Teledyne HASTINGS 200 Series User manual

200/202 Series
Flowmeters and
Controllers
INSTRUCTION MANUAL
www.teledyne-hi.com
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I S O 9 0 0 1
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Manual Print History
The print history shown below lists the printing dates of all revisions created for this manual. The revision level
letter increases alphabetically as the manual undergoes subsequent updates. Each new revision includes a
revised copy of this print history page.
Revision A (Document Number 140-0999) ......................................................................................................................... September 1999
Revision B (Document Number 140-1199)............................................................................................................................... November 1999
Revision C (Document Number 140-102002).............................................................................................................................October 2002
Revision D (Document Number 140-082005).............................................................................................................................August 2005
Revision E (Document Number 140-112007)...........................................................................................................................November 2007
Revision F (Document Number 140-062008)................................................................................................................................... June 2008
Revision G (Document Number 140-082008).............................................................................................................................August 2008
Revision H (Document Number 140-022009) ......................................................................................................................... February 2009
Revision J (Document Number 140-102009) ..............................................................................................................................October 2009
Revision K (Document Number 140-102009A)..........................................................................................................................October 2009
Revision L (Document Number 140-082010) ................................................................................................................................ August 2010
Revision M (Document Number 140-072011)........................................................................................................................................ July 2011
Revision N (Document Number 140-072013)....................................................................................................................................... July 2013
Revision P (Document Number 140-032021) .................................................................................................................................March 2021
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Description of Symbols and Messages used in this manual
WARNING: indicates a hazardous situation, which, if not avoided, could result in death or
serious injury. Do not proceed beyond a WARNING notice until the indicated conditions are
fully understood.
CAUTION: indicates a hazardous situation, which if not avoided, could result in minor or
moderate injury. Do not proceed beyond a CAUTION notice until the indicated conditions are
fully understood and met.
NOTICE: calls attention to a procedure or practice that if not correctly performed or adhered
to, could result in equipment damage, loss of data, or inaccurate data.
NOTE: is used for tips and other digressions.
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.

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Table of Contents
1. GENERAL INFORMATION .................................................................................................. 5
FEATURES................................................................................................................ 6
SPECIFICATIONS HFM-200*.............................................................................................. 7
SPECIFICATIONS HFC-202*.............................................................................................. 8
OPTIONAL 4-20 MACURRENT OUTPUT................................................................................... 9
ACCESSORIES............................................................................................................ 10
1.5.1. Power Supplies................................................................................................ 10
1.5.2. Cables .......................................................................................................... 10
2. INSTALLATION AND SETUP ..............................................................................................11
RECEIVING INSPECTION .................................................................................................. 11
POWER REQUIREMENTS.................................................................................................. 11
2.2.1. ±15 VDC Option ............................................................................................... 11
2.2.2. 24 VDC Option ................................................................................................ 11
OUTPUT SIGNAL ........................................................................................................ 12
MECHANICAL CONNECTIONS ............................................................................................. 12
2.4.1. Mounting....................................................................................................... 12
2.4.2. Gas Quality .................................................................................................... 12
2.4.3. Upstream & Differential Pressure ......................................................................... 12
2.4.4. Other Mounting & Fitting Options, Notes ................................................................ 12
2.4.5. Laminar Flow Element (LFE) Configuration.............................................................. 13
ELECTRICAL CONNECTIONS .............................................................................................. 14
2.5.1. Bipolar (±15 VDC) Power Supply to Bipolar Connections .............................................. 14
2.5.2. Unipolar (24 VDC) Power Supply to Unipolar Connections ............................................ 15
2.5.3. General Connection Notes .................................................................................. 15
OPERATION ............................................................................................................. 16
2.6.1. Operating Conditions ........................................................................................ 16
2.6.2. Zero Check..................................................................................................... 16
2.6.3. High Pressure / High Density Option...................................................................... 16
2.6.4. Gas Blending .................................................................................................. 17
OPERATION WITH EXTERNAL DEVICES.................................................................................... 17
2.7.1. Operation with a Hastings Power Supply................................................................. 17
2.7.2. Operation with a Non-Hastings Power Supply ........................................................... 18
2.7.3. Operation with an External Sensor (External Input) ................................................... 19
2.7.3.1. 15 Volt Units............................................................................................................ 19
2.7.3.2. 24 Volt Units............................................................................................................ 19
2.7.4. Response to Command Changes............................................................................ 20
RANGE CHANGING ...................................................................................................... 20

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VALVE-OVERRIDE CONTROL ............................................................................................. 20
3. MAINTENANCE .............................................................................................................21
AUTHORIZED MAINTENANCE ............................................................................................. 21
TROUBLESHOOTING ..................................................................................................... 21
ADJUSTMENTS........................................................................................................... 22
3.3.1. Calibration Procedure (controller) ........................................................................ 22
3.3.2. Miscellaneous Adjustments ................................................................................. 23
ENDCAP REMOVAL....................................................................................................... 23
PRINTED CIRCUIT BOARD REPLACEMENT ................................................................................. 23
SENSOR REPLACEMENT .................................................................................................. 23
ORIFICE CHANGES....................................................................................................... 23
3.7.1. HFC-202 Orifice............................................................................................... 24
4. WARRANTY AND REPAIR .................................................................................................25
WARRANTY REPAIR POLICY.............................................................................................. 25
RETURN POLICY......................................................................................................... 25
5. DRAWINGS ..................................................................................................................26

