McMillan 80 User manual

80-M001, pg. 1 of 32
Manual 80-M001
November 2005
Revision 1
www.mcmflow.com
MODEL 80
MODEL 80S
MODEL 80D
MODEL 80SD
THERMAL MASS FLO-CONTROLLERS®
Installation Manual & Operating Instructions
READ THIS MANUAL COMPLETELY BEFORE ATTEMPTING TO CONNECT
OR OPERATE YOUR FLO-SENSOR. FAILURE TO DO SO MAY RESULT IN
INJURY TO YOU OR DAMAGE TO THE FLO-SENSOR.
© COPYRIGHT 2005 R.D. MCMILLAN COMPANY, INC.

80-M001, pg. 2 of 32
TABLE OF CONTENTS
A. Introduction 3
1. Unpacking......................................................................................................... 3
2. Product Overview And Principle Of Operation......................................................... 4
3. Non-Standard Products (Z Suffixes) ........................................................................ 4
B. Installation............................................................................................................. 5
1. General Considerations ....................................................................................... 5
2. Mounting The FLO-CONTROLLER® .................................................................... 6
3. Tubing Connections ............................................................................................ 7
4. Installing a McMillan Inline Filter (Optional) ............................................................ 7
5. Electrical Connections ......................................................................................... 8
a) Overview ................................................................................................ 8
b) Connecting The 6 Pin Mini Din Connector.................................................... 9
c) Connecting The 6 Pin Mini Din Connector and Cable Assembly..................... 10
d) Connections For The 9 Pin D Sub Connector .............................................. 11
e) Connections For The 15 Pin D Sub Connector ............................................ 12
f) Using a 0-5VDC Output / Input Power Adapter Package ............................... 13
C. Operation ........................................................................................................... 14
1. Warm-Up ........................................................................................................ 14
2. Verification Of Zero .......................................................................................... 14
3. Flow Readings.................................................................................................. 14
4. Changing The Flow Rate Set-Point (From An External Voltage Source) ....................... 15
5. Changing The Flow Rate Set-Point – Model 80D And 80SD..................................... 16
6. Power Save Mode ............................................................................................. 16
7. Zero Adjustments .............................................................................................. 17
8. Recalibration.................................................................................................... 17
9. Changing The Calibration Gas – Model 80D And 80SD Only ................................. 17
D. Maintenance And Product Care .............................................................................. 18
1. General .......................................................................................................... 18
2. Returning Units For Repair Or Recalibration .......................................................... 18
E. Part Number Information ....................................................................................... 20
F. Accessories.......................................................................................................... 21
G. Specifications....................................................................................................... 22
H. Dimensions.......................................................................................................... 23
I. Limited Warranty .................................................................................................. 24
J. Gas K Factors ...................................................................................................... 27
K. Trouble Shooting Guide......................................................................................... 28
L. Contacting McMillan............................................................................................. 30

80-M001, pg. 3 of 32
A. Introduction
1. Unpacking
McMillan suitably packages all sensors to prevent damage during shipping. If
external damage is noted upon receipt of the package, please contact
the shipping
company
immediately. McMillan Company 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 McMillan Company to resolve the problem.
Contents of Box
Model 80/80S shown; Model 80D and 80SD have an integrated display.
Caution: Take care not to
drop your controller. 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 24 for more details).

