volts If the output signal from flow controller A is connected to the command potentiometer of flow controller B it then becomes a variable reference voltage for flow controller B proportional to the flow rate of flow controller A If the set point potentiometer of flow controller B is set at 50 of full scale and the reference voltage from flow controller A is 4 00 then the command signal going to flow controller B would be 2 00 Volts 4 00 Volts x 50 0 2 00 Volts The flow of gas through flow controller B is then controlled at 4 slpm 2 00 Volts 5 00 Volts x 10 slpm 4 slpm The ratio of the two gases is 20 1 80 slpm 4 slpm The mixture of gas A is 95 2 80 slpm 84 slpm and the mixture of gas B is 4 8 4 slpm 84 slpm Should the flow of flow controller A drop to 78 slpm flow controller B would drop to 3 9 slpm hence maintaining the same ratio of the mixture 78 slpm 100 slpm x 5 Volts 3 90 Volts x 50 1 95 Volts 1 95 Volts 5 00 v x 10 slpm 3 9 slpm
36. se are not separate parts but special options or modifications built into the flow meter 2 2 Power Reguirements The HFM 200 HFC 202 series bipolar 15 Volt version require 15 VDC 30 mA 1 Watt HFM 200 60 mA 185 mA 3 Watts HFC 202 for proper operation The supply voltage should be sufficiently regulated to no more than 50 mV ripple The supply voltage can vary from 14 0 to 16 0 VDC Surge suppressors are recommended to prevent power spikes reaching the instrument The Hastings power supplies described in Section 1 4 1 satisfy these power requirements The HFM 200 HFC 202 series 24 Volt version require 14 32 VDC 1 9 Watts HFM 200 and 4 2 Watts HFC 202 for proper operation The supply voltage should be reasonably regulated as power supply ripple may propagate to the output The supply common is galvanically isolated from the signal common such that this instrument can be powered from a bipolar 15 Volt supply using only the positive and negative output terminal 30 Volts Surge suppressors are recommended to prevent power spikes reaching the instrument Wan Attempting to operate the 24 volt version for any significant length of time at a voltage less than the specified mmimimum voltage will cause the internal DC DC convertors to fail The HFM 200 HFC 202 series instruments have an integral 5 VDC reference source This stable voltage is on pin 15 of the DA 15 connector pin 1 of the DE 9 for 24 Volt and may be use
37. sion for l Mo accepting a 0 5 VDC or 0 10 VDC output from an external sensor at pin 13 of the DA 15 15 Volt Pin 1 of the DE 9 24 Volt connector To activate this feature the cover of the HFC must be removed to gain access to the electronics card and move a jumper 2 s 2 For the 15 Volt units JP1 is a three pin jumper block located just below the D connector In the normal operating mode the jumper covers the bottom two pins To select External Sensor move the jumper to the upper two pins This swaps the flow input to the controller circuit from the flow meter output to pin 13 of the DA 15 connector Fig 2 3 For the 24 Volt units JP6 is a six pin jumper block located just to the right of the sensor connector Pin 1 is in the lower right corner There are three jumpers installed horizontally The bottom jumper ties the flow output to the valve control 21 a circuit and the middle jumper ties Pin 1 of the DE 9 connector 4 O to reference voltage circuit Remove both of the lower two a SEE jumpers and reinstall one jumper vertically between the outside 2217 two pins pins 1 amp 3 This will tie Pin 1 of the DE 9 ke J connector to the valve control circuit and allow the controller to maintain the external
38. t requires sufficient conductance before entering and after exiting the LFE sensor taps to allow the flow to fully develop with a minimum of turbulence This provides the best conditions for accurate sampling of the flow by the sensor branch See Theory of Operation Please note that for laminar flow elements whose diameter is less than 3 the inlet and outlet taps of the sensor circuit are 1 5 from the ends of an 8 LFE Laminar flow elements whose diameter is 3 or greater have inlets and outlets sensor taps 2 5 from the ends of a 10 LFE These distances may be taken into account and treated as part of the following rule of thumb 1 an upstream flow tube length of 5 times or greater the diameter of the selected LFE before the sensor inlet tap 2 downstream tube length of 1 time or greater the diameter of the selected LFE after the sensor inlet tap 140 072011 200 202 Series Page 9 of 24 EXAMPLE Suppose a 4 LFE is selected The length of 4 diameter tubing or pipe upstream of the sensor inlet tap will be a minimum of 20 The minimum length of 4 tubing or pipe downstream from the sensor outlet tap will be 4 The length of additional 4 inlet tubing required for the 4 LFE is 20 2 5 17 5 The additional length of 4 tubing required for the outlet side of the 4 LFE is 4 overall length of the assembly to 19 2 5 1 5 This brings the Tubular configur
39. the end ofthis document In this section and other sections throughout this manual when a power supply is mentioned itis assumed that the customer has a Hastings Power Supply These sections are not applicable if another type of power supply is used 3 1 Overall Functional Description The Hastings flow controller consists l a of a sensor electronic circuitry a shunt HEATER MA and a valve The sensor measures the flow rate from 0 to 10 sccm of the gas to be metered The shunt divides the flow TC such that the flow through the sensor is a precise percentage of the flow through the shunt The flow through the sensor and the shunt is always laminar The circuit board amplifies the sensor output and uses this output to control the valve position The valve is an automatic metering solenoid type its height off the Z seat is controlled by the voltage in its coil All of these components working together result in a fast stable flow controller Figure 3 1 TC 2 NS 3 2 Sensor The Hastings HFM 200 HFC 202 series operates on a unique thermal electric principle whereby a metallic capillary tube is heated uniformly by a resistance winding attached to the midpoint of the capillary see Figure 3 1 Thermocouples TC 1 and TC 2 are welded at equal distances from the midpoint and develop equal outputs at zero flow
40. to stabilize 3 Step change the command voltage to 100 and observe the flow through the controller If the overshoot is too large remove the jumper Reset the command voltage to 10 and allow the controller to stabilize 4 To prevent loss of the unused jumper place it over one pin only on JP4 JP6 2 8 Range Changing The range of the flow controller can be changed in the field if recalibration facilities are available The flow controller may require a different orifice which can be purchased separately from the factory A listing of the orifices available and their flow rates can be found in Section 5 0 The instructions to change the flow range can be found in Section 4 6 2 9 Valve Override Control The valve override control line provides a method to override the loop controller and open or close the valve regardless of the flow or command signals During normal operation this line must be allowed to float freely This will allow the loop control to open and close the valve as it requires If the valve override line is forced high gt 10 Volts the valve will be forced full open If the valve override line is forced negative lt 0 Volts the valve will be forced closed 140 072011 200 202 Series Page 15 of 24 3 Theory of Operation This section contains a functional description of Hastings flow controllers Detailed schematics and parts lists can be obtained by contacting Hastings using the contact information found at
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