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1. General Information
The Hastings HFM-200 mass flow meter and HFC-202 flow controller are designed to accurately measure and
control mass flow over the range of 10 sccm to 30 slm, without corrections or compensations for gas pressure
and temperature with an accuracy of better than ±1% FS (Full Scale). Hastings mass flow instruments do not
require any periodic maintenance under normal operating conditions with clean gases. No damage will occur
from the use of moderate overpressures (~500 psi/3.45MPa) or overflows. Instruments are normally calibrated
with the appropriate standard calibration gas (nitrogen) then a correction factor is used to adjust the output
for the intended gas.
NOTICE: The instruments described in this manual may be available with multiple pinouts.
Ensure that all electrical connections are correct.
NOTICE: The instruments described in this manual are designed for INDOOR and DRY use only.
NOTICE: The instruments described in this manual are designed for Class 2 installations in
accordance with IPC standards.
CAUTION: There are no operator serviceable parts or adjustments inside the product.
CAUTION: If this equipment is used in a manner other than that specified, the protection
provided by the equipment may be impaired.

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Features
STABILITY. The Hastings HFM-200/HFC-202 instruments operate on a unique thermal electric principle using a
heated metallic capillary tube and thermocouple temperature measurement. This results in an output that is
stable with time.
THERMAL MASS FLOW MEASUREMENT. The 200 Series sensor output is a function of the mass flow rate and the
heat capacity of the gas. Changes in gas composition usually only require a simple multiplier to account for the
difference in heat capacity. This gas conversion factor allows Hastings flowmeters to measure a wide variety
of gases.
LINEAR BY DESIGN. The HFM-200/HFC-202 Series is inherently linear (no linearization circuitry is employed).
Should recalibration in the field be desired (a calibration standard is required), the customer needs to simply
set the zero and span points.
MODULAR SENSOR WITH LOCKING CONNECTOR. The HFM-200/HFC-202 Series incorporates a
removable/replaceable sensor module with a reliable sensor to board connection. Field repairs to units can be
achieved with a minimum of production line downtime with confidence in the sensor to PCB connection.
SETTLING TIME. Filtering in the meter circuitry and more modern valve circuitry have improved the standard
200 Series response time in meters and controllers. HFC-202s perform 10-100% flow changes under 3.5
seconds. HFM-200s perform 0-100% flow changes under 5.7 seconds.
LOW TEMPERATURE DRIFT. 200 Series flow instruments have a thermal coefficient of span that is no more
than 0.06% of full scale/°C from -20-70°C and a thermal coefficient of about 0.035% of reading/°C from -20-
70°C.
CURRENT LOOP. The 4-20 mA option gives the user the advantages of a current loop output to minimize
environmental noise pickup.
FLEXIBLE POWER REQUIREMENTS. 200 Series instruments using the 24V board can operate with power
supplies capable of providing 11 –36 VDC via the 9-pin D connector provided the supply meets the current
requirements (see sections 1.2 and 1.3).

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Specifications HFM-200*
WARNING: Do not operate instruments exceeding the specifications listed below. Failure to
heed this warning could result in serious personal injury and/or damage to the equipment.
Accuracy1and Linearity: ±1% of FS
Repeatability: ±0.043% FS
Standard Pressure Rating: 500 psig
Pressure Coefficient: +0.0067%/psig (0-1000 psig N2) typical
High Pressure Option: Proof tested to 1500 psig
Leak Integrity: Less than 1x10-9 sccs
Operating Temperature: -20°C to 70°C
Temperature Coefficient: Zero ±0.035% FS/°C (-20 to 70°C), Span ±0.06% FS/°C (-20 to 70°C)
WARNING: Operation above 60 °C ambient may result in case temperatures capable of causing
burns.
Power (±15V meter, 0-5 VDC): +(14-16) VDC @ 35 mA, -(14-16) VDC @ 20 mA (~ 0.88 watts)
Power (±15V meter, 4-20 mA): +(14-16) VDC @ 55 mA, -(14-16) VDC @ 20 mA (~ 1.2 watts)
Power (24V meter, 0-5 VDC): (11-36) VDC ~ 1.08 watts
Power (24V meter, 4-20 mA): (11-36) VDC ~ 1.80 watts
NOTICE: Use of an underpowered or under-voltage supply could result in equipment damage.
Output Flow Signal: 0-5.00 VDC linear or 4-20 mA
Wetted Material2: 316 SS, Viton®, 82/18 Au/Ni Braze, Trace Silver Solder
Connector: 15-pin subminiature D / (9-pin for 24V)
Fittings: ¼-inch Swagelok®, others available
Weight (approx.) 1.5 lb. (0.68 kg)
WARNING: Do not power with isolated drive circuits that are more than 36 volts above ground
potential or could reach 36 volts in the event of a fault. Failure to heed this warning could
result in serious personal injury and/or damage to the equipment.
Response Time (0-100%): 5 seconds typical, 5.7 seconds max
1 Stated accuracy is for nitrogen or other gas specific calibration and using this gas only.
2 Other materials are available. Viton is the standard O-ring option.
* Specifications may vary for instruments with ranges above 10 slm.