80-M001, pg. 4 of 32
2. Product Overview and Principle of Operation
McMillan Model 80 Series Mass FLO-CONTROLLERS® are capable of measuring and
controlling the flow of virtually any clean, dry gas as low as 0-20 sccm or as high as
0-10 l/min. Repeatable results are achieved using a patented thermal mass flow
sensor design. This proven design minimizes zero drift while maintaining fast
response and linear outputs with virtually no maintenance.
The McMillan Company Model 80 Series
utilizes thermal flow sensing technology.
A portion of the gas flowing through the
unit is redirected into a small sensor
tube. This tube has two coils on the
outside. The first coil introduces a small
amount of heat into the gas stream. As
the gas passes through the tube heat is
transferred from one coil to the other.
The flow rate is proportional to the
amount of heat transfer. Smart
electronics analyze the amount of
temperature change in the second coil
and provide a linearized analog output.
McMillan’s patented* system insures
that the zero remains stable and the
sensor is extremely repeatable.
Flow in the Model 80 Series is controlled by a proportional solenoid valve with active
servo electronics. The flow measurement signal is analyzed by micro-processor
controlled electronics and compared to a set-point. Adjustments are then made to
the valve in order to achieve the required flow rate. The set point can be either
externally input via a 0-5VDC signal or in the case of the Model 80D and 80SD it can
be input manually on the unit.
The output of the thermal mass flow sensor is directly related to the specific heat
characteristic of the gas being measured. A sensor is calibrated for one gas but may
be used with other gases by applying a correction factor to the output. The
calibration gas for each specific FLO-CONTROLLER® is detailed on the product label.
3. Non-Standard Products (Z Suffixes)
Please note that the installation instructions, operating instructions, and
specifications included within this manual apply to standard production models only.
If your FLO-CONTROLLER® has a “Z” suffix (e.g. 80SD-
Z0911 ) then your unit is non-
standard. Contact the factory to check if the installation, operation, or specifications
of your sensor are different than detailed in this manual.

80-M001, pg. 5 of 32
B. Installation
Caution: Do not exceed the pressure, temperature or power operating
ranges detailed in the SPECIFICATIONS section of this manual. McMillan
Company 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 (before) of the
controller.
All wetted parts should be checked for compatibility with the gas to be used. If there
are any incompatibilities eg. 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.
In order to operate the differential pressure across the controller should be in the
range 15-45psid (1-3 bar). For optimum performance a differential pressure of
25psid is recommended.
For Example, consider the following system:
The differential pressure across the flow controller in this system would be 100 psi –
14 psi = 86 psid. Consequently the FLO-CONTROLLER® would NOT be able to
control flow. For the unit to operate at optimum performance the supply pressure

80-M001, pg. 6 of 32
from the gas cylinder would need to be lowered to 39 psig to give 39 psi -14 psi =
25 psid.
2. Mounting the FLO-CONTROLLER®.
McMillan Model 80 series controllers have no particular orientation or installation
requirements so may be mounted in any convenient position.
It is recommended that units be fixed to a suitable substrate using the two 4-40
mounting holes provided.
Mounting View from Bottom
(mounting hardware not included with sensor)

80-M001, pg. 7 of 32
3. Tubing Connections
All tubing must be clean, dry and purged with clean dry air before installation of the
FLO-CONTROLLER®.
If the gas to be used may contain particles then a filter (20 microns or less) should
be installed upstream of (before) the unit.
Caution: Only use the fittings factory installed 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
McMillan Company Service Department for assistance.
When connecting the sensor to the tubing, take care not to over-tighten the fittings
or leaking may occur.
4. Installing a McMillan Inline Filter (Optional).
An optional 20 Micron Aluminum filter is available for use with the Model 80 series. If
this is ordered at the same time (recommended) as the FLO-CONTROLLER® it will
be preinstalled at the factory.
To install the filter carefully remove the fitting from the INLET side of the sensor
making sure that traces of PTFE tape are removed from the internal threads.
Replace the PTFE tape on the fitting and screw it into the filter. The filter and fitting
assembly should then be screwed into the sensor body.
Caution: The filter is supplied with PTFE tape pre-installed on the male
fitting. Do not add to or remove the tape. Take care not to over-tighten
the connections or leaking may occur.
Model 80 With Model 90 Inline Filter (ranges 3-8)

