Hastings HFM-D-301 User manual

INSTRUCTION MANUAL
HFM-D-301/305 FLOW METERS
HFC-D-303/307 FLOW CONTROLLERS
TELEDYNE
HASTINGS
INSTRUMENTS

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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 163-042008)........................................................................... April 2008
Revision B (Document Number 163-092008).................................................................. September 2008
Revision C (Document Number 163-072009) ............................................................................ July 2009
Revision D (Document Number 163-082009) .......................................................................August 2009
Revision E (Document Number 163-112009).................................................................. November 2009
Visit www.teledyne-hi.com for WEEE disposal guidance.
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.
The instruments described in this manual are designed for Class 2 installations
in accordance with IAW/IPC standards
CAUTION:
CAUTION:
The ins truments described in this manual are designed for INDOOR use only.
The ins truments described in this manual are av ailable with multiple pin-outs .
Ensure that all electrical connections are correct.
CAUTION:

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Table of Contents
1. GENERAL INFORMATION............................................................................................................................................ 4
1.1. Features.......................................................................................................................................................................... 4
1.2. Specifications................................................................................................................................................................. 5
1.3. Other Accessories.......................................................................................................................................................... 6
2. INTRODUCTION..............................................................................................................................................................7
3. INSTALLATION & OPERATION.................................................................................................................................. 8
3.1. Receiving Inspection.....................................................................................................................................................8
3.2. Power Requirements.....................................................................................................................................................8
3.3. Output Signal ................................................................................................................................................................. 8
3.4. Quick Start ..................................................................................................................................................................... 8
4. SETUP................................................................................................................................................................................. 9
4.1. Mechanical Connections...............................................................................................................................................9
4.2. Electrical Connections..................................................................................................................................................9
5. DIGITAL COMMUNICATION.....................................................................................................................................14
5.1. Basics.............................................................................................................................................................................14
5.2. Operating States..........................................................................................................................................................15
5.3. Digital Control ............................................................................................................................................................. 15
6. OPERATION....................................................................................................................................................................20
6.1. Operating Conditions.................................................................................................................................................. 20
6.2. Zero Check ...................................................................................................................................................................20
6.3. High Pressure Operation ............................................................................................................................................20
6.4. Blending of Gases........................................................................................................................................................22
6.5. Controlling Other Process Variables ........................................................................................................................ 22
6.6. Command Input ........................................................................................................................................................... 23
6.7. Valve Override Control............................................................................................................................................... 23
7. THEORY OF OPERATION...........................................................................................................................................24
7.1. Overall Functional Description .................................................................................................................................24
7.2. Sensor Description ......................................................................................................................................................24
7.3. Sensor Theory .............................................................................................................................................................. 25
7.4. Base ...............................................................................................................................................................................26
7.5. Shunt description ........................................................................................................................................................ 28
7.6. Shunt Theory................................................................................................................................................................ 28
7.7. Control Valve ............................................................................................................................................................... 32
8. MAINTENANCE..............................................................................................................................................................34
8.1. Authorized Maintenance ............................................................................................................................................34
8.2. Troubleshooting...........................................................................................................................................................34
8.3. End Cap Removal.........................................................................................................................................................38
9. GAS CONVERSION FACTORS....................................................................................................................................39
10. REFERENCES .................................................................................................................................................................42
11. WARRANTY AND REPAIR .......................................................................................................................................... 43
11.1. Warranty Repair Policy ..............................................................................................................................................43
11.2. Non-Warranty Repair Policy ......................................................................................................................................43