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Specifications HFC-202*
WARNING: Do not operate instruments exceeding the specifications listed below. Failure to
heed this warning could result in serious personal injury and/or damage to the equipment.
Accuracy1and Linearity: ±1% of FS
Repeatability: ±0.043% FS
Standard Pressure Rating: 500 psig
Pressure Coefficient: +0.0067%/psig (0-1000 psig N2) typical
High Pressure Option: Proof tested to 1500 psig
Control Valve Differential Pressure*Per customer order
Leak Integrity: Less than 1x10-9 sccs
Operating Temperature: -20°C to 70°C
Temperature Coefficient: Zero ±0.035% FS/°C (-20 to 70°C), Span ±0.06% FS/°C (-20 to 70°C)
WARNING: Operation above 60 °C ambient may result in case temperatures capable of causing
burns.
Power (±15V controller, 0-5 VDC): +(14-16) VDC @ 21 mA, -(14-16) VDC @ 175 mA (~ 3.14 watts)
Power (±15V controller, 4-20 mA): +(14-16) VDC @ 40 mA, -(14-16) VDC @ 175 mA (~ 3.44 watts)
Power (24V controller, 0-5 VDC): (12-36) VDC ~ 3.64 watts
Power (24V controller, 4-20 mA): (13-36) VDC ~ 3.96 watts
NOTICE: Use of an underpowered or under-voltage supply could result in equipment damage.
Output Flow Signal / CMD Input: 0-5.00 VDC linear or 4-20 mA
Wetted Material2: 316 & 302 SS, Ni, Viton®, Kalrez® 82/18 Au/Ni Braze, Trace Ag Solder
Connector: 15-pin subminiature D / (9-pin for 24V)
Fittings: ¼-inch Swagelok®, others available
Weight (approx.) 1.8 lb. (0.82 kg)
WARNING: Do not power with isolated drive circuits that are more than 36 volts above ground
potential or could reach 36 volts in the event of a fault. Failure to heed this warning could
result in serious personal injury and/or damage to the equipment.
Response Time (10-100%): 3.4 seconds typical, 3.5 seconds max
1 Stated accuracy is for nitrogen or other gas specific calibration and using this gas only.
2 Other materials are available. Viton is the standard O-ring option.
* Specifications may vary for instruments with ranges above 10 slm.

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Optional 4-20 mA Current Output
An option to the standard 0-5 VDC output is the 4-20 mA current output that is proportional to flow. The 4-20
mA signal is produced from the 0-5 VDC output of the flow meter. The current loop output is useful for remote
applications where pickup noise could substantially affect the stability of the voltage output or long cable runs
where cable resistance would cause a voltage signal to decay.
The current loop signal replaces the voltage output on pin 6 of the DA-15 connector (pin 2 of DE-9 24 Volt).
The current loop is sourced internally from the +15 VDC supply and must be returned to the signal supply
common after (pin 5 [±15 VDC] or pin 8 [24 VDC]) passing through the monitoring circuitry to complete the
loop. The load must be between 0 and 600 Ohm.
The 4-20 mA I/O option can accept a current input for flow controllers. The 0-5 VDC command signal on pin 14
/ (pin 3 for 24 Volts) can be replaced by a 4 - 20mA command signal. The loop presents an impedance of 50
Ohms and is returned to the signal common. On the 24 Volt units, the signal common will need to be tied to
the power supply common external to the flow controller to complete the loop since the signal common is
galvanically isolated internally from the supply common. This line must be current limited (< 50 mA) to
prevent short circuit currents from damaging the receiving circuit in the flow controller.