80-M001, pg. 8 of 32
Model 80 With Model 91 Inline Filter (ranges 9-10)
5. 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 Model 80 Series provides a 0-5VDC analog output proportional to the flow rate.
This output may be connected to a display, data acquisition system or voltmeter with
an impedance of greater than 2.5 kΩ(kilo ohms).
The flow controller needs to be supplied with a 0-5 VDC set point signal to enable
control. On the Model 80D and 80SD this may be generated internally by altering the
set-point potentiometer on the front panel of the unit.
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
conductor cable should be used if the length of the wiring is to be longer than 2
meters.
Units are supplied with either a 6 pin mini DIN type connector (requires mating cable
assembly), a 9 Pin D Sub connector or 15 Pin D Sub connector.
Caution: Cutting off the integrated connectors on the unit IS NOT
RECOMMENDED and will void the product warranty. Mating cables should
be ordered along with each unit.

80-M001, pg. 9 of 32
b) Connecting The 6 Pin Mini Din Connector
Using a suitable mating connector the pins of the integrated connector should be
wired as follows:
Connecting To The Integrated 6 Pin Connector
Pin 2 should be connected to the Positive of the power source.
Pin 6 should be connected to the Negative (Ground) of the power source.
Pin 3 provides the signal output and should be connected to the positive terminal of
the display, data acquisition system or voltmeter.
Pin 1 is the signal negative (ground) and should be connected to the negative
(Ground) terminal of the display, data acquisition system or voltmeter.
Pin 4 provides the input signal and should be connected to the positive terminal of
the voltage source. The (0-5VDC) voltage control signal should be supplied from a
low impedance source.
Pin 5 is the input signal negative (ground) and should be connected to the negative
(Ground) terminal of the voltage source.
Caution: Avoid high voltage static discharges to the input signal
connection. Do not short the input/output signal wires or allow them to
contact the power wires at any time. DAMAGE WILL RESULT!
Pin Out of Integrated
Connecto
r

80-M001, pg. 10 of 32
c) Connecting The 6 Pin Mini Din Connector and Cable Assembly
The two mating connectors should be pushed together and the pigtail leads wired as
follows:
Connecting To The Integrated 6 Pin Connector Using A 50-C-X Cable Assembly
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 ORANGE wire provides the signal output and should be connected to the
positive terminal of the display, data acquisition system or voltmeter.
The BROWN wire is the signal negative (ground) and should be connected to the
negative (Ground) terminal of the display, data acquisition system or voltmeter.
The YELLOW wire provides the input signal and should be connected to the
positive terminal of the voltage source. The (0-5VDC) voltage control signal should
be supplied from a low impedance source.
The GREEN wire is the input signal negative (ground) and should be connected to
the negative (Ground) terminal of the voltage source.
The wire colors above describe the pigtail leads of the 50-C-X cable assembly and
may not correspond with the internal wiring of your flow sensor.
Caution: Avoid high voltage static discharges to the input signal
connection. Do not short the input/output signal wires or allow them to
contact the power wires at any time. DAMAGE WILL RESULT!

80-M001, pg. 11 of 32
d) Connections For The 9 Pin D Sub Connector
Using a suitable mating connector the pins of the integrated connector should be
wired as follows:
Connecting To The Integrated 9 Pin Connector
PIN 3 should be connected to the Positive of the power source.
PIN 4 should be connected to the Negative ( Ground ) of the power source.
PIN 2 provides the signal output and should be connected to the positive terminal
of the display, data acquisition system or voltmeter.
PIN 8 is the signal negative (ground) and should be connected to the negative
(Ground) terminal of the display, data acquisition system or voltmeter.
Pin 6 is the input signal and should be connected to the positive terminal of the
voltage source. The (0-5VDC) voltage control signal should be supplied from a low
impedance source.
Pin 7 is the input signal negative (ground) and should be connected to the negative
(Ground) terminal of the voltage source.
Pins 1, 5, and 9 are not used.
Caution: Avoid high voltage static discharges to the input signal
connection. Do not short the input/output signal pins or allow them to
contact the power connections at any time. DAMAGE WILL RESULT!
Pin Out of Integrated
Connecto
r