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1. General Information
The Hastings mass flow meter (HFM-D-301/305) and controllers (HFC-D-303/307) are intrinsically linear
and are designed to accurately measure and control mass flow over the range of 5 sccm to 2500 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 conversion factor is used to adjust the output for the intended gas.
Calibrations for other gases, such as oxygen, helium and argon, are available through special order.
1.1. Features
•LINEAR BY DESIGN. The 300 series is intrinsically linear. The output of the sensor has a non-linearity
less than 2% before the curve fit. This minimizes the density driven errors that occur when gases
other than the calibration gas are measured.
•CURVE FIT CORRECTION. The Digital 300 series uses a curve fitting technique to remove any residual
non-linearity from the system to improve the overall accuracy. This significantly improves the % of
Reading errors when flow rates are at a small fraction of the controller’s full scale flow.
•FLEXIBLE POWER REQUIREMENTS. The Digital 300 series can operate with any power supply capable
of providing 15 -30 vdc between the high and low supply pins. Bipolar ±12 vdc, ±15 vdc or unipolar 24
vdc are all acceptable.
•DIGITAL COMMUNICATIONS. The Digital 300 series can communicate or be controlled via an RS232
port or a RS485 bus. Baud rates up to 19.2k baud are supported.
•ANALOG EMULATION. The Digital 300 series instrument can be set up to mimic an analog instrument.
In this configuration the flow output is available as an analog signal and flow controllers will respond
to analog commands.
•AUTO-ZERO. The Digital 300 series of flow controllers can re-zero automatically. This feature is
enabled by default at the factory. Auto-zeroing will occur whenever the command signal is set to
zero for more than 3 minutes. This feature removes most temperature driven zero shifts.
•LOW TEMPERATURE DRIFT. The temperature coefficient of span for the Digital 300 series is less than
0.05% of Reading per °C. The temperature coefficient of zero is negligible when the auto-zero system
is active.
•CURRENT LOOP. The 0-20 mA or 4-20 mA option gives the user the advantages of a current loop
output to minimize environmental noise pickup.
•NO FOLDOVER. The output signal is linear for very large over flows and is monotonically increasing
thereafter. The output signal will not come back on scale when flows an order of magnitude over the
full scale flow rate are measured. This means no false acceptable readings during leak testing.

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1.2. Specifications
Accuracy.................................................................................................... ±(0.2% (F.S.) + 0.5% of reading)
Repeatability..............................................................................................................................±0.1% of F.S.
Maximum Pressure...........................................................................................................500 psi [3.45 MPa]
Maximum Pressure................................................................................ 1000 psi [6.9 MPa] (301/303 only)
................................................................................................................................. (with high pressure option)
Pressure Coefficient .............................................................................. (Span) 0.01%/psi (N2)(0-50 psig)
........................................................................................................... See pressure section for pressure errors
Operating Temperature................................................................ 0-50°C in non-condensing environment
Temperature Coefficient of Zero............................................................ N/A for controller with Auto-zero
......................................................................................................................... (zero) < 0.25%/°C of Full Scale
Temperature Coefficient of Span.........................................................................maximum ±500 ppm/°C
Leak Integrity......................................................................................................................<1x10-8 std. cc/s
Standard Output.............................................................................................0-5 VDC. (Load min 2k Ohms)
Optional Output................................................................................................ 0-10 VDC 0-20 mA, 4-20 mA
Power Requirements ............................................................................... 15-30 VDC @ 5.5 watts (meters)
.......................................................................................................................................@ 7.5 watts (controller)
..................................................................................................................................Class 2 power 150 VA max
Wetted Materials.............................................................. 302/304 & 316 stainless steel, nickel 200, Viton
.....................................................................................................................................Kalrez® (controller only)
Attitude Sensitivity of Zero ..........................................................................................Zero < 0.7% of F.S.
...............................................................................................................................{N2 at 19.7 psia (135 KPa)}
Attitude Sensitivity of Span ................................................................................ Span < 0.05% of reading
...............................................................................................................................{N2 at 19.7 psia (135 KPa)}
Weight .................................................................................................................. HFM-D-301; 4.1 lb (1.9 kg)
................................................................................................................................. HFC-D-303; 6.7 lb (3.0 kg)
................................................................................................................................HFM-D-305; 8.7 lb (4.0 kg)
...............................................................................................................................HFC-D-307; 15.4 lb (7.0 kg)
Electrical Connector ................................................................................................ 15 pin subminiature “D”
Fitting Options................................................HFM-D-301/HFC-D-303; 1/2” Swagelok®, 3/4” Swagelok®,
........................................................................................................................................... 1/2”VCR®, 1/2”VCO®
................................................................................ HFM-D-305/HFC-D-307; 1”Swagelok®, 1”VCR®, 1”VCO®

