Teledyne HFM-E-200, HFC-E-202 User Manual
TELEDYNE
HASTINGS
INSTRUMENTS
INSTRUCTION MANUAL
HFM-E-200/HFC-E-202 SERIES
FLOWMETERS/CONTROLLERS
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 A (Document Number 138-102002)............................................................... October 2002
Revision B (Document Number 138-102004)............................................................... October 2004
Revision C (Document Number 138-082005) ................................................................August 2005
Revision D (Document Number 138-032007) .................................................................March 2007
Revision E (Document Number 138-092008)............................................................September 2008
Revision E (Document Number 138-082010)................................................................. August 2010
Visit www.teledyne-hi.com for WEEE disposal guidance.
CAUTION:
CAUTION:
CAUTION:
The ins truments des cribed in this manual are av ailable w ith multiple pin-outs .
Ensure that all electrical connections are correct.
The ins truments des cribed in this manual are des igned for INDOOR us e 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.
HFM-E-200/HFC-E-202
Page 2 of 30
Table of Contents
1. INSTALLATION AND OPERATION............................................................................................................................. 4
1.1. FEATURES.................................................................................................................................................................... 4
1.2. SPECIFICATIONS........................................................................................................................................................... 5
1.3. OPTIONAL 4-20 MA CURRENT OUTPUT .......................................................................................................................6
1.4. OTHER ACCESSORIES...................................................................................................................................................6
1.4.1. Hastings Model 40, THPS-100 and THPS-400 Power Supplies.............................Error! Bookmark not defined.
2. INSTALLATION AND OPERATION............................................................................................................................. 7
2.1. RECEIVING INSPECTION ............................................................................................................................................... 7
2.2. POWER REQUIREMENTS ............................................................................................................................................... 7
2.3. OUTPUT SIGNAL...........................................................................................................................................................7
2.4. MECHANICAL CONNECTIONS....................................................................................................................................... 7
2.5. ELECTRICAL CONNECTIONS......................................................................................................................................... 8
2.6. OPERATION.................................................................................................................................................................. 9
2.6.1. Operating Conditions............................................................................................................................................. 9
2.6.2. Zero Check............................................................................................................................................................. 9
2.6.3. High Pressure Operation ..................................................................................................................................... 10
2.6.4. Blending of Gases.................................................................................................................................................10
2.7. OPERATION WITH EXTERNAL DEVICES ...................................................................................................................... 10
2.7.1. Operation with a Hastings power supply.............................................................................................................10
2.7.2. Operation with a power supply other than a Hastings.........................................................................................10
2.7.3. Operation with an external sensor. (Fig. 2.2).................................................................................................... 11
2.7.4. Soft Start...............................................................................................................................................................11
2.8. RANGE CHANGING:.................................................................................................................................................... 11
3. THEORY OF OPERATION...........................................................................................................................................12
3.1. OVERALL FUNCTIONAL DESCRIPTION: ...................................................................................................................... 12
3.2. SENSOR:..................................................................................................................................................................... 12
3.3. ELECTRONICS: ...........................................................................................................................................................12
3.4. SHUNT: ...................................................................................................................................................................... 13
3.5. VALVE:...................................................................................................................................................................... 14
4. MAINTENANCE..............................................................................................................................................................15
4.1. AUTHORIZED MAINTENANCE.....................................................................................................................................15
4.2. TROUBLESHOOTING ................................................................................................................................................... 15
4.3. ADJUSTMENTS...................................................................................................................................................... 16
4.3.1. Calibration Procedure: (Figure 4.1).................................................................................................................... 16
4.3.2. Miscellaneous adjustments................................................................................................................................... 17
4.4. INLET REMOVAL:....................................................................................................................................................... 17
4.5. PRINTED CIRCUIT BOARD REPLACEMENT.................................................................................................................. 17
4.6. SENSOR REPLACEMENT: ............................................................................................................................................17
4.7. ORIFICE CHANGES:.................................................................................................................................................... 17
4.7.1. HFC-E-202 Orifice...............................................................................................................................................18
4.8. REPLACEMENT PARTS ........................................................................................................................................19
5. CONVERSION FACTOR TABLE................................................................................................................................. 20
6. WARRANTY....................................................................................................................................................................24
6.1. WARRANTY REPAIR POLICY ...................................................................................................................................... 24
6.2. NON-WARRANTY REPAIR POLICY .............................................................................................................................24
7. DRAWINGS...................................................................................................................................................................... 25
7.1. NOTES:....................................................................................................................................................................... 25
HFM-E-200/HFC-E-202
Page 3 of 30
1. Installation and Operation
The Hastings HFM-E-200 mass Flow-meter and HFC-E-202 Flow-co n troller 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 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
1.1. Features
• LINEAR BY DESIGN. The HFM-E-200/HFC-E-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.