80-M001, pg. 12 of 32
e) Connections For The 15 D Sub Connector
Using a suitable mating connector the pins of the integrated connector should be
wired as follows:
Connecting To The Integrated 15 Pin Connector
PIN 7 should be connected to the Positive of the power source.
PIN 5 should be connected to the Negative ( Ground ) of the power source.
PIN 2 provides the signal output and should be connected to the positive terminal
of the display, data acquisition system or voltmeter.
PIN 10 is the signal negative (ground) and should be connected to the negative
(Ground) terminal of the display, data acquisition system or voltmeter.
Pin 8 is the input signal and should be connected to the positive terminal of the
voltage source. The (0-5VDC) voltage control signal should be supplied from a low
impedance source.
Pin 1 is the input signal negative (ground) and should be connected to the negative
(Ground) terminal of the voltage source.
Pins 3, 4, 6, 9, 11, 12, 13, 14 and 15 are not used.
Caution: Avoid high voltage static discharges to the input signal
connection. Do not short the output signal pins or allow them to contact
the power connections at any time. DAMAGE WILL RESULT!
Pin Out of Integrated
Connecto
r

80-M001, pg. 13 of 32
f) Using a 0-5VDC Input / Output Power Adapter Package.
An optional 0-5VDC Input / Output Power Adapter Package is available for use with
the Model 80 series. This consists of a power source (115VAC or 230VAC), a
connection hub and two cable assemblies with pig-tail (soldered wire) ends. This
should be assembled as shown in the following diagram.
Assembling an C-115VAC Power Adapter Package
(the C-230VAC Power Adapter Package is similar)
The RED connector should be inserted in the RED socket on the connection hub.
The WHITE connector should be inserted in the WHITE socket on the connection
hub.
The cable with a RED connector provides the input signal. The RED wire of this
cable should be connected to the positive terminal of the voltage source. The (0-
5VDC) voltage control signal should be supplied from a low impedance source. The
bare wire of this cable assembly is the input signal negative (ground) and should be
connected to the negative (Ground) terminal of the voltage source.
The cable with a WHITE connector provides the signal output. The WHITE wire
should be connected to the positive terminal of the display, data acquisition system
or voltmeter with an impedance of greater than 2.5 kΩ(kilo ohms). The bare wire
of this cable assembly is the signal negative (ground) and should be connected to
the negative (Ground) terminal of the display, data acquisition system or voltmeter.
Caution: Avoid high voltage static discharges to the input signal
connection. Do not short the output signal wires or allow them to
contact the power wires at any time. DAMAGE WILL RESULT!

80-M001, pg. 14 of 32
C. Operation
1. Warm Up
Before applying power to the unit check all tubing and electrical connections. Once
correct installation is verified switch on the power. The unit should then be allowed
to warm up for 5 minutes before gas pressure is applied.
2. Verification of Zero
Flow through the unit should be stopped by sealing or capping the inlet of the
controller. It is not adequate to only stop flow by turning off the gas supply or
closing a valve as there may be a leak in the system. This would give a false
reading.
After 5 minutes, the zero should be stable when there is no flow through the unit. If
after 10-15 minutes the output is still not zero volts (within ±0.05 volts) the unit
should be adjusted as detailed in section C part 6.
It should be noted that power supply voltage variations and changes in ambient
temperature can have an effect on zero readings.
3. Flow Readings
Each controller is factory calibrated for a specific flow range and gas (or gas
mixture). The calibration gas and flow range are shown on the unit’s label and
calibration certificate.
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 scaleable enabling calculation of flow rates with in the sensor’s
range. For example:
For a flow range of 0-500sccm (Range 6) :
At 500sccm the output signal would be 5VDC
If the output signal were 3.5VDC then the flow rate would be:
500 ÷ 5 × 3.5 = 350sccm
If the maximum flow rate is exceeded non-linear and inaccurate readings will result.

