Dwyer Instruments TFP-GI Series Technical Document

Manual F-20-TFP-G
June 2008
Revision 1
MODEL TFP-GI
MODEL TFP-GV
Flow Sensors and Flow Meters For Gases
Installation Manual & Operating Instructions
READ THIS MANUAL COMPLETELY BEFORE ATTEMPTING TO CONNECT
OR OPERATE YOUR FLOW SENSOR. FAILURE TO DO SO MAY RESULT
IN INJURY TO YOU OR DAMAGE TO THE FLOW SENSOR.
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F-20-TFP-G, pg. 2 of 27
T A B L E O F C O N T E N T S
A. Introduction ..............................................................................3
1. Unpacking ....................................................................................3
2. Product Overview And Principle Of Operation ................................4
B. Installation................................................................................5
1. General Considerations.................................................................5
2. Mounting The Flow Sensor Or Flow Meter ....................................5
3. Tubing Connections.......................................................................6
4. Electrical Connections....................................................................8
a) Overview ................................................................................8
b) Connecting A Cable Assembly....................................................8
c) Electrical Connections - Voltage Output Units ..............................9
d) Using A 0-5VDC Output Power Adapter Package ......................10
C. Operation...............................................................................11
1. Start-Up......................................................................................11
2. Flow Readings.............................................................................11
a) 0-5VDC Analog Outputs ..........................................................11
b) Units With An Integral Display ..................................................12
3. Operating At Flow Rates Outside The Calibrated Flow Range ........12
a) Flows Above The Maximum Rated Flow .....................................12
b) Flows Below The Minimum Rated Flow ......................................13
4. Zero Adjustments ........................................................................13
5. Recalibration...............................................................................13
6. Using Flow Sensors Or Flow Meters With Different Gases..............13
D. Maintenance And Product Care ................................................15
1. General ......................................................................................15
2. Cleaning And Flushing ................................................................16
3. Returning Units For Repair Or Recalibration..................................16
E. Specifications ..........................................................................17
F. Connector Pin And Wire Color Cross Reference .........................18
G. Dimensions.............................................................................19
H. Trouble Shooting Guide ...........................................................25
I. Limited Warranty.....................................................................27
J. Contacting Dwyer....................................................................27
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F-20-TFP-G, pg. 3 of 27
A. Introduction
1. Unpacking
All sensors are suitably packaged to prevent damage during shipping. If
external damage is noted upon receipt of the package, please contact
the
shipping company
immediately. Dwyer Instruments is not liable for damage
to the device once it has left the manufacturing premises.
Open the package from the top, taking care not to cut too deeply into the
package. Remove all the documentation and contents. Take care to remove
all the items and check them against the packing slip. The products should
also be checked for any concealed shipping damage. If any shortages or
damage is noted, please contact the shipping company and/or Dwyer
Instruments to resolve the problem.
Typical Contents of Box
Sensor, Calibration Certificate & Instruction Manual
(Model TFP-GV shown, other models similar).
CAUTION: Take care not to drop your sensor or subject it to
sudden impact. Read the installation section of this manual before
providing power or tubing connections to the unit. Any damage
caused by improper installation or careless handling will not be
repaired under warranty (see limited warranty on page 27 for
more details).
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F-20-TFP-G, pg. 4 of 27
2. Product Overview and Principle of Operation
TFP Series Flow Meters and Flow Sensors for gases are capable of
measuring volumetric flows as low as 20-100 ml/min or as high as 100-
500 l/min. Highly repeatable results are achieved using a patented Pelton
Turbine Wheel flow sensor design. This proven design minimizes zero drift
while maintaining fast response and linear outputs with virtually no
maintenance.
Patented technology measures flow using a miniature turbine wheel similar
in size to a U.S. dime (16 mm diameter, 0.75 mm thick). The micro-turbine
wheel is supported on a very small sapphire shaft that is held in position by
two sapphire bearings.
As flow passes through the flow sensor, a precision machined nozzle directs
the gas onto the very small teeth of the micro-turbine wheel. This causes the
wheel to spin at a speed proportional to the volumetric flow rate.