• MODULAR SENSOR. The HFM-E-200/HFC-E-202 series incorporates a removable/replaceable sensor
module. Field repairs to units can be achieved with a minimum of producti on line downtime.
• LOW TEMPERATURE DRIFT. The temperature coefficient of span for the HFM-E-200/HFC-E-202
series is typically less than 0.05% of full scale/°C from 10-50°C. The temperature coefficient of zero
is typically less than 0.1 % of reading/°C from 10-50°C.
• CURRENT LOOP. The 4-20 mA option gives the user the advantages of a current loop output to
minimize environmental noise pickup.
HFM-E-200/HFC-E-202
Page 4 of 30
1.2. Specifications
Accuracy.............................................................................................................. ±1% full scale (F.S.)
Repeatability .............................................. <±0.125% of F.S.or ±0.075% of rdg. +0.05% F.S. (max)
Maximum operational pressure .............................................................................500 psi [3.45 MPa]
...................................................................................................(Option-P- up to 1000 psi [6.9 MPa]
Pressure coefficient ..............................................................................<0.0067% of reading/psi (N2)
...............................................................................................See pressure section for pressure errors.
Normal operating temperature ............................................10-50°C in non-condensing environment
Operating temperature limits ......................................................................... 0-60°C non-condensing
Temperature coefficient (zero) ........................................ maximum ±0.085%/°C (from 10 to 50oC)
Temperature coefficient (span) ......................................... maximum ±0.05%/°C (from 10 to 50oC)
Leak integrity .......................................................................................................... <1x10-9 std. cc/s.
Standard flow ranges .....................................................................5, 10, 20, 50, 100, 200, 500, sccm.
............................................................................................. 1, 2, 5, 10, 20, 30* slpm (N2 equivalent)
Standard output.......................................................................................... 0-5 VDC (load 2k Ohms)
Optional output ..................................4 -20 mA (load < 600 Ohms when loop return is @ common)
........................................................................(600-1200 Ohm load when loop return is @ -15VDC)
Power requirements..............................+(14 to 16) VDC @ 45 mA, -(14 to 16) VDC @ 185 mA
Wetted materials ......................................................................... 302 & 316 stainless steel, nickel 200,
........................................................Viton (optional), 82/18 Au-Ni braze, Kalrez, silver solder (trace)
Attitude sensitivity of zero .................................................. < ±0.25% F.S. for 90° without re-zeroing
................................................................................................................{N2 at 44.7 psia (308 KPa)}
Controller weight ..............................................................................................1.6 lb (0.6 kg) approx.
Meter weight.....................................................................................................1.6 lb (0.6 kg) approx.
Electrical connector ......................................................................................15 pin subminiature “D”
Standard fittings ................................................... 1/4” Swagelok®, 1/8” Swagelok®, VCR®, VCO®
* (Specifications may vary for instruments with ranges greater than 10 slpm)
HFM-E-200/HFC-E-202
Page 5 of 30
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 Flowmeter. 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 3 of the “Edge” connector. The current loop
may be returned to either the power supply ground or the -15 VDC connections on the power supply. If
the current loop is returned to the power supply ground, 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.
The 4-20 mA I/O option can accept a current input. The 0-5 VDC command signal on pin A 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.teledyne-hi.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
HFM-E-200/HFC-E-202
Page 6 of 30
2. Installation and Operation
This section contains the necessary steps to assist in getting a new Flowmeter/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-E-200/HFC-E-202 series instrument and any accessories that have also
been ordered. Inspect for any obvious signs of damage to the shipment. Imm ediately 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., 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 ga s calibrations. They
may also refer to special helium leak tests, or high pressure tests. In most cases, these are not separate
parts, but special options or modifications built into the Flowmeter.
