Manfrotto Automobile Parts 203 User Manual

TELEDYNE  
HASTINGS  
INSTRUMENTS  
INSTRUCTION MANUAL  
201/203 SERIES  
FLOW METERS/CONTROLLERS  
Table of Contents  
1.  
2.  
GENERAL INFORMATION............................................................................................................................................ 4  
1.1.  
FEATURES .................................................................................................................................................................... 4  
SPECIFICATIONS........................................................................................................................................................... 5  
OPTIONAL 4-20 MA CURRENT OUTPUT ....................................................................................................................... 6  
OTHER ACCESSORIES................................................................................................................................................... 6  
1.2.  
1.3.  
1.4.  
INSTALLATION AND OPERATION............................................................................................................................. 7  
2.1.  
RECEIVING INSPECTION ............................................................................................................................................... 7  
POWER REQUIREMENTS ............................................................................................................................................... 7  
OUTPUT SIGNAL........................................................................................................................................................... 7  
MECHANICAL CONNECTIONS....................................................................................................................................... 7  
ELECTRICAL CONNECTIONS......................................................................................................................................... 8  
OPERATION.................................................................................................................................................................. 9  
RANGE CHANGING:.................................................................................................................................................... 11  
2.2.  
2.3.  
2.4.  
2.5.  
2.6.  
2.7.  
3.  
4.  
THEORY OF OPERATION ........................................................................................................................................... 12  
3.1.  
OVERALL FUNCTIONAL DESCRIPTION: ...................................................................................................................... 12  
SENSOR:..................................................................................................................................................................... 12  
ELECTRONICS: ........................................................................................................................................................... 12  
SHUNT: ...................................................................................................................................................................... 13  
VALVE:...................................................................................................................................................................... 14  
3.2.  
3.3.  
3.4.  
3.5.  
MAINTENANCE.............................................................................................................................................................. 15  
4.1.  
AUTHORIZED MAINTENANCE..................................................................................................................................... 15  
TROUBLESHOOTING ................................................................................................................................................... 15  
ADJUSTMENTS ........................................................................................................................................................... 16  
END CAP REMOVAL:.................................................................................................................................................. 17  
PRINTED CIRCUIT BOARD REPLACEMENT.................................................................................................................. 17  
SENSOR REPLACEMENT: ............................................................................................................................................ 17  
ORIFICE CHANGES: .................................................................................................................................................... 17  
REPLACEMENT PARTS................................................................................................................................................ 18  
4.2.  
4.3.  
4.4.  
4.5.  
4.6.  
4.7.  
4.8.  
5.  
WARRANTY .................................................................................................................................................................... 20  
5.1.  
5.2.  
WARRANTY REPAIR POLICY ...................................................................................................................................... 20  
NON-WARRANTY REPAIR POLICY ............................................................................................................................. 20  
201/203 Series  
Page 3 of 20  
1. General Information  
The Hastings HFM-201/HFC-203 series Mass flow meter (HFM-201) and controller (HFC-203)  
are designed to accurately measure and control mass flow over the range of 30 slm to 500 slm,  
without corrections or compensations for gas pressure and temperature with an accuracy of better  
than ±1% from the mean (±2% FS for 500 slm). 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. Special calibrations for other gases, such as oxygen, helium  
and argon, are available upon special order.  
1.1. Features  
LINEAR BY DESIGN. The HFM-201/HFC-203 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-201/HFC-203 series incorporates a removable/replaceable sensor  
module. Field repairs to units can be achieved with a minimum of production line downtime.  
METER SETTLING TIME. Changes in flow rate for the HFM-201 are detected in less than 2 seconds  
when using the speed up circuitry.  
LOW TEMPERATURE DRIFT. The temperature coefficient of span for the HFM-201/HFC-203 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.  
FIELD RANGEABLE. The HFM-201/HFC-203 series is available in ranges from 30 slm to 500 slm. For  
HFC-203 controller’s, an orifice change is required as well. Calibration is required after all changes.  
CURRENT LOOP. The 4-20 mA option gives the user the advantages of a current loop  
output to  
minimize environmental noise pickup.  
201/203 Series  
Page 4 of 20  
1.2. Specifications  
Accuracy ...........................................................................................................±1% full scale (F.S.)  
Repeatability..............................................................................................................<±0.1% of F.S.  
Maximum operational pressure .........................................................................500 psi [3.45 MPa].  