80-M001, pg. 15 of 32
Units may be used for gases other than the calibration gas. In this case a “K Factor”
would need to be applied and a corrected value calculated using the following
formula:
Q1/ Q2= K1/ K2
Q1is the flow rate of the new gas
Q2is the flow rate of the original calibration gas
K1is the K factor of the new gas
K2is the K factor of the original calibration gas
Q1= (K1/ K2) Q2
If K2is larger than K1then linear results will only be achieved if the unit does not
exceed 5(K1/ K2)VDC for the full scale output.
Example 1
For a 0-200sccm unit calibrated for air the flow at 5.0VDC would be 200sccm. The K
factor for air is 1. If the unit is used with Helium (K factor 1.454 relative to air) then
the flow at 5VDC (i.e. the maximum flow) would be (1.454/1)200 = 290.8 sccm
Example 2
For a 0-10.0 l/min unit calibrated for Argon the flow at 5.0VDC would be 10.0l/min.
The K factor for Argon is 1.45. If the unit is used with Carbon Dioxide (K factor 0.74)
then the flow rate 5.0VDC would be (0.74/1.45)10.0 = 5.10l/min
The accuracy of readings using K factors is not as good as that achieved for the
calibration gas. The accuracy obtained (typically ±3% for K factors similar to the
calibration gas) depends on the gas being used and the flow rate.
For a list of common K Factors see Section J.
4. Changing The Flow Rate Set-Point (From External Voltage Source)
The required flow rate is selected by adjusting the set-point voltage. The normal
control signal voltage is 0-5VDC with 0VDC corresponding to zero flow and 5VDC
being equivalent to the maximum rated flow of the unit. This input is linear and
scaleable allowing different flow rates within the range of the unit to be selected. For
example:
For a flow range of 0-500sccm (Range 6) :
A 5 VDC Input Signal would correspond to a flow rate of 500sccm
If a flow rate of 300sccm were required then the set-point would be:
(300 ÷ 500) × 5 = 3.0VDC

80-M001, pg. 16 of 32
If a gas other than the calibration gas is used then the adjusted maximum (full
scale) flow for the unit should be calculated using the K Factor for that gas (see
section C3 above).
A zero or negative set-point voltage will cause the solenoid valve to close fully.
Whilst closed, the valve is configured to withstand pressures up to 60 psig (higher
pressures on request).
Caution: The FLO-CONTROLLER®valve will open if the pressure
exceeds 60psig. For safety it is recommended that a separate positive
shut-off valve is installed upstream of the controller.
5. Changing The Flow Rate Set-Point – Model 80D and 80SD
On the Model 80D and 80SD the set-point may be input from an external source or
be supplied internally.
For an external set-point, dip switch 1 should be OFF and dip switch 2 ON. See
section C4 above for details of how to adjust the set-point using an external voltage
source.
For an internal set-point, dip switch 1 should be ON and dipswitch 2 OFF.
Adjustment of the internal set-point is made by turning the coarse and fine set-point
potentiometers on the front panel of the display, with the gas is flowing, until the
desired flow rate is achieved.
Model 80D /80SD Set-Point Potentiometers
6. Power Save Mode.
To improve valve performance and reliability over time, the Model 80 Series features
a Power Save Mode. This is activated after a prolonged application of a zero or