2.2. Power Requirements
The HFM-E-200/HFC-E-202 series requires ±15 VDC @ ±50 mA (HFM -E-200) +50 mA, -200 mA (HFC-E-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 supply described in Section 1.4.2 satisfies
these power requirements.
2.3. Output Signal
The standard output of the Flowmeter 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 3 of the “Edge” connector and is
referenced to pin 2. It is recommended that the load resistance be no less that 2kW. If the optional 420 mA output is used, the load impedance must be selected in accordance with Section 1. 3 .
2.4. Mechanical Connections
The Flowmeter may be mounted in any position as long as the direction of gas flow throu gh the
instrument follows the arrow marked on the bottom of the Flowmeter case label. The preferred
orientation is with the inlet and outlet fittings in a horizontal plane (if 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-E-200/HFC-E-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 pressure 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 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 the unit should be less than 6” of H
O at maximum flow.
2
There are two 8-32 threaded holes, located on the bottom of the base that can be used to secure it to a
mounting bracket, if desired (screws provided).
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
HFM-E-200/HFC-E-202
Page 7 of 30
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 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 HFM-E200/HFC-E-202 series cable from the “D” connector on the rear of the power supply to the “Edge”
connector on the top of the Flowmeter. If a different power supply is used, follow the instru ctions
below when connecting the flow meter.
This HFM-E-200/HFC-E-202 series requires Hastings cable #65-854. Use of any other cable can severely
damage the instrument and void the warranty. Figure 2.1 shows the schematic layout for connecting the
instrument to an appropriate power supply.
The power supply used must be capable of supplying +15VDC at 50mA and -15VDC at -200mA for each
controller. These voltages must be referenced to a circuit Common terminal. Connect -15VDC to pin F
and +15VDC to pin 4.
Pins 2, B and C are all Commons and they are connected together internally with solder jumpers to
ensure compatibility with legacy flow controllers. At least one of these Common pins must be connected
to the Common pin on the power supply. However for new designs and for installations with long cable
runs between the transducer and the power supply it is recommended that pin C be isolated from the
other Common pins of the transducer and provided a separate wire to connect it to the power supply
Common.
Figure 2.1
This pin carries the valve current and under conditions when the impedance of the wire connecting the
transducer Common to the power supply Common is high, tying these Commons together at the
transducer can create cross-talk that may result in flow instabilities or errors in the Command signal or
the Flow Output signal. In order to isolate pin C, solder jumpers JP8 and JP10 must be unsoldered while
JP7 remains soldered. This will be performed at assembly time in the factory if there is an indication at
the time of order that this is desired or it can be performed in the field. The Common pins can be
reconfigured to put the valve return current on different pins. Consult factory if it is necessary to match
previously installed wiring.
HFM-E-200/HFC-E-202
Page 8 of 30
Pin 1 is the case ground. It should be connected to the cable shield if available and to the AC ground at
the power supply.
Pin 3 is the output signal from the flow controller. This output will be 0-5VDC, 5VDC being 100% of rated
or full flow. Pin A is the command input. This should be a 0-5VDC signal and must be free of spikes or
other electrical noise, as these will generate false flow commands that the controller would attempt to
flow.
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
J. Connect +15VDC to one end of the switch, and -15VDC to the other end. This will result in the valve
being full open when +15VDC is supplied to pin J, off when -15VDC is supplied and auto-control when
there is no connection to pin J (OPEN-AUTO-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 Flowmeter temperature remains between 10 and 50°C. (Most accurate measurement of flow will be
obtained if the Flowmeter is zeroed at operating temperature as temperatur e shifts result in some zero
offset.) The HFM-E-201/HFC-E-203 series is intended for use in non-condensing environments only.
Condensate or any other liquids which enter the Flowmeter may destroy its electronic co mponents.
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 lower outlet side of the
Flowmeter 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, 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
HFM-E-200/HFC-E-202
Page 9 of 30
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