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Accessories
1.5.1. Power Supplies
Hastings power supplies are available in one or four channel versions. They convert 100, 115 or 230VAC
to the voltage required to operate the instruments and provide a digital indication of the flow rate.
Hastings power supplies are power limited to no more than 150 VA max (fused) and use a switch
compliant to EN 60601-1. Interface terminals for the analog output signals and a main power on/off
switch are located on the rear panel as well. For safety reasons it is recommended that the power
supply (and on/off switch) be kept near the flow instruments and that the on/off switch not be blocked.
Throughout this manual, when reference is made to a power supply, it is assumed the customer is using a
Hastings power supply. Designs and models offered as Hastings Power supplies change as new technology
becomes available. For knowledge of the most up-to-date Hastings power supplies, please consult either
Hastings sales staff or our website at http://www.teledyne-hi.com
WARNING: To prevent the spread of fires in the event of a fault, only use power supplies power
limited to no more than 150 VA. The current available from a power supply used with a 200
Series instrument should be no greater than 1.6 A. Hastings power supplies meet these
requirements.
1.5.2. Cables
Cables to power Hastings flow instruments connect from the 15 pin "D" connector on the back of the
power supply directly to any of the 200 Series flow instruments. More information about the available
cables can be found on our website at http://www.teledyne-hi.com

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2. Installation and Setup
This section contains the necessary steps to install a new flow meter/controller into operation as quickly and
easily as possible. Please read the following thoroughly before attempting to install the instrument.
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
instrument and any accessories that have been ordered. Check each component shipped with the packing list.
Ensure that all parts are present (i.e. flowmeter, controller, power supply, cables, etc.). Optional equipment
or accessories will be listed separately on the packing list. There may also be one or more OPT (option) items
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 instrument.
Power Requirements
See specifications in sections 1.2 and 1.3. The HFM-200/HFC-202 Series supply voltages should be reasonably
regulated as power supply ripple may propagate to the output. Surge suppressors are recommended to prevent
power spikes reaching the instrument. The Hastings power supplies in section 1.5.1 satisfy these requirements.
Hastings power supplies are limited to no more than 150VA max and it is strongly recommended that power
supplies used with 200 Series instruments meet the recommendations in section 1.5.1.
NOTICE: Use of an underpowered or under-voltage supply could result in equipment damage.
2.2.1. ±15 VDC Option
The supply voltage for bipolar units (±15 VDC option) can vary in magnitude from 14.0 to 16.0 VDC. The
table below shows the recommended current draw and power requirements for ±15 VDC 200 Series boards.
±15V Input Power Results
0-5 VDC
4-20 mA
Current Draw (mA)
Power (watts)
Current Draw (mA)
Power (watts)
Meters at Full Flow
+(14 to 16 V)
34
0.55
54
0.87
-(14 to 16 V)
20
0.32
20
0.32
Controllers Open
+(14 to 16 V)
21
0.34
40
0.64
-(14 to 16 V)
173
2.77
173
2.77
2.2.2. 24 VDC Option
The recommended operating range of 24V units is 11 to 36 VDC for meters, 12 to 36 VDC for 0-5 V
controllers, and 13 to 36 VDC for 4-20 mA controllers.
24V Input Power Results
0-5 VDC
4-20 mA
Max Draw (mA)
Power (watts)
Current Draw
(mA)
Power (watts)
Meters (Full Flow)
90
1.08
110
1.80
Controllers (Valve Open)
380
3.64
400
3.96

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Output Signal
The standard output of the flow meter is a 0-5 VDC signal proportional to the flow rate. In Hastings power
supplies, the output is routed to the display and is also available at the terminals on the rear panel. If a
Hastings supply is not used, the output is available on pin 6 of the DA-15 connector (pin 2 of the DE-9 for 24
Volt) and is referenced to pin 5 (pin 8 for 24 Volt). 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 1.4.
Mechanical Connections
2.4.1. Mounting
If the instrument uses a dense gas or high pressures, the instrument must be installed horizontally.
Outside of this special case, the flowmeter may be mounted in any position provided the direction of
gas flow through the instrument follows the arrow marked on the bottom of the flowmeter case label.
Having the inlet and outlet fittings in a horizontal plane is preferred. Whenever a flow instrument is
mounted in a different orientation, the instrument should be re-zeroed at zero flow with the system
pressurized to the expected operating pressure.
NOTICE: The flow instrument should be installed in a clean and careful manner. Take care not to
drop the product and avoid impacts to prevent damage.
2.4.2. Gas Quality
Impurities or foreign debris in the gas lines can have negative effects on device performance. The
smallest of the internal passageways in the HFM-200/HFC-202 Series is the diameter of the sensor tube,
0.0125” (0.31 mm), so the instrument requires adequate filtering of the gas supply to prevent blockage
or clogging of the tube.
2.4.3. Upstream & Differential Pressure
The pressure regulator and the plumbing upstream must be of sufficient size to minimize changes in the
upstream pressure. In general, high capacity regulators and large internal diameter plumbing help to
make the system more stable. When switching from full flow to zero flow, the inlet pressure of the
instrument should rise to no more than 30% above the inlet pressure at full flow. The pressure drop
between the upstream regulator and the instrument should be minimized (use shorter length or larger
inner diameter pipe or tubing). The differential pressure across a meter should be less than 6” of H2O
(~0.217 psi) at maximum flow. Controllers may have much higher differential pressures depending upon
the size of the installed orifice.
WARNING: Make sure the work area is safe (de-pressurized) before installing a flow instrument. Make sure
emergency shutoff or pressure release valves are available for safe working conditions. Do not exceed 500
psig unless the flowmeter is specifically rated for higher pressures
2.4.4. Other Mounting & Fitting Options, Notes
There are two 8-32 threaded holes, located on the bottom of the base that can be used to secure it to a
mounting bracket (screws provided). Other holes for special mounting can be added to the
endcap upon request. The standard inlet and outlet fittings for the 200/202 are 0.25” and 0.125”
Swagelok (optional VCR or VCO fittings). The O-rings for the end cap and the sensor are Viton® (optional
Kalrez® or Neoprene). It is recommended that all connections be checked for leaks after installation. Do
this by pressurizing the instrument (do not exceed 500 psig unless the Flowmeter is specifically rated for