The micro-turbine wheel has alternating white and black sections evenly
spaced on one side of the wheel. An infrared light beam is directed onto the
wheel. As the wheel rotates the infrared beam is reflected off each white
section. The reflected beam is detected by a phototransistor that converts the
reflections into electrical pulses. As the wheel spins faster the pulse rate
increases. Processing circuitry provides analog and/or pulse output that are
linearly proportional to the volumetric flow rate
When the wheel stops (under zero flow conditions), no pulses are
generated. Consequently, zero drift is not possible and zero adjustments are
never required.
Every unit is supplied with a calibration certificate detailing the results
obtained during calibration. Units are calibrated using AIR as the reference
media. Flowing gases with different physical characteristics may affect the
calibration.
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F-20-TFP-G, pg. 5 of 27
B. Installation
CAUTION: Do not exceed the pressure, temperature or power
operating ranges detailed in the Specifications section of this
manual. Dwyer Instruments shall not be liable for any damage or
injury caused by incorrect operation of their products.
1. General Considerations
It is recommended that a safety shut-off valve be installed upstream of
(before) the sensor.
All wetted parts should be checked for compatibility with the gas to be used.
If there are any incompatibilities e.g. highly corrosive gas, then the unit may
be damaged or fail prematurely. Such damage will not be repaired under
warranty.
Units should be installed in a clean, dry environment with an ambient
temperature that is as stable as possible. Avoid areas with strong magnetic
fields, strong air flows or excessive vibration.
If the gas to be used may contain particles larger than 25 microns then a
filter (25 microns or less) should be installed upstream of (before) the unit.
2. Mounting The Flow Sensor Or Flow Meter.
CAUTION: On high flow units (2.0-10.0 L/min and above) DO
NOT disassemble the shunt / mounting plate assembly or the unit
will not operate correctly and the warranty will be void.
The TFP Series of Flow Sensors and Flow Meters have no particular
installation requirements so may be mounted in any convenient position. For
optimum results the unit should be mounted with the mounting feet horizontal
on top of a flat horizontal surface. This is the same position that the unit is
calibrated in at the factory. Please contact Dwyer Customer Service if
calibration for mounting in another orientation is desired.
It is recommended that units be fixed to a suitable substrate with #4 screws
using the two mounting holes provided.
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F-20-TFP-G, pg. 6 of 27
Mounting The Sensor
(Mounting hardware not included with sensor)
3. Tubing Connections
CAUTION: DO NOT FLOW ANY LIQUID THROUGH A GAS
FLOW SENSOR OR FLOW METER. THIS WILL SERIOUSLY
AFFECT THE PERFORMANCE AND VOID THE WARRANTY.
CAUTION: DO NOT FLOW A HIGH PRESSURE GAS
THROUGH THE SENSOR. A burst of high pressure gas may
cause the unit to be damaged. Always flow gas at a pressure and
flow rate within the specifications of the unit.
All tubing must be clean, dry and without crimps, burrs or scratches.
Only use the factory installed fittings on the unit. If the fittings are removed
the calibration of the unit may be effected and leaking may occur. If
different fittings are required please contact the Dwyer Instruments Service
Department for assistance.
When connecting the sensor to the tubing a wrench should be used to stop
the fitting rotating in the sensor body. Take care not to over tighten the
fittings or leaking may occur.
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F-20-TFP-G, pg. 7 of 27
Connecting and tightening the Fittings
CAUTION: DO NOT over tighten the fittings into the sensor
body. Excessive force may damage the sensor body. This type of
damage will NOT be repaired under warranty.
The flow direction for the unit is clearly marked on the label. Do not reverse
the flow direction or the unit will not function.
Close Up of Label Showing Flow Directions
(All models similar)
The tubing ID should be as large as possible to avoid restrictions and
turbulence. For the best results, a straight length of tubing before the unit is
recommended. This should be 20 times the tubing I.D. or greater.
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F-20-TFP-G, pg. 8 of 27
4. Electrical Connections
CAUTION: Incorrect wiring may cause severe damage to the
unit. Applying an AC voltage (115VAC or 230VAC) directly to
the unit will cause damage. Read the following instructions
carefully before making any connections.
a) Overview
The TFP-GV Series provides a 0-5VDC output proportional to the volumetric
flow rate. This output may be connected to a display, data acquisition
system or voltmeter.
The TFP-GI Series features an integral display that provides a local flow
reading. These units also have a 0-5VDC analog output available. If
required, this may be connected to another display, data acquisition system
or voltmeter.
