Teledyne HFC-302, HFM-300 User Manual
TELEDYNE
HASTINGS
INSTRUMENTS
INSTRUCTION MANUAL
HFM-300 FLOW METER,
HFC-302 FLOW CONTROLLER
ISO 9001
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 C (Document Number 151-032000) .................................................................March 2000
Revision D (Document Number 151-072000) .....................................................................July 2000
Revision E (Document Number 151-092002)............................................................September 2002
Revision F (Document Number 151-082005)................................................................. August 2005
Revision G (Document Number 151-032007) .................................................................March 2007
Revision H (Document Number 151-062008) .................................................................... June 2008
Revision J (Document Number 151-092008).............................................................September 2008
Revision K (Document Number 151-082009) ................................................................ August 2009
Revision L (Document Number 151-102009)............................................................... October 2009
Revision M (Document Number 151-082010)................................................................ August 2010
Visit www.teledyne-hi.com for WEEE disposal guidance.
CAUTION:
CAUTION:
CAUTION:
The instruments des cribed in this manual are available with multiple pin-outs.
Ensure that all electrical connections are correct.
The instruments des cribed in this manual are des igned for INDOOR use only.
The instruments described in this manual are designed for Class 2 installations
in accordance with IAW/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.
Manual: 151-082010 300-302 Series Page 2 of 31
Table of Contents
1. GENERAL INFORMATION............................................................................................................................................ 4
1.1. FEATURES.................................................................................................................................................................... 4
1.2. SPECIFICATIONS...........................................................................................................................................................5
1.3. OPTIONAL 4-20 MA CURRENT OUTPUT............................................................................................................................ 5
1.4. OTHER ACCESSORIES ......................................................................................................................................................6
1.4.1. Hastings Power supplies........................................................................................................................................6
1.4.2. Interconnecting Cables...........................................................................................................................................6
2. INSTALLATION AND OPERATION............................................................................................................................. 7
2.1. RECEIVING INSPECTION ............................................................................................................................................... 7
2.2. POWER REQUIREMENTS ............................................................................................................................................... 7
2.3. OUTPUT SIGNAL...........................................................................................................................................................7
2.4. MECHANICAL CONNECTIONS....................................................................................................................................... 8
2.4.1. Filtering..................................................................................................................................................................8
2.4.2. Mounting ................................................................................................................................................................ 8
2.4.3. Plumbing ................................................................................................................................................................ 8
2.5. ELECTRICAL CONNECTIONS......................................................................................................................................... 8
2.6. OPERATION.................................................................................................................................................................. 9
2.6.1. Operating Conditions.............................................................................................................................................9
2.6.2. Zero Check........................................................................................................................................................... 10
2.6.3. High Pressure Operation ..................................................................................................................................... 10
2.6.4. Blending of Gases.................................................................................................................................................11
2.7. OUTPUT FILTER ......................................................................................................................................................... 12
2.8. CONTROLLING OTHER PROCESS VARIABLES ............................................................................................................. 12
2.9. COMMAND INPUT....................................................................................................................................................... 13
2.10. VALVE-OVERRIDE CONTROL..................................................................................................................................... 13
2.11. GAIN POTENTIOMETER .............................................................................................................................................. 13
2.12. TEMPERATURE COEFFICIENTS ...................................................................................................................................14
3. THEORY OF OPERATION...........................................................................................................................................15
3.1. OVERALL FUNCTIONAL DESCRIPTION........................................................................................................................ 15
3.2. SENSOR DESCRIPTION................................................................................................................................................ 15