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higher pressures), applying a diluted soap solution to the flow connections, and monitoring the
connections for bubbles of escaping gas.
2.4.5. Laminar Flow Element (LFE) Configuration
200 Series flowmeters can also be mounted in parallel with a larger laminar flow element. The
installation of a Laminar Flow Element (LFE) in a flow circuit requires sufficient conductance before
entering and after exiting the LFE sensor taps to allow the flow to fully develop and promote accurate
flow sampling with a minimum of turbulence. To ensure the proper conductance around the flow
instrument with LFE, a rule of thumb is employed when choosing the lengths of pipe or tubing upstream
and downstream of LFEs:
1) The upstream flow tube length must be at least 5 times the inner diameter of
the selected LFE before the sensor inlet tap.
2) The downstream tube length must be at least the diameter of the selected LFE
after the sensor outlet tap.
To properly apply the rule of thumb we also need to know the distance between
the LFE edges and the sensor taps:
LFE ID
Edge to Sensor Tap
LFE length
< 3 inches
1.5 inches
8 inches
≥ 3 inches
2.5 inches
10 inches
Example: Suppose a 4-inch LFE is selected. The length of 4-inch inner diameter tubing or pipe,
upstream of the sensor inlet tap, will be a minimum of 20 inches. The minimum length of 4-inch tubing
or pipe downstream from the sensor outlet tap will be at least 4 inches. The length of additional 4-inch
inlet tubing required for the 4-inch LFE is (20 –2.5 = 17.5) inches. The additional length of 4-inch
tubing required for the outlet side of the 4-inch LFE is (4 –2.5 = 1.5) inches. This brings the overall
length of the assembly to (17.5 + 1.5 + 10 = 29 inches).
Tubular configurations upstream or downstream that
involve conical shapes or optimized expansion nozzles
will reduce the length of tubing required for flow
straightening, but the actual length necessary will be
a function of that geometrical shape. Testing of that
configuration will be necessary for each application.
The same is true for screen meshes or flow
straighteners. A brief listing of the ranges associated
with LFEs of different sizes is given on the right.

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Electrical Connections
If a power supply from Hastings Instruments is used with a ±15 Volt version of the HFM-200/HFC-
202, installation consists of connecting the HFM-200/HFC-202 Series cable (#AF-8AM) from the “D”
connector on the rear of the power supply to the “D” connector on the top of the flow meter. If a
different power supply is used, use the following instructions when connecting the flow meter.
WARNING: Care must be taken to avoid any high voltages that may be present when dealing
with power supplies. Power supplies used with 200 Series instruments should be power limited
to no more than 150 VA max. The available current for each 200 Series instrument connected
to a power supply should not exceed 1.6 A.
2.5.1. Bipolar (±15 VDC) Power Supply to Bipolar Connections
Connecting the HFM-200/HFC-202 Series flowmeters with anything other than the prescribed cables and
power supplies discussed above can severely damage the instrument and void the warranty. The figure
below shows the schematic layout for connecting the instrument to an appropriate ±15 Volt power
supply. A pinout is also given to show the signals available to the user and the signals given and used by
the power supply (Not all signals from the PCB are used by Hastings supplies).
The power supply used must be meet the power requirements delineated in the specifications. If a
bipolar supply is required, the voltages must be referenced to a common ground. Connect -15 VDC to pin
9 of the DA-15 connector and +15 VDC to pin 11. Pins 5 and 12 are both commons and they must be
connected together and to the ground connection at the power supply. Do not connect them together at
the flow controller as the resulting crosstalk could result in flow instabilities.
Pin #
PCB Signal
Hastings Power
Supply
1
Option 1
Not used
2
Valve Control
3
Thermocouple
Downstream
4
Thermocouple
Upstream
5
Signal Common
Signal Common
6
Signal Output
(0-5V or 4-
20mA)
Signal Output
(0-5V or 4-
20mA)
7
Case Ground
Case Ground
8
Control Valve
Override
Control Valve
Override
9
-15 VDC
-15 VDC
10
Option 10
Not used
11
+15 VDC
+15 VDC
12
Valve Return
Valve Return
13
External Input
Not used
14
Set Point (0-5V
or 4-20mA)
Set Point (0-5V
or 4-20mA)
15
5V Reference
Not used