A stable D.C. power supply is required to operate the unit. The voltage and
current requirements depend on the configuration of the unit. Full details
may be found in the Specification section of this manual.
Connecting wires should be as short as possible to avoid voltage drops.
Twisted 2 pair conductor cable of a suitable gauge should be used if the
length of the power wires is to be longer than 1 meter (3.2 feet).
Units are supplied with an integral 4 pin connector. Connections to the unit
are made using a mating cable assembly or power adapter package as
detailed in the following sections. A connector pin and wire color cross
reference may also be found in Appendix F (Page 18) of this manual.
b) Connecting a Cable Assembly
The connector on the cable assembly should be pushed into the mating
socket on the sensor taking care to ensure that it is the correct way up.
Connecting the Cable Assembly
(All models similar)
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F-20-TFP-G, pg. 9 of 27
c) Electrical Connections – Voltage Output Units
The cable assembly should be connected to the sensor as detailed in section
4(b) above. Do not apply power to the sensor until all the connections have
been made and checked. Electrical connections should be made as follows:
Wiring Schematic For Voltage Output Units.
The RED wire should be connected to the Positive of the power source.
The BLACK wire should be connected to the Negative ( Ground ) of the
power source.
The WHITE wire provides the signal output and should be connected to the
positive terminal of the display, data acquisition system or voltmeter with an
impedance greater than 2500Ω(Ohms).
The GREEN wire is not used.
CAUTION: Avoid high voltage static discharges to any of the
connections. Do not short the input/output signal wires or allow
them to contact the power wires at any time. DAMAGE WILL
RESULT!
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F-20-TFP-G, pg. 10 of 27
d) Using a 0-5VDC Output Power Adapter Package.
An optional 0-5VDC Output Power Adapter Package is available for use
with the TFP Series.
The 0-5VDC Output Power Adapter Package consists of a power source
(115VAC or 230VAC) and cable assembly with pig-tail (soldered wire)
ends for the signal output. This should be assembled as shown in the
following diagram.
Connecting the Power Adapter to the Flow Sensor
(All other models similar)
Electrical connections to the cable assembly should be made as follows:
YELLOW WIRE: This provides the 0-5VDC signal output and should be
connected to the positive terminal of the display, data acquisition system or
voltmeter with an impedance of greater than 2500Ω(Ohms).
GREEN WIRE: This is not used.
WHITE WIRE: This is the signal negative and should be connected to the
negative (ground) terminal of the voltmeter, display or data acquisition
system.
CAUTION: Avoid high voltage static discharges to any of the
connections. Do not short the output signal wires or allow them to
contact the power wires at any time. DAMAGE WILL RESULT!
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F-20-TFP-G, pg. 11 of 27
C. Operation
CAUTION: DO NOT FLOW ANY LIQUID THROUGH A GAS
FLOW SENSOR. THIS WILL SERIOUSLY AFFECT THE
PERFORMANCE AND VOID THE WARRANTY.
1. Start Up
Before applying power to the unit check all tubing and electrical
connections. Once correct installation is verified switch on the power.
2. Flow Readings
The TFP-GV Series for gases provides a 0-5VDC output proportional to the
volumetric flow rate.
The TFP-GI Series features an integral 3.5 digit display that provides a local
flow reading and a 0-5VDC analog output proportional to the volumetric
flow rate.
Each unit is factory calibrated for a specific flow range. The flow range is
shown on the unit’s label and calibration certificate. Units are calibrated
using AIR as the reference media unless otherwise noted. Calibrations are
carried out with the mounting feet horizontal on a flat horizontal surface.
a) 0-5VDC Analog Outputs
By monitoring the voltage output signal it is possible to determine the flow
rate of the gas. Units are configured so that an output signal of 5.0VDC is
provided when the maximum flow (i.e. Full Scale flow) is passing through
the unit. The output signal is linear and scalable enabling calculation of flow
rates within the sensor’s range. For example:
For a flow range of 100-500ml/min:
At 500ml/min the output signal would be 5VDC
If the output signal were 3.5VDC then the flow rate would be:
(500 ÷ 5) × 3.5 = 350ml/min
If the maximum flow rate is exceeded non-linear and inaccurate readings
will result.