.............................................................................................. (Option -P- up to 1000 psi [6.9 MPa])  
Pressure coefficient ....................................................... <0.01% of reading/psi [0.0015%/kPa] (N2)  
Operating temperature ........................................................0-50°C in non-condensing environment  
Temperature coefficient (zero) ........................................................ ±0.1%/°C (±0.05%/0C typical)  
Temperature coefficient (span) ..................................................±0.1 ppm/°C (±0.05%/0C typical)  
Zero drift .............................................................................................................................±0.1%FS  
Leak integrity ........................................................................................................ <1x10-9 std. cc/s.  
Flow ranges .............................................................................. 30, 50, 100, 300, 500, 600 slm (N2)  
Output ............................................................................................................................... 0-5 VDC  
Optional output ................................................................................................................. 4 -20 mA  
Power requirements........................................................................................ ±(15) VDC @ 50 mA  
Wetted materials ......................................................................304 & 316 stainless steel, nickel 200,  
.......................................................................................................................... Viton, Au13Ni braze  
Attitude sensitivity of zero .................................................. < ±6.5% F.S. for 90° without re-zeroing  
..............................................................................................................{N2 at 19.7 psia (135 KPa)}  
Controller weight ......................................................................................................5.6 lb (2.54 kg)  
Meter weight.............................................................................................................3.3 lb (1.50 kg)  
Electrical connector ....................................................................................15 pin subminiature “D”  
Standard fittings ................................................. 1/2” Swagelok®, 3/4” Swagelok®, VCR®, VCO®  
201/203 Series  
Page 5 of 20  
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 power supply ground or the -15 VDC connection 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 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.  
Totalizer (TR-1J)  
The Hastings Flow Totalizer integrates the 0-5 VDC signal generated by the flow meter to give a  
total flow reading. Count rates from 0 to 999 counts per minute are selectable by internal setting.  
1.4.2.  
Hastings Model 40/200/400 Power Supply  
Hastings power supplies are available in either two or four channel versions. They convert 115 or  
230VAC to the ±15 VDC required to operate the flow meter. Interface terminals for the ±15 VDC  
input and the 0-5 VDC linear output signal are located on the rear of the panel. Also, a cable can be  
supplied with the power supply that provides the +15 VDC on pin 11 of a 15-pin “D” connector  
and the 0 - 5VDC output measurement on pin 6. Pins 5, 7 and 12 are common, and pin 7 is chassis  
ground. Throughout this manual, when reference is made to a power supply, it is assumed the  
customer is using a Hastings Model 200/400/40 supply. Hastings power supplies do not meet CE  
standards at this time.  
201/203 Series  
Page 6 of 20  
2. Installation and Operation  
This section contains the necessary steps 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 201/203 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 (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, but special options or modifications built into the flow meter.  
2.2. Power Requirements  
The HFM-201/HFC-203 series requires ±15 VDC @ ±50 mA (HFM-201) +50 mA, -200 mA  
(HFC-203)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.  
The HFM-201/HFC-203 series instruments have an integral 5 VDC ref. source. This stable voltage  
is on pin 15 of the “D” connector and may be used for the command voltage on the controller  
(HFC-203).  
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  
and is referenced to pin 5. It is recommended that the load resistance be no less that 2kW. If the  
optional 4-20 mA output is used, the load impedance must be selected in accordance with Section  
1.3.  
2.4. Mechanical Connections  
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 (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 201/203 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  
201/203 Series  
Page 7 of 20  
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 H2O at maximum flow.  
There are two 8-32 threaded holes, 0.25” deep, located on the bottom of the base that can be used to  
secure it to a 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 201/203 are 0.5” and 0.75” 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 flow meter 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-  
201/HFC-203 series cable from the “D” connector on the rear of the power supply to the “D”  
connector on the top of the flow meter. If a different power supply is used, follow the instructions  
below when connecting the flow meter.  
This HFM-201/HFC-203 series requires Hastings cable #AF-8AM. 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  
supplying  
be  
capable  
+15VDC  
of  
at  
50mA and -15VDC at -  
200mA for each controller.  
These voltages must be  
referenced to a common  
ground. Connect -15VDC  
to pin 9 and +15VDC 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. Pin 7 is the case  
ground.  
It should be  
connected to the cable  
shield if available and to the  
AC ground to the power  
supply.  
Pin 6 is the output signal from the flow controller. This output will be 0-5VDC, 5VDC being 100%  
of rated or full flow. Pin 14 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. Pin 15 is a well regulated +5.00VDC output reference. The reference is  
designed to provide the command signal for pin 14 by connecting one end of a potentiometer to pin  
15 and the other end to ground. The center lead would then be connected to pin 14.  