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2.5.2. Unipolar (24 VDC) Power Supply to Unipolar Connections
Refer to the diagram below when connecting 24 Volt units. Connect the positive lead of the power supply
to pin 7 of the DE-9 connector and negative lead to pin 4. The supply input is diode protected such that
reversing the input polarity will not damage the instrument. The power supply is galvanically isolated
from all other pins. A pinout is also given to show the signals available to the user and the signals given
and used by the power supply (Not all signals from the PCB are used by Hastings supplies). A special
cable is available to connect the 9-pin unipolar power option 200 Series instruments to ±15VDC power
supplies.
2.5.3. General Connection Notes
Pin 7 of the DA-15 (15 Volt), and pin 9 of the DE-9 (24 Volt) are the case grounds. Case should be
connected to the cable shield if available and to the AC ground to the power supply. Pin 6 of the DA-15
(15 Volt), and pin 2 of the DE-9 (24 Volt) is the output signal from the flow controller. This output will be
0 –5 VDC/(4 - 20 mA), 5 VDC/20 mA being 100% of rated or full flow. Pin 14 of the DA-15 (15 Volt), and
pin 3 of the DE-9 (24 Volt) is the command input. This should be a 0 –5 VDC or (4 - 20 mA) signal and
must be free of spikes or other electrical noise, as these will generate false flow commands that the
controller would attempt to adjust for. Pin 15 of the DA-15 (15 Volt), and pin 1 of the DE-9 (24 Volt) is a
regulated 5 VDC output (±0.005 V) reference which is occasionally used as a full-scale command. If a
valve override switch is not desired, the unit is now ready for use.
If an override switch is desired, connect the center pin of a single pole, three-position switch with the
center off position to pin 8 of the DA-15 (15 Volt), pin 6 of the DE-9 (24 Volt). Connect a voltage source
>10 VDC to one end of the switch, and negative voltage to the other end. This will result in the valve
being full open when the positive voltage is supplied to the override pin, closed when the negative
voltage is supplied, and auto-control when the valve override pin floats (OPEN-AUTO-CLOSE). This setup
will be adequate for most purposes, but there will be a small delay for capacitors to charge between
switch operation and control override.
WARNING: Care must be taken to avoid any high voltages that may be present when
dealing with power supplies.
Pin #
PCB Signal
Hastings Power
Supply
1
5V Reference
Not used
2
Signal Output
(0-5V or 4-
20mA)
6
3
Set Point (0-5V
or 4-20mA)
14
4
Power Common
9
5
Valve Voltage
Not used
6
Control Valve
Override
8
7
Power Input (11
to 36 VDC)
11
8
Signal Common
5
9
Case Ground
7

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Operation
The standard instrument output signal is 0 - 5 VDC and is proportional to the flow i.e., 0
Volts = zero flow and 5 Volts = 100% of rated flow. The 4 - 20 mA option is also proportional to flow, 4
mA = zero flow and 20 mA = 100% of rated flow. It is recommended that all connections be checked for leaks
after installation. Do this by pressurizing the instrument (do not exceed 500 psig unless the Flowmeter is
specifically rated for higher pressures), applying a diluted soap solution to the flow connections, and
monitoring the connections for bubbles of escaping gas.
WARNING: Make sure the work area is safe (de-pressurized) before installing a flow
instrument. Make sure emergency shutoff or pressure release valves are available for safe
working conditions. Do not exceed 500 psig unless the flowmeter is specifically rated for
higher pressures
2.6.1. Operating Conditions
For proper operation, the combination of ambient temperature and gas temperature must be such that
the flow meter temperature remains between -20 and 70°C. The most accurate measurement of flow will
be obtained if the flow meter is zeroed at operating temperature as temperature shifts result in some
zero offset. The HFM-200/HFC-202 Series is intended for use in non-condensing environments only.
Condensate or any other liquids which enter the flow meter may destroy its electronic components.
2.6.2. Zero Check
Turn the power supply on if not already energized. Allow for a 1 hour warm-up. Stop all flow through
the instrument and wait 2 minutes. Caution: Do not assume that all metering valves completely shut off
the flow. Even a slight leakage will cause an indication on the meter and an apparent zero shift. For the
standard 0 - 5 VDC output, adjust the zero potentiometer located on the inlet side of the flowmeter until
the meter indicates zero. For the optional 4 - 20 mA output, adjust the zero potentiometer so that the
meter indicates 4 mA. This zero should be checked periodically during normal operation. Zero
adjustment is required if there is a change in ambient temperature, or vertical orientation of the flow
meter/controller.
2.6.3. High Pressure / High Density Option
When operating at high pressure or with high density gases, the increased density of gas will cause
natural convection to flow through the sensor tube if the instrument is not mounted in a level position.
This natural convection flow will be proportional to the system pressure. This will be seen as a shift in
the zero flow output that is directly proportional to the system pressure. This zero shift can be corrected
by adjusting the zero potentiometer after mounting the flow controller in its final operating position. See
section 2.4.1 and 2.6.2. Additionally, because the specific heat of a gas changes with pressure, an
associated error is introduced with increased pressure. It is directly proportional to the change in specific
heat versus pressure for that particular gas. For helium, there is virtually no change in indicated output;
for nitrogen, the indicated output will increase at approximately 0.0067%/psi, which is the pressure
coefficient. So we have:
𝐴𝑐𝑡𝑢𝑎𝑙 𝑓𝑙𝑜𝑤 =𝑖𝑛𝑑𝑖𝑐𝑎𝑡𝑒𝑑 𝑓𝑙𝑜𝑤
(1 + (𝑝𝑟𝑒𝑠𝑠𝑢𝑟𝑒 × 𝑝𝑟𝑒𝑠𝑠𝑢𝑟𝑒 𝑐𝑜𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑡))