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1.3. Other Accessories
1.3.1. Hastings Power Supplies
Hastings power supplies are available in one or four channel versions. They convert 100, 115 or
230VAC to the 15-30 VDC required to operate the flow meter. Interface terminals for the analog
output signals are located on the rear of the panel. Throughout this manual, when reference is
made to a power supply, it is assumed the customer is using a Hastings THPS 100/400 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.
1.3.2. 301/303/305/307 Series Power Supply Interface Cables
The HFM-D-301/305 and HFC-D-303/307 normally come with the standard “H” pin-out connector.
This type of connector is supplied on the Hastings Instruments AF-8-AM cable with grey back-
shells (P/N 65-149). “U” pin-out versions of the 300 series instruments require a different cable
to connect to the power supply. This cable is identifiable by black back-shells and is available as
Hastings Instrument (P/N 65-791).

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2. Introduction
The Digital 300 is an all-digital instrument that is based on the standard 300 series flow controller. This
digital version uses the same base, flow shunting arrangement, and sensor as the analog 300 series. The
sensor is operated in the same “constant temperature above ambient” manner as the analog 300 series.
The valve is essentially the same except some metal has been removed from the sides of the orifices and
pole pieces to make room for the cover. The coil cover has been modified to reduce the fringing
magnetic fields. Mechanically the Digital 300 series has the same foot print and mounting-hole
arrangement as the analog 300 series and, with consideration given for its additional height, could be a
drop in replacement for improved control and flexibility.
The meter card and controller cards on the analog 300 have been replaced with a Main and I/O board.
These boards are higher than the analog versions but the Digital 300 Series has the same 15 pin D
connector as an analog 300 Series along with 2 digital connectors (RJ-12). The Digital 300 series will,
normally, be setup at the factory to emulate an analog 300 unit. It will accept the same command
signals and generate the same analog output signals.
Because the sensors and shunts are the same as those used in the analog version of these instruments,
the digital version starts with excellent linearity and stability. It then uses a precision A/D converter to
supply digital readings. The product of the converted sensor current and voltage signals produces a
digital power signal. This digital conversion accounts for the improved accuracy and stability over the
analog version. A measure of the power signal at a known zero flow condition is stored in non-volatile
storage and subtracted from the instantaneous power measurement to produce a signal proportional to
the molar gas flow.
During initial calibration, the residual non-linearity is measured and a fifth order polynomial is fitted to
the error signal. This fifth order polynomial is stored in non-volatile RAM on board the flow controller.
The polynomial is applied to the instantaneous power measurement to convert the power signal to a flow
signal. This flow signal is then converted to the desired engineering units and to the % of the desired
full-scale flow. These flow signals are made available on the digital port. The % of full-scale signal is
converted to the desired analog signal (0-5 Vdc, 0-10 Vdc or 4-20 mA). This signal is presented to the D
connector in the same position as the analog 300 Series.
In analog control mode the analog signal present on the command input pin is converted to a % of full-
scale value. This % of full-scale command value is compared to the % of full-scale flow signal and an
error signal is generated. The error signal is used to adjust the voltage supplied to the valve coil to
adjust the actual gas flow to force the gas flow to match the desired flow. This measurement/control
loop is performed approximately 1000 times a second to maintain real time control of the flow stream.
The following section contains the steps needed to get a new flow meter/controller operating as quickly
and easily as possible. Please read the following thoroughly before attempting to install the instrument.