201/203 Series  
Page 8 of 20  
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. 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 8, off when -15VDC is supplied and  
auto-control when there is no connection to pin 8 (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 flow meter temperature remains between 0 and 50°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 201/203 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.  
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 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, 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 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 provides 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  
201/203 Series  
Page 9 of 20  
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/4slpm). The % mixture of gas A is 95.2 (80slpm/84slpm  
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/100slpm x 5v = 3.90v x 50% = 1.95v;  
1.95v/5.00v x 10 slpm = 3.9 slpm; 78 slpm:3.9 slpm = 20:1)  
2.6.5.  
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 over ride) and a potentiometer knob labeled  
“COMMAND”. For normal operation, the valve over ride 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 over ride 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.  
The “COMMAND” pot adjusts the 0-5 VDC command signal sent to the flow controller. The  
setting for each controller connected to the power supply can be observed by rotating the  
“POWER/CHANNEL SELECT” knob to the channel connected to the controller that you wish to  
observe, and rotating the “FLOW/COMMAND” knob to “COMMAND”. The display will then  
indicate the command signal. (Depending on how the power supply was set up, the display could  
indicate in flow units or percent of full scale.) To observe the flow output of the flow controller,  
rotate the “FLOW/COMMAND” knob to “FLOW”. The display will now indicate the flow output  
signal.  
2.6.6.  
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 the “D” connector. A 0-5 VDC signal proportional to the  
flow rate through the instrument will be present on pin 6 of the “D” connector. The control mode is  
selected via pin 8 of the “D” connector. Apply +15 volts for full open, -15 volts for closed and allow  
pin 8 to float for flow proportional to the command voltage. Refer to your power supply manual for  
the specifics of implementing these parameters.  
2.6.7.  
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 in the flow controller. For example, you might want to control the pressure in a  
vacuum system by adjusting the rate at which the system is backfilled with a gas. The new,  
enhanced HFC series of flow controllers have provision for accepting a 0-5VDC output from an  
external sensor at pin 13 of the “D” connector. To activate this feature, the cover of the HFC must  
be removed to gain access to PC-828 and move a jumper on JP1. 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 “D” connector.  
201/203 Series  
Page 10 of 20  
2.6.8.  
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. Should it be necessary, the response is adjustable using the jumper labeled “JP4,”  
located in the center of PC-828.  
The fastest response to command changes is obtained when JP4 is covered by the jumper. This  
setup allows large overshoot and undershoot swings in the actual flow rate while the control circuit is  
establishing control at the new command point. The slowest response to command changes is  
obtained when JP4 is not covered by a jumper. This setup results in no overshoot or undershoot in  
the actual flow rate as the controller circuit establishes control at the new command point.  
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 with a jumper. (see fig. 2.2)  
2) Set the command voltage to 10% of full scale. Allow the flow 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.  
2.6.9.  
Operating Temperature  
For proper operation, the combination of ambient temperature and gas temperature must be such  
that the Flowcontroller temperature remains between 0 and 500C. Most accurate measurement of  
flow will be obtained if the flow controller is re-zeroed at operating temperature, as temperature  
shifts result in some zero offset.  
2.7. 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.  
201/203 Series  
Page 11 of 20  
3. Theory of Operation  
This section contains an overall functional description of HFC Flow Controllers. Detailed  
schematics and parts lists can be found at the end of the manual in Section 6.0. In this section and  
other sections throughout this manual, when a power supply is mentioned, it is 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 HFC Flow Controller consists of a  
sensor, electronic circuitry, a shunt 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 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 2 stage valve  
employs an automatic metering solenoid,  
used to control the pressure differential  
across the main diaphragm seat assembly.  
All of these components working together  
result in a fast, stable flow controller.  
FIG 3.1  
3.2. Sensor:  
The Hastings HFM-201/HFC-203 series instruments operate 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.  
When flow occurs through the tubing, heat is transferred from the tube to the gas on the inlet side,  
and from the gas back to the tube on the outlet side creating an asymmetrical temperature  
distribution (sees Figure 3.2). The thermocouples sense this decrease and increase in the capillary  
tube temperature and produce a millivolt output signal proportional to that change.  
For a constant power input, the differential thermocouple output is a function of the mass flow rate  
and the heat capacity of the gas. Since the heat capacity of many gases is 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 HFM-201/HFC-203 series instruments use 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 magnitude.  
201/203 Series  
Page 12 of 20  
This signal is amplified by the meter circuitry until 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 of the error signal, and tends to  
minimize the error signal.  
