McMillan FLO-SENSOR 100 Technical Document

Manual 100-M004
July 2007
Revision 4
www.mcmflow.com
© COPYRIGHT 2007 R.D. MCMILLAN COMPANY, INC
MODEL 100
MODEL 110
MODEL S-110
MODEL S-113
FLO-METERS®and FLO-SENSORS®For Gases
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.
.

100-M004, pg. 2 of 36
TABLE OF CONTENTS
A. Introduction....................................................................................3
1. Unpacking .................................................................................3
2. Product Overview And Principle Of Operation ...............................3
3. Non-Standard Products (Z Suffixes) ...............................................4
B. Installation .....................................................................................4
1. General Considerations...............................................................5
2. Mounting the FLO-SENSOR®or FLO-METER®............................5
3. Tubing Connections ....................................................................6
4. Electrical Connections .................................................................7
a) Overview .............................................................................7
b) Connecting a Cable Assembly...................................................8
c) Electrical Connections - Voltage Output Units .............................9
d) Using a 0-5VDC Output Power Adapter Package ......................10
e) Using a 4-20mA Output Signal Converter Package (D-24VDC) ..11
C. Operation ....................................................................................12
1. Start-Up ...................................................................................12
2. Flow Readings ..........................................................................12
a) 0-5VDC Analog Outputs ........................................................12
b) 4-20mA Outputs (Using the 4-20mA Signal Converter)..............13
c) Units with an Integral Display...................................................14
3. Operating at Flow Rates Outside the Calibrated Flow Range .........14
a) Flows Above the Maximum Rated Flow.....................................14
b) Flows Below the Maximum Rated Flow .....................................14
4. Zero Adjustments ......................................................................15
5. Recalibration ............................................................................15
6. Using FLO-SENSORS®or FLO-METERS®with different Gases ........15
D. Maintenance And Product Care......................................................17
1. General ...................................................................................17
2. Cleaning and Flushing...............................................................17
3. Returning Units For Repair Or Recalibration .................................17
E. Part Number Information ...............................................................19
F. Accessories...................................................................................20
G. Specifications ...............................................................................21
H. Connector Pin and Wire Color Cross Reference ...............................22
I. Dimensions ..................................................................................23
J. Limited Warranty...........................................................................30
K. Trouble Shooting Guide.................................................................33
L. Contacting McMillan.....................................................................35

100-M004, pg. 3 of 36
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.
Typical Contents of Box
Sensor, Calibration Certificate & Instruction Manual
(Model 100 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 30
for more details).
2. Product Overview and Principle of Operation
McMillan Micro Turbine Wheel FLO-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

100-M004, pg. 4 of 36
while maintaining fast response and linear outputs with virtually no
maintenance.
McMillan’s 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 FLO-
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 effect the
calibration.
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-SENSOR® or FLO-METER®has a “Z” suffix (e.g.
100-
Z0123 ) 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.
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.

100-M004, pg. 5 of 36
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 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.
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 FLO-SENSOR®or FLO-METER®.
Caution: On high flow units (2.0-10.0 L/min, range 9,
and above) DO NOT disassemble the shunt / mounting
plate assembly or the unit will not operate correctly and
the warranty will be void.
McMillan FLO-SENSORS®and FLO-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 the McMillan Service
Department 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.
Mounting The Sensor
(mounting hardware not included with sensor)

100-M004, pg. 6 of 36
3. Tubing Connections
CAUTION: DO NOT FLOW ANY LIQUID THROUGH A GAS
FLO-SENSOR®OR FLO-METER®. THIS WILL SERIOUSLY
EFFECT 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 SPECIFCATIONS 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 McMillan
Company 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.
Connecting and tightening the Fittings
(S Series shown, other models similar)
Caution: DO NOT over tighten the fittings into the FLO-
SENSOR®or FLO-METER®body. Excessive force may
damage the sensor body. This type of damage will NOT
be repaired under warranty.

100-M004, pg. 7 of 36
The flow direction for the FLO-SENSORS®or FLO-METERS®is clearly
marked on the label. Do not reverse the flow direction or the unit will not
function correctly.
Close Up of Label Showing Flow Directions
(Model 101 shown, other 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
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
McMillan FLO-SENSORS®for gases provide a 0-5VDC output proportional
to the volumetric flow rate. This output may be connected to a display,
data acquisition system or voltmeter. The Model 110, S-110 and S-113
FLO-METERS®feature 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.

100-M004, pg. 8 of 36
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 H (Page 20) of this manual.
b) Connecting a Cable Assembly
The connector on the end of 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
(Model 101 shown, other models similar)
Electrical connections to the cable assembly are made as detailed in the
following sections.

100-M004, pg. 9 of 36
c) Electrical Connections – Voltage Output Units
The cable assembly should be connected to the sensor as detailed in
section 5(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!

100-M004, pg. 10 of 36
d) Using a 0-5VDC Output Power Adapter Package.
An optional 0-5VDC Output Power Adapter Package is available for use
with the Model 100, S-110 and S-113. The Model 110 is supplied complete
with a 0-5VDC Output Power Adapter Package.
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
(Model 100 shown, other models similar)
The 0-5VDC analog output may be connected to a display, data acquisition
system or voltmeter with a minimum load of 2.5 kΩ(kilo ohms).
The YELLOW wire of the cable assembly provides the 0-5VDC signal
output and should be connected to the positive terminal of the display,
data acquisition system or voltmeter.
The GREEN wire is not used.
The WHITE wire of the cable assembly 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!