80-M001, pg. 17 of 32
negative set-point. When a control voltage greater than 0 VDC is applied after the
Power Save Mode has been initiated there may be a short delay (1-2 secs) before
the valve actuates.
7. Zero Adjustments
The zero should be checked as detailed in section C part 2. If an adjustment is
needed the Zero Potentiometer should be carefully turned until the output (VDC)
becomes zero.
Caution: Do NOT adjust the Gain Potentiometer when adjusting the zero
or the unit will need to be recalibrated.
Making Zero Adjustments Using a Small Flathead Screwdriver
Care should be taken to only make small adjustments to the zero potentiometer. If
too much of an adjustment is made and difficulties are being experienced in
achieving a zero reading then turn the potentiometer fully anti-clockwise and begin
making small clockwise adjustments until a zero reading is obtained.
8. Recalibration
If recalibration is required please contact the McMillan Service Department.
9. Changing the Calibration Gas – Model 80 and 80SD Only
The Model 80D and 80SD may be calibrated for up to three gases. These gases,
their corresponding flow ranges and accuracy specifications are detailed on the
calibration certificate.
The calibration gas required is determined by selecting the corresponding dip switch
on the front panel of the display.

80-M001, pg. 18 of 32
Model 80D /80SD Dip Switches
Dip switch 4 is allocated to the primary calibration gas.
Dip switch 5 is allocated to the second calibration gas (if applicable).
Dip switch 6 is allocated to the third calibration gas (if applicable).
To select the gas, the dip switch should be turned ON. All other switches allocated
to gases (i.e. 4, 5 or 6 except the required switch/gas) should be set to OFF.
D. Maintenance and Product Care
1. General
Inlet filters should be periodically checked and cleaned or 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.
Do not allow any liquid or moisture to enter the sensor or damage will occur.
2. Returning Units for Repair or Recalibration
To return a unit for repair or recalibration please contact the McMillan Service
Department or follow the procedure detailed on the McMillan web site. A Return to
Manufacturer 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

80-M001, pg. 19 of 32
necessary work the unit will be processed and returned. No charges will be made for
Warranty Repairs (see section ).
The McMillan Service Department may be contacted as follows:
Mailing address: McMillan Company
P.O. Box 1340
Georgetown, TX 78627
U.S.A.
Phone: U.S.A. [phone]
Fax: U.S.A. [phone]
Email: t[email protected]
Website: www.mcmflow.com

80-M001, pg. 20 of 32
E. Part Number Information
DESCRIPTION CODE
Model 80 Aluminum Mass FLO-CONTROLLER® 80
Model 80D Aluminum Mass FLO-CONTROLLER® w/display 80D
Model 80S Stainless Steel Mass FLO-CONTROLLER® 80S
Model 80SD Stainless Steel Mass FLO-CONTROLLER® w/display 80SD
Flow Range (sccm of air)
0-50 sccm 3
0-100 sccm 4
0-200 sccm 5
0-500 sccm 6
0-1,000 sccm 7
0-2,000 sccm 8
0-5,000 sccm 9
0-10,000 sccm 10
Power
12.5-15.0 VDC Standard
22.0-25.0 VDC E
Fittings
1/8” Acetal Compression Tube A2
1/4” Acetal Compression Tube A4
3/8” Acetal Compression Tube A6
1/8” Brass B2
1/4” Brass B4
3/8” Brass B6
1/8” Stainless Steel S2
1/4” Stainless Steel S4
3/8” Stainless Steel S6
3 mm Stainless Steel M3
6 mm Stainless Steel M6
8 mm Stainless Steel M8
1/4” VCR V4
1/4” Nylon Barb AB
1/4” Stainless Steel Barb SB
Electrical Connector
6-pin Mini-DIN (PS/2 type) Standard
9-pin D-Sub D1
15-pin D-Sub D2
Calibration Gas
Air Standard
Nitrogen G1
Oxygen G2
Hydrogen G3
Helium G4
Argon G5
Carbon Dioxide G6
Other Single Gas (specify in item description) G7
Other Gas Blend (specify gases and percentages) G8
Calibrate for 2 Gases Similar to Air (Model 80D & 80SD Only) G9
Calibrate for 3 Gases Similar to Air (Model 80D & 80SD Only) G10
Options
NIST-Traceable Calibration Certificate NIST