3.3. SENSOR THEORY........................................................................................................................................................ 15
3.4. BASE..........................................................................................................................................................................17
3.5. SHUNT DESCRIPTION.................................................................................................................................................. 17
3.6. SHUNT THEORY ......................................................................................................................................................... 17
3.7. CONTROL VALVE.......................................................................................................................................................21
3.8. ELECTRONIC CIRCUITRY............................................................................................................................................21
4. MAINTENANCE..............................................................................................................................................................22
4.1. TROUBLESHOOTING ................................................................................................................................................... 22
4.2. ADJUSTMENTS ........................................................................................................................................................... 23
4.2.1. Calibration Procedure ......................................................................................................................................... 23
4.3. END CAP REMOVAL................................................................................................................................................... 23
4.4. PRINTED CIRCUIT BOARD REPLACEMENT.................................................................................................................. 24
4.5. SENSOR REPLACEMENT ............................................................................................................................................. 24
5. GAS CONVERSION FACTORS.................................................................................................................................... 25
6. VOLUMETRIC VS MASS FLOW.................................................................................................................................27
7. DRAWINGS AND REFERENCES ................................................................................................................................ 28
8. WARRANTY....................................................................................................................................................................31
8.1. WARRANTY REPAIR POLICY ...................................................................................................................................... 31
8.2. NON-WARRANTY REPAIR POLICY .............................................................................................................................31
Manual: 151-082010 300-302 Series Page 3 of 31
1. General Information
The Teledyne Hastings HFM-300 is used to measure mass flow rates in gases. In addition to flow rate
measurement, the HFC-302 includes a proportional valve to accurately control gas flow. The Hastings mass flow
meter (HFM-300) and controller (HFC-302), hereafter referred to as the Hastings 300 series, are intrinsically
linear and are designed to accurately measure and control mass flow over the range of 0-5 sccm to 0-10 slm
with an accuracy of better than ±0.75% F.S. at 3σ from the mean (versions >10 slm are ±1.0% F.S.) . Hastings
mass flow instruments do not require 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. Calibrations for other gases, such as oxygen, helium and
argon, are available upon special order.
1.1. Features
• LINEAR BY DESIGN. The Hastings 300 series is intrinsically linear (no linearization circuitry is
employed). Should recalibration (a calibration standard is required) in the field be desired, 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.
• NO FOLDOVER. The output signal is linear for very large over flows and is monotonically increasing
thereafter. The output signal will not come back on scale when flows an order of magnitude over the
full scale flow rate are measured. This means no false acceptable readings during leak testing.
• MODULAR SENSOR. The Hastings 300 series incorporates a removable/replaceable sensor module.
Field repairs to units can be achieved with a minimum of production line downtime.
• LARGE DIAMETER SENSOR TUBE. The Hastings 300 sensor is less likely to be clogged due to its large
internal diameter (0.026”/ 0.66mm). Clogging is the most common cause of failure in the industry.
• LOW ∆P. The Hastings 300 sensor requires a pressure of approximately 0.25 inches of water (62 Pa) at
a flow rate of 10 sccm. The low pressure drop across this instrument is ideal for leak detection
applications since the pneumatic settling times are proportional to the differential pressure.
• FAST SETTLING TIME. Changes in flow rate are detected in less than 250 milliseconds when using the
standard factory PC board settings.
• LOW TEMPERATURE DRIFT. The temperature coefficient of span for the Hastings 300 series is less
than 0.03% of full scale/°C from 15-50°C. The temperature coefficient of zero is less than 0.1 % of
reading/°C from 0-60°C.
• FIELD RANGEABLE. The Hastings 300 series is available in ranges from 0-5 sccm to 0-25 slpm. Each
flow meter has a shunt which can be quickly and easily exchanged in the field to select different
ranges. Calibration, however, is required.
• METAL SEALS. The Hastings 300 series is constructed of Stainless Steel. All internal seals are made
with Ni 200 gaskets, eliminating the permeation, degradation and outgassing problems of elastomer Orings.
• LOW SURFACE AREA. The shunt is designed to have minimal wetted surface area and no un-swept
volumes. This will minimize particle generation, trapping and retention. CURRENT LOOP. The 4-20
mA option gives the user the advantages of a current loop output to minimize environmental noise
pickup.
Manual: 151-082010 300-302 Series Page 4 of 31
1.2. Specifications
Accuracy .................................................................................... < ±0.75% full scale (F.S.) at 3σ
(±1.0% F.S. for >10 slm versions)
Repeatability .............................................................................±0.05% of reading + 0.02% F.S.
Maximum Pressure........................................................................................500 psi [3.45 MPa]
(With high pressure option) 1000 psi [6.9 MPa]
Pressure Coefficient .................................................. <0.01% of reading/psi [0.0015%/kPa] (N2)
See pressure section for higher pressure errors.