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F-20-TFP-G, pg. 12 of 27
b) Units With An Integral Display
The TFP-GI Series features an integral 3.5 digit LCD display. This is
configured to read in ml/min for flow ranges up to 100-500 ml/min and in
l/min for all other flow ranges. The display will only operate if power is
applied to the unit.
Flow readings may be taken directly from the display or by monitoring the
0-5VDC analog output provided (see above).
LCD Flow Display
(TFM-LI Series Shown, TFP-GI models similar)
3. Operating At Flow Rates Outside The Calibrated Flow Range
CAUTION: If the flow through the unit exceeds 120% of the
maximum rated (full scale) flow the unit may be damaged. This
type of damage will not be repaired under warranty.
Flow measurement is only accurate within the calibrated flow range for the
unit. This is detailed on the calibration certificate. The unit will still operate, to
some degree, outside this flow range.
Results obtained when operating outside the specified range of the unit are
not accurate but may be considered repeatable.
a) Flows Above The Maximum Rated Flow.
If the flow rate is above the maximum rated (or full scale) flow, the unit will
still operate and provide an output signal proportional to the flow rate.
Flows must not exceed 120% of the maximum rated flow or the unit may be
damaged.
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F-20-TFP-G, pg. 13 of 27
b) Flows Below The Minimum Rated Flow.
Signal outputs may be obtained at flow rates below the minimum specified
for your unit. The amount of flow that may be measured below the minimum
specified varies from unit to unit.
4. Zero Adjustments
It is impossible for there to be any zero drift so zero adjustments are never
required.
5. Recalibration
Please contact Dwyer Customer Service if your flow sensor or flow meter
needs recalibration.
6. Using Flow Sensors Or Flow Meters With Different Gases
The TFP Series For Gases will operate with most gases subject to
compatibility of the wetted parts.
For information about calibrating for
Hydrogen or Helium, contact Dwyer Customer Service.
Units are calibrated with AIR at a pressure of 760mmHg and temperature
of 23°C unless otherwise detailed on the calibration certificate. Using other
gases will affect the calibration. The amount of calibration error will depend
on the characteristics of the gas being flowed.
The flow reading correction factor (or calibration factor) may be
approximately calculated with the following formula:
Cf= ( Snew ÷ Scurrent )0.3
Cf= Correction factor
Snew = Specific gravity of new gas
Scurrent = Specific gravity of original calibration gas
A corrected flow reading may then be calculated using the correction factor
as follows:
Corrected Flow = Flow Reading X Correction Factor
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F-20-TFP-G, pg. 14 of 27
For example, if the unit is calibrated for AIR but the user wants to measure
the flow of Carbon Dioxide (CO2) with a specific gravity of 1.517 the flow
reading correction factor would be calculated as follows:
Snew = Specific gravity of CO2= 1.517
Scurrent = Specific gravity of Air = 1.000
Cf= (Scurrent ÷ Snew)0.3
Cf= ( 1.000 ÷ 1.517 )0.3
Cf= 0.88
If the unit has a flow reading of 200ml/min then the corrected flow reading
(for CO2) would be:
Corrected Flow = 200 X 0.88 = 176 ml/min
CAUTION: The use of correction factors can be subject to
inaccuracy and errors of up to ±10%. Please contact Dwyer
Customer Service if accurate, certified recalibration is required.
Calculating a correction factor for a gas enables the calibration of the unit
to be adjusted for that gas. This is accomplished by:
i) Calculate the corrected flow reading or VDC output at 100% of
flow using the above formulas.
ii) Adjust the flow of (the new) gas to give this flow reading
iii) Maintain this flow and ensure a stable reading.
iv) Adjust the gain potentiometer on the unit so that a 5VDC output is
obtained. The unit is now calibrated for the new gas.
For example: A 2.0 -10.0 l/min unit that has been calibrated for Air is to be
used with CO2. The correction factor, calculated as above, is 0.88. When
flowing CO2the unit will read high i.e. at 5VDC the flow of CO2would
actually be 8.8 l/min and not 10 L/min. A flow of 10 l/min of CO2 through
the unit would give a reading of 10/0.88 = 11.36 l/min or 5.68 VDC on
the unit. Flow should be adjusted so that an output of 5.68VDC or reading
of 11.36l/min is obtained. The gain potentiometer is then adjusted so that
the voltage output becomes 5VDC or the display reads 10l/min. The unit
has now been adjusted for CO2and no further corrections to flow readings
are required (if flowing CO2).