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2.6.4. Gas Blending
In the blending of two gases, it is possible to maintain a fixed ratio of one gas to another. In this case,
the output of one flow controller is used as the setpoint or a scaled setpoint signal of a second flow
controller. The output signal of the first flow controller controls the flow rate of the second gas as a
percentage of the flow rate of the first gas. Multichannel Hastings Power Supplies allow users to
configure this option (see Ratio Control), but other devices can be used to achieve this affect provided
they can scale the output signal of one controller and feed it to the input of the other.
The following formulas are useful:
𝐴 𝐹𝑙𝑜𝑤 = (𝐴 𝑂𝑢𝑡𝑝𝑢𝑡)(𝐴 𝐹𝑢𝑙𝑙 𝑆𝑐𝑎𝑙𝑒 𝐹𝑙𝑜𝑤)
(𝐴 𝐹𝑢𝑙𝑙 𝑆𝑐𝑎𝑙𝑒 𝑂𝑢𝑡𝑝𝑢𝑡) , 𝐵 𝐹𝑙𝑜𝑤 = (𝐴 𝑂𝑢𝑡𝑝𝑢𝑡 )(𝐺𝑎𝑖𝑛 𝐹𝑎𝑐𝑡𝑜𝑟 𝑜𝑓 𝐴)(𝐵 𝐹𝑢𝑙𝑙 𝑆𝑐𝑎𝑙𝑒 𝐹𝑙𝑜𝑤) (𝐵 𝐹𝑢𝑙𝑙 𝑆𝑐𝑎𝑙𝑒 𝑂𝑢𝑡𝑝𝑢𝑡)
𝐹𝑙𝑜𝑤 𝑅𝑎𝑡𝑖𝑜 = 𝐵 𝐹𝑙𝑜𝑤
𝐴 𝐹𝑙𝑜𝑤 =(𝐺𝑎𝑖𝑛 𝐹𝑎𝑐𝑡𝑜𝑟 𝑜𝑓 𝐴)(𝐵 𝐹𝑢𝑙𝑙 𝑆𝑐𝑎𝑙𝑒 𝐹𝑙𝑜𝑤)(𝐴 𝐹𝑢𝑙𝑙 𝑆𝑐𝑎𝑙𝑒 𝑂𝑢𝑡𝑝𝑢𝑡)
(𝐴 𝐹𝑢𝑙𝑙 𝑆𝑐𝑎𝑙𝑒 𝐹𝑙𝑜𝑤)(𝐵 𝐹𝑢𝑙𝑙 𝑆𝑐𝑎𝑙𝑒 𝑂𝑢𝑡𝑝𝑢𝑡)
𝐺𝑎𝑖𝑛 𝐹𝑎𝑐𝑡𝑜𝑟 𝑜𝑓 𝐴 = (𝐹𝑙𝑜𝑤 𝑅𝑎𝑡𝑖𝑜)(𝐴 𝐹𝑢𝑙𝑙 𝑆𝑐𝑎𝑙𝑒 𝐹𝑙𝑜𝑤)(𝐵 𝐹𝑢𝑙𝑙 𝑆𝑐𝑎𝑙𝑒 𝑂𝑢𝑡𝑝𝑢𝑡)
(𝐵 𝐹𝑢𝑙𝑙 𝑆𝑐𝑎𝑙𝑒 𝐹𝑙𝑜𝑤)(𝐴 𝐹𝑢𝑙𝑙 𝑆𝑐𝑎𝑙𝑒 𝑂𝑢𝑡𝑝𝑢𝑡)
In most cases the analog output full scales are the same so those two terms cancel out.
EXAMPLE: Controller A is a 5 V controller with a full scale flow rate of 100 SLM. Controller B is a 5 V
controller with a full scale flow rate of 10 SLM. What gain factor on the output of controller A will result
in controller B flowing 5% of controller A?
Use the formulas above:
𝐺𝑎𝑖𝑛 𝐹𝑎𝑐𝑡𝑜𝑟 𝑜𝑓 𝐴 = (0.05)(100)(5)
(10)(5)= 0.5
Cut the output of controller A in half and route the signal to the setpoint of controller B to flow 5% of
controller A.
Operation with External Devices
2.7.1. Operation with a Hastings Power Supply
Hastings power supplies display flow instrument outputs (in flow units or percent of full scale) and offer
users an easy setup for controlling and monitoring each instrument’s status.Meters connected to
Hastings power supplies simply have their output signals displayed on the front screen. Controllers have
three states of operation when connected to a Hastings power supply: AUTO, OPEN, and CLOSED. Buttons
on the supply front panel allow users to toggle between these states. Controllers in the “AUTO” state
will accept setpoint commands from a Hastings power supply and control the flow rate accordingly. The
valve changes its position with the user input setpoint, and the setpoint issued to a controller can be
adjusted using the other available buttons on the supply front panel. Controllers in the CLOSED state
have their valves overridden shut and will not accept setpoint commands. The OPEN state overrides the
valve fully open regardless of any user setpoint. The OPEN position is useful for purging systems. See the
following power supply feature guide.