Operating Temperature ....................................................0-60°C in non-condensing environment
Temperature Coefficient (zero) .................................... Maximum ±0.1%F.S./°C (from 0 to 60°C)
Temperature Coefficient (span) ..................................Maximum ±300 ppm/°C (from 15 to 50 °C)
Maximum ±450 ppm/°C (from 0 to 60 °C)
Leak Integrity ...............................................................................................<1x10-9 std. cc/s.
Flow Ranges .................................................................. 0-5 sccm to 0-25* slpm. (N2 Equivalent)
Standard Output ........................................................................... 0-5 VDC. (load min 2k Ohms)
Optional Output ............................................................................ 4 -20 mA. (load < 600 Ohms)
Power Requirements..................................................................... ±(15) VDC @ 55 mA (meters)
± (15) VDC @ 150 mA (controller)
Class 2 power 150VA max
Wetted Materials ................................................................................ stainless steel, nickel 200
Attitude Sensitivity of zero ..............................................< ±0.7% F.S. for 90° without re-zeroing
{N2 at 19.7 psia (135 KPa)}
Weight ............................................................................................................ 1.93 lb [0.88 kg]
Electrical Connector............................................................................... 15 pin subminiature “D”
Fitting Options................... ¼” Swagelok®, 1/8” Swagelok®, VCR®, VCO®, 9/16”-18 Female thread
Face Seal to Face Seal Length................................................................ 1.88”(47.75 mm) VCR®
(Specifications may vary for instruments with ranges greater than 10 slpm)
1.3. 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.
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.
The current loop signal replaces the voltage output on pin 6 of the “D” connector. The current loop
may be returned to either the signal common or the -15 VDC connection on the power supply. If the
current loop is returned to the signal common, the load must be between 0 and 600 ohm. If it is
returned to the -15VDC, the load must be between 600 and 1200 ohm. Failure to meet these
conditions will cause failure of the loop transmitter.
Manual: 151-082010 300-302 Series Page 5 of 31
The 4-20 mA I/O option can accept a current input. The 0-5 VDC command signal on pin 14 can be
replaced by a 4-20mA command signal. The loop presets an impedance of 75 ohms and is returned to
the power supply through the valve common.
1.4. Other Accessories
1.4.1. Hastings Power supplies
Hastings Power Pod power supply/display units are available in one and four channel versions. They
convert 100, 115 or 230VAC 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.teledynehi.com/products/powerpod-series.htm
1.4.2. 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 of the 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
Manual: 151-082010 300-302 Series Page 6 of 31
2. Installation and Operation
This section contains the steps necessary to assist in getting 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 unit 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 (i.e., flow meter, 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, these are not separate parts, rather, they are
special options or modifications built into the flow meter.
Quick Start
1. Insure flow circuit mechanical connections are leak free
2. Insure electrical connections are correct (see label).
3. Allow 30 min. to 1 hour for warm-up.
4. Note the flow signal decays toward zero.
5. Run ~20% flow through instrument for 5 minutes.
6. Insure zero flow; wait 2 minutes, then zero the instrument.
7. Instrument is ready for operation
2.2. Power Requirements
The HFM-300 meter requires +15 VDC @ 55 mA, -15 VDC @50 mA for proper operation. The HFC-302
controller requires ±15 VDC @ 150mA. 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 supply described
in Section 1.4.2 satisfies these power requirements.
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 supply 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 “D” connector. It is
recommended that the load resistance be no less that 2kΩ. If the optional 4-20 mA output is used, the
load impedance must be selected in accordance with Section 1.3.
Manual: 151-082010 300-302 Series Page 7 of 31
2.4. Mechanical Connections
2.4.1. Filtering
The smallest of the internal passageways in the Hastings 300 is the diameter of the sensor tube, which
is 0.026”(0.66 mm), and the annular clearance for the 500 sccm shunt which is 0.006"(0.15 mm) (all
other flow ranges have larger passages), so the instrument requires adequate filtering of the gas supply
to prevent blockage or clogging of the tube.
2.4.2. Mounting
There are two mounting holes (#8-32 thread) in the bottom of the transducer that can be used to
secure it to a mounting bracket, if desired.
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.
As explained in the section on operating at high pressures, pressure can have a significant affect on
readings and accuracy. When considering mounting a flow meter in anything other than a horizontal
attitude, consideration must be given to the fact that the heater coil can now set up a circulating flow
through the sensor tube, thereby throwing the zero off. This condition worsens with denser gases or
with higher pressures. Whenever possible, install the instrument horizontally.