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F-20-TFP-G, pg. 15 of 27
It should be noted that the maximum output voltage for the units is
approximately 5.9VDC. It is not possible to adjust units if an output of
greater than 5.9 VDC is required.
Adjusting the Gain Potentiometer Using a Flat Head Screwdriver
(TFP-GV Series shown, other models similar)
D. Maintenance And Product Care
1. General
CAUTION: Do not disassemble your flow meter or flow sensor
for any reason. If the unit appears to be malfunctioning please
contact Dwyer Customer Service.
The TFP Series requires no periodic maintenance if used within the
recommended specifications.
The next recommended recalibration date is stated on the calibration
certificate supplied with the unit. Please contact Dwyer Customer Service for
further information.
Inlet filters should be periodically checked and cleaned / replaced as
necessary.
Regularly check all electrical and process connections for damage or
deterioration.
If the sensor is to be stored, keep both the inlet and outlet ports sealed.
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F-20-TFP-G, pg. 16 of 27
2. Cleaning and Flushing
If there is a buildup of deposits or particles from the measured gases it may
be necessary to clean
or flush the unit. This should be done by flowing
clean, particle free air (or Nitrogen) through the unit at a flow rate, pressure
and temperature within the specifications of the unit. If necessary, flow may
be reversed to assist flushing.
CAUTION: Do not flow a high pressure gas through the sensor.
A burst of high pressure gas may cause the turbine wheel sensor
to be damaged. Always flow gas at a pressure and flow rate
within the specifications of the unit.
3. Returning Units For Repair Or Recalibration
To return units for repair or recalibration please contact Dwyer Customer
Service. A Return Material Authorization (RMA) Number will then be issued
to enable the unit to be returned. Please note that no returns will be
accepted unless the RMA number is clearly indicated on the outside of all
packages.
Once the unit has been received it will be evaluated and the cost of any
repairs / recalibration determined. Once agreement has been received to
pay for all the necessary work the unit will be processed and returned. No
charges will be made for Warranty Repairs.
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F-20-TFP-G, pg. 17 of 27
E. Specifications
Model TFP-GV Model TFP-GI
Display None 3.5 Digit LCD,
0.39” (10mm) high digits
Accuracy (including linearity) ±3.0% Full Scale*
Repeatability ±0.5% Full Scale*
Pressure Rating 40 psig
(2.8 bar)
Temperature Rating Operating Range: 5 to 55°C
Storage Range: 0 to 70°C
Temperature Sensitivity ±0.2% F.S.* or less per °C
Wetted Materials Ryton®
Epoxy
Glass
Sapphire
O-Ring Material Standard - Viton®
Fitting Material (Standard) Acetal
Fitting Material Optional Acetal, brass, or stainless steel
Recommended Filtration 25 microns or less
Compatible Gases Clean, dry
0-5VDC Output Signal Standard. (Minimum 2.5 KΩload)
Typical Power Consumption 12 VDC @ 35 mA (11.5-15 VDC)
Response Time Typically <30 seconds for 67% of final value
Reliability 100,000 hours MTBF
Certifications CE Approved
89/336/EEC (EN 55011 & EN 50082-1)
73/23/EEC Low Voltage Directive
Ratings IP10 (NEMA 1)
Warranty 1 year limited
*Specifications from 20-100% of rated flow. Linearity is best fit straight line. All calibrations
performed with AIR unless otherwise stated on calibration certificate
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F-20-TFP-G, pg. 18 of 27
F. Connector Pin And Wire Color Cross Reference
Pin Configuration For Connector Socket And Connector
Pin Cable Wire Color Description
1 Black Signal & Power Negative
(Ground)
2 White Voltage Output
3 Red Power Positive
4 Green Not Used
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F-20-TFP-G, pg. 19 of 27
G. Dimensions
ALL DIMENSIONS IN INCHES (MILLIMETERS IN BRACKETS)
TFP-GV Series For Gases
20-200 ml/min To 1.0-5.0 l/min Units
1/4”Acetal Fittings Shown
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F-20-TFP-G, pg. 20 of 27
TFP-GV Series For Gases
2.0-10.0 l/min Units
1/4”Acetal Fittings Shown
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