FIG 3.2  
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 passing through the capillary  
tube resulting in low power requirements, while retaining all the mass measuring characteristics.  
The HFC-203 uses corrugated and fused shunts similar to the shunts used in the lower flow range  
instruments. These high range shunts are factory adjustable from 0-30 slpm to 0-500 slpm (see  
Figure 3.4), using specific corrugated shunts that give the desired flow range.  
FIG 3.4  
FIG 3.3  
201/203 Series  
Page 13 of 20  
3.5. Valve:  
At flow rates higher than 30 slm, two valves are used in parallel. A solenoid valve is used as a pilot  
valve to control a much larger pneumatic diaphragm valve. The pilot 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, thus effectively controlling the  
flow through the valve.  
Figure 3.6 shows the combination of  
the two valves. When pressure is  
first applied to the upstream side of  
the valve, flow will pass through until  
the chamber above the diaphragm is  
pressurized through a small bleed  
screw. System pressure and spring  
force will then close the valve. The  
pilot valve controls the pressure in  
the chamber above the diaphragm  
thus controlling the height of the  
large plunger above its seat.  
FIG 3.6  
201/203 Series  
Page 14 of 20  
4. Maintenance  
This section contains service and calibration information. Some portions of the instrument are  
delicate. Use extreme care when servicing the flow controller. The potentiometer positions and the  
electrical components referred to in the troubleshooting section can be found in Section 6.0 on the  
electrical component layout drawing.  
4.1. Authorized Maintenance  
With proper 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 warranty. Do  
not perform repairs on these assemblies while unit is still under warranty.  
4.2. Troubleshooting  
SYMPTOM: Output reads 40% of flow with no flow. Zero pot has no effect.  
CAUSE: Power supply locked up or shorted out.  
ACTION: Turn off power supply for a few seconds, then turn back on. If this proves ineffective,  
disconnect the unit from the power supply. If power supply display does not return to zero, then a  
regulator chip in the power supply is probably burned out. Check supply voltages and replace faulty  
regulator. If display returns to zero after disconnecting the power supply from the unit there is a  
short in the unit to ground. Check capacitors C10 & C11 first.  
SYMPTOM: Override switch is in CLOSE position, but flow remains or 0.00 VDC is commanded  
and flow remains.  
CAUSE: Orifice out of adjustment or faulty op-amp  
ACTION: Check valve voltage at connector pins TP-3 & TP-6. If voltage is less than 3.00 VDC,  
then turn orifice clockwise until flow stops. If voltage is greater than 3.00 VDC. If they are greater,  
replace U1; if less, replace transistor Q1.  
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 J2. Check the following resistance: The resistance between pins 2 &  
3 of the sensor should be approximately 2500 ohms (see Figure 3.1 on page 8). The resistance  
between pins 1 & 4 should be approximately 2.3 ohms. The resistance between pins 2 & 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 & 3 of the jack in the board. If it does not read approximately 22  
VDC then replace op-amp U2.  
SYMPTOM: Sensor has proper resistance readings, but little or no output with flow.  
CAUSE: Plugged sensor.  
201/203 Series  
Page 15 of 20  
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 switch OPEN.  
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 potentiometer 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  
4.3.1.  
Calibration Procedure: (Figure 4.1)  
NOTE: Adjusting the SPAN pot will require the use of a  
calibration reference in Step 5.  
1) 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.  
SPAN  
ZERO  
2) Set ZERO (R19) potentiometer for 0.000 VDC output.  
3) Turn on gas supply to inlet of instrument. Put Valve Override  
switch into CLOSE position. Adjust the orifice underneath  
controller to obtain zero flow. Put Valve Override switch into  
AUTO. Ensure that full range flow can still be obtained at  
minimum inlet pressure.  
FIG 4.1  
201/203 Series  
Page 16 of 20  
4) Set command to 100%. Adjust SPAN (R29) pot until the flow reference reads full scale flow (5.000  
VDC). NOTE: Perform this step only if a calibrated reference flow meter is available.  
5) Record flow meter and flow reference outputs for flow rates of 20%, 40%, 60%, 80% and 100%.  
4.3.2.  
Miscellaneous adjustments  
Periodically, during normal operation, the ZERO should be checked and adjusted when required. If  
system parameters change, the RESPONSE pot may require a small adjustment for optimum  
stability. If the instrument is not shutting completely off when Valve Override switch is in the  
CLOSE position, 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 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 4.4.1.  