Always re-zero the instrument with zero flow, at its normal operating temperature and purged with its
intended gas at its normal operating pressure.
2.4.3. Plumbing
The standard inlet and outlet fittings for the Hastings 300 Series are VCR-4, VCO-4 or 1/4" Swagelok. 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 flow meter is specifically rated for
higher pressures) and applying a diluted soap solution to the flow connections.
2.5. Electrical Connections
If a power supply from Hastings Instruments is used, installation consists of connecting the HFM300/302 series cable from the “D” connector on the rear of the power supply to the “D” connector on
the top of the flow meter /controller. The “H” pin-out requires cable AF-8-AM (grey molded
backshell). The “U” pin-out requires cable # 65-791 (black molded backshell).
If a different power supply is used, follow the instructions below when connecting the flow meter and
refer to either table 2.1 or 2.2 for the applicable pin-out. The power supply used must be bipolar and
capable of providing ±15 VDC at 55 mA for flow meter applications and ±15 VDC at 150 mA for
controllers. These voltages must be referenced to a common ground. One of the “common” pins must
be connected to the common terminal of the power supply. Case ground should be connected to the
AC ground locally. The cable shield (if available) should be connected to AC ground at the either the
power supply end, or the instrument end of the cable, not at both. Pin 6 is the output signal from the
flow meter. The standard output will be 0 to 5 VDC, where 5 VDC is 100% of the rated or full scale
flow.
The command (set point) input should be a 0-5 VDC signal (or 4-20mA if configured as such), and must
be free of spikes or other electrical noise, as these would generate false flow commands that the
controller would attempt to follow. The command signal should be referenced to signal common.
A valve override command is available to the flow controller. Connect the center pin of a single pole,
three-position switch (center off) to the override pin. Connect +15 VDC to one end of the three
position switch, and -15 VDC to the other end. The valve will be forced full open when +15 VDC is
supplied to the override pin, and full closed when -15 VDC is applied. When there is no connection to
the pin (the three-position switch is centered) the valve will be in auto control, and will obey the 0-5
VDC commands supplied to command (set-point) input.
Manual: 151-082010 300-302 Series Page 8 of 31
Fig. 2.1 Fig. 2.2
Figures 2.1/2.2, and Tables 2.1/2.2, show the 300/302 pin out.
Table 2.1
"U" Pin-Out
Pin # Pin #
1 Signal Common 1 Do not use
2 Do not use 2 Do not use
3 Do not use 3 Do not use
4 +15 VDC 4 Do not use
5 5 Signal Common
6 Output 0-5 VDC (4-20mA) 6 Output 0-5 VDC (4-20mA)
7 Signal Common 7 Case Ground
8 Case Ground 8 Valve Override
9 Valve Override 9 -15VDC
10 10 Do not use
11 -15VDC 11 +15VDC
12 External Input 12 Signal Common
13 Signal Common 13 External Input
14 Signal Common 14 Set Point 0-5 VDC (4-20mA)
15 Set Point 0-5 VDC (4-20mA) 15 Do not use
Table 2.2
"H" Pin-Out
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.
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. (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 Hastings 300 series instrument is intended for use in non-condensing environments
only. Condensate or any other liquids which enter the flow meter may destroy its electronic
components.
Manual: 151-082010 300-302 Series Page 9 of 31
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 completely 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 inlet side of the flow meter
until the meter indicates zero (Fig 2.3). For the optional 4-20 mA
output, adjust the zero potentiometer so that the meter indicates
slightly more than 4 mA, i.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
Fig. 2.3
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.
Fig. 2.4
2.0%
0.0%
-2.0%
-4.0%
-6.0%
-8.0%
-10.0%
-12.0%
Span Error (% reading)
-14.0%
-16.0%
-18.0%
Span Error vs Pressure
(0.026" Sensor Tube)
Mean error
max
min
-20.0%
0 100 200 300 400 500 600 700 800 900 1000
y = 9.8877E-11x33.4154E-07x - 28.3288E-05x +
Pressure(psig)
Manual: 151-082010 300-302 Series Page 10 of 31
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