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3. Installation & 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.
3.1. Receiving Inspection
Prior to opening, inspect for obvious signs of damage to the shipment. Immediately advise the carrier
who delivered the shipment if any damage is suspected. If the shipment has arrived intact, carefully
unpack the meter/controller and any accessories that have been ordered. 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.
3.2. Power Requirements
The Digital 300 series controllers require 15-30 VDC, 5.5 watts (360 mA @ 15 volts) for proper operation.
The HFC-D-302 controller requires 15-30 VDC, 7.5 watts (500mA @ 15 volts). This voltage can be bipolar
or unipolar, i.e., +/-12, +/-15 or 24 VDC, as long as, together, they are regulated to within 50 mV ripple.
Surge suppressors are recommended to prevent power spikes reaching the instrument. The Hastings
power supplies described in Section 1.4.3 satisfies these power requirements.
3.3. Output Signal
The standard output of the flow meter is a 0-5 Vdc signal proportional to the flow rate. In a Hastings
power supplies, the analog output is routed to the display and is also available at terminals on the rear
panel. If a Hastings supply is not used, the output is available on pin 6 of the “D” connector. It is
recommended that the load resistance be no less than 2kΩ. If the optional 4-20 mA output is used, the
load impedance must be selected in accordance with Section 4.
3.4. Quick Start
Quick Start
1. Insure flow circuit mechanical connections are leak free
2. Insure electrical connections are correct (see label).
3. Shut off all flow & set command to 0 (no flow).
4. Allow 30 min. to 1 hour for warm-up.
5. Note the flow signal decays toward zero.
6. Run ~20% flow through instrument for 5 minutes.
7. Insure zero flow; wait 2 minutes, then zero the instrument.
8. Instrument is ready for operation

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4. Setup
4.1. Mechanical Connections
The flow meter/controller 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 Instrument case label. The preferred
orientation is with the inlet and outlet fittings on 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 300 series is the diameter of the sensor tube
and the annular clearance of the shunt. This varies with the range of flow and can be as small as 0.014”
(0.36 mm) for the sensor tube and 0.006" (0.15 mm) for the shunt. It should be clear from this that the
instrument requires adequate filtering of the gas supply to prevent blockage or clogging of the tube.
There are two mounting holes (#8-32) in the bottom of the transducer for securing to a mounting
bracket. The standard inlet and outlet fittings for the 300 series are VCR-4, VCO-4 or 1/4" Swagelok. It
is suggested that all connections be checked for leaks after installation. This can be done by pressurizing
the instrument (do not exceed 500 psig unless the instrument is specifically rated for higher pressures)
and applying a diluted soap solution to the flow connections.
4.2. Electrical Connections
4.2.1. Power Input
Apply a source of dc power to the input power pins. Since the Digital 300 Series has its own internal
switching power supply, the value of this voltage is flexible and anything between 15 to 30 volts will
work. Determine the pin-out configuration for the instrument from the back label and see the pin out
below for connection. Note that typical bipolar flow controller power supplies produce ±15 VDC. The
voltage between the positive pins and the negative pins is 30 volts and is perfectly adequate. The
Digital 300 series of instruments will not need connection to the power supply common for a bipolar
supply.
POWER PIN-OUT
H Pin- U Pin-
+Vdc 11 4
-Vdc 9 11
Case Gnd 7 8
4.2.2. Analog Connection
If no analog control or output signals are needed or desired, skip the Analog Connection section and
proceed to the Digital Connection section.
There are two versions of the assembled I/O card. One version supports voltage I/O and the other
supports current I/O. The version is selected at time of purchase. See your shipping memo to determine
which one was included with this instrument.
The voltage output version may be set to 5 volts full scale or to 10 volts full scale. The standard value is
5 Volts and will have been set as such unless another value was specified at time of order. The analog,
full scale settings can be changed in the field with digital commands. The standard current I/O version
is 4-20 mA full-scale. Selecting a full-scale value affects both the flow signal output and the command
signal input.

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Each of these inputs and outputs require two pins since they are isolated from each other and from the
power supply. It is permissible to tie the minus pins together to generate a common signal to minimize
the number of wires required for the voltage I/O versions. If this instrument is a flow meter only unit
there is no Analog Input signal and it is not necessary to connect these lines. Determine the pin-out
configuration for the instrument from the back label and see the pin out below for connection.
ANALOG SIGNAL PIN-OUT
H Pin-out
U Pin-out
+ Analog out 6 6
- Analog Out 5 13
+ Analog In 14 15
- Analog In 12 14
The current output versions can be operated using an isolated supply or by using the flow meter supply,
(see figure 4.1).
Fig. 4.1