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 4.7 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. Orifice Changes:  
The orifice may require replacement if a flow range change is desired, if a large change in 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. See Section 4.8 for the list of standard  
orifices and their flow rates in air.  
When using nonstandard pressures or gases that have specific gravities different than air (such as  
hydrogen or helium), the diameter of the orifice must be calculated using the following procedure:  
201/203 Series  
Page 17 of 20  
Orifice Changes:  
A) Determine the minimum expected upstream pressure (Pu) in PSI absolute and the maximum  
expected downstream pressure (Pd) in PSI absolute for full flow conditions.  
B) If Pu >2Pd, use formula 1; otherwise use formula 2.  
Where:  
Formula 1:  
Formula 2:  
0.0014Q  
ΔΡ•Ρd  
σ
0.0028σQ  
Pμ  
D =  
D =  
D
Q
=
=
=
=
=
=
Diameter in inches  
Flow rate in standard liters per minute  
Pu - Pd in PSI  
P
Pu  
Pd  
σ
Upstream pressure in PSIA  
Downstream pressure in PSIA  
Specific gravity of gas  
Choose the orifice form Section 5.0 that has the closes larger diameter to the calculated diameter.  
4.7.1. HFC-203 Orifice  
To change the orifice in the HFC-203 unit, the valve must be dismantled. Remove the four 1/4"  
Allen head machine screws in the top of the main valve. Lift off the valve top, exposing the spring  
and diaphragm. Note that a small brazed ball bearing is on the down stream side of the valve top.  
Remove the spring and diaphragm assembly. The orifice is located in the bottom of the valve body  
and can be removed with a 9/16 socket wrench. See Figure 4.5.  
To reinstall an orifice, first install the gasket onto the orifice (replacement gaskets can be obtained  
from the factory). Next screw the orifice into the valve base. Snug up the orifice but do not over  
tighten. Place diaphragm assembly into the base. Line up the two small holes in the diaphragm with  
the two small holes in the valve base. Place the  
spring on top of the diaphragm. Examine the o-  
ring on the valve top for damage if required. Install  
the valve top, ensuring that the ball bearing in the  
side is on the downstream side. Tighten down the  
valve top evenly to insure a proper seal at the  
diaphragm.  
4.8. Replacement Parts  
The following is a list of the available replacement  
parts and their factory stock numbers. The HFM-  
201 and the HFC-203 shunts and filter discs are  
interchangeable. The same sensor module is used  
on all models. All HFM models use the same  
printed circuit board.  
FIG 4.5  
201/203 Series  
Page 18 of 20  
STOCK NO. DESCRIPTION ..................................................................................AIR RANGE  
28-13-190  
28-13-164  
28-13-163  
28-13-189  
28-13-162  
28-13-178  
28-13-161  
Orifice 0.046...............................................................................................HFC-203  
Orifice 0.086...............................................................................................HFC-203  
Orifice 0.13.................................................................................................HFC-203  
Orifice 0.156...............................................................................................HFC-203  
Orifice 0.250...............................................................................................HFC-203  
Orifice 0.312...............................................................................................HFC-203  
Orifice 0.375...............................................................................................HFC-203  
39-02-002  
LARGE FILTER DISC.............................................................................HFC-203  
81-213  
81-105  
SENSOR MODULE (10 SCCM ONLY).......................................ALL MODELS  
SENSOR MODULE .......................................................................ALL MODELS  
NOTE: Ranges listed are for same standard temperature and pressure.  
To place an order or to obtain information concerning replacement parts, contact the factory or our  
local manufacturer’s representative in you area. See below, or this manual’s last page for the address  
or phone number. When ordering, include the following information:  
Instrument model number  
Part description  
Hastings part number  
201/203 Series  
Page 19 of 20  
5. WARRANTY  
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 refund 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  
TOLL FREE  
FAX  
(757) 723-6531  
1-800-950-2468  
(757) 723-3925  
E MAIL  
Repair Forms may be obtained from the “Information Request” section of the Hastings Instruments  
web site.  
201/203 Series  
Page 20 of 20  

Omega Speaker Systems 23222 User Manual
Samsung Aw060cm User Manual
Savin 9940dp User Manual
Schumacher 6000a User Manual
Schumacher Scf 2500a User Manual
Sprint Nextel Samsung M320 User Manual
Subaru Robin Power Products Automobile Parts 12 2b User Manual
Toshiba Air Conditioner Rav Sm566bt E User Manual
Trion Air Boss Mp600m User Manual
Xerox Workcentre Xk35c User Manual