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Hastings Power Supply Feature Guide
Feature
THCD-101
THCD-401
# of Channels
1
4
Front Panel Display
Yes
± 15 Volts
Yes
Analog Interface
Yes
Valve Override
Yes
Totalizer
No
Yes
Reads 4-20 mA
Yes
4-20 mA Setpoints
No
Yes
Reads/Commands 0-5 VDC
Yes
Reads/Commands 0-10 VDC
Yes
Ratio Control
No
Yes
Alarms
Yes
Communications
USB emulating RS232, Ethernet
2.7.2. Operation with a Non-Hastings Power Supply
See the connection diagrams in sections 2.5.1 and 2.5.2.
WARNING: Care must be taken to avoid any high voltages that may be present when dealing
with power supplies.
To successfully operate a flow controller, a 0-5 VDC command signal proportional to the intended flow (0
Volts = zero flow; 5 Volts = 100% of rated flow) must be applied to pin 14 of the DA-15 (15 Volt), Pin 3 of
the DE-9 (24 Volt) connector. A 0–5 VDC signal proportional to the flow rate through the instrument will be
present on pin 6 of the DA-15 (15 Volt), Pin 2 of the DE-9 (24 Volt) connector. The control mode is selected
via pin 8 of the DA-15 (15 Volt), Pin 6 of the DE-9 (24 Volt) connector. Apply > 10 Volts for full open, < 0
Volts for closed and allow the override to float for flow proportional to the command voltage. Refer to your
power supply manual for the specifics of implementing these parameters.

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2.7.3. Operation with an External Sensor (External Input)
In some instances, it might be desirable to use an external sensor to provide process information to the
control circuitry in a Hastings flow instrument. For example, you might want to control the pressure in a
vacuum system by adjusting the rate at which the system is backfilled with a gas. Hastings flow controllers
have provision for accepting a 0–5 VDC output from an external sensor at pin 13 of the DA-15 (15 Volt), Pin
1 of the DE-9 (24 Volt) connector.
2.7.3.1. 15 Volt Units
To activate this feature, the cover of the
HFC must be removed to gain access to the
electronics card and move a jumper. For
the 15 Volt units, J6 is located on the left
side of the PCB between the span
potentiometer (R7) and the large D
connector (J1). In the normal operating
mode, the jumper covers the left two pins.
To select an external sensor input, move
the jumper to the right two pins. This
swaps the flow input to the controller
circuit from the flow meter output to pin
13 of the “DA-15”connector.
2.7.3.2. 24 Volt Units
For the 24 Volt units J8 is a six-pin jumper
block located down and to the right from
the DC-DC converter. There are three
jumpers installed horizontally. The middle
jumper ties the flow output to the valve
control circuit and the top jumper ties Pin
1 of the DE-9 connector to the 5 volt
reference voltage circuit. Remove both of
the upper two jumpers and reinstall one
jumper vertically between the top two pins
on the right side (see diagram below). This
will tie Pin 1 of the DE-9 connector to the
valve control circuit and allow the
controller to maintain the external process
variable equal to the desired setpoint. The
5 Volt reference is not available in this
configuration.
J8
J6
J15

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2.7.4. Response to Command Changes
The response of the valve control circuit to command signal changes is set at the factory for a fast and
stable response. The default configuration is the fastest response to command changes and allows some
overshoot and undershoot in the actual flow rate while the control circuit is establishing the new
command point. If excessive overshoot is present and not desirable, the response can be slowed by
removing the jumper labeled J15 for 15 V boards or for 24 V boards, the jumper across the bottom two
pins of J8 (see images in section 2.7.3 above). This setup results in no overshoot or undershoot in the
actual flow rate as the controller circuit establishes control at the new command point. This jumper does
not affect the system gain and will not dampen out oscillations. To adjust the response, you need a
means of producing a step change in the command voltage from 10% of full scale to 100% of full scale.
Follow the steps outlined below:
1) Cover J15 (bottom two pins of J8 for 24 V boards) with a jumper.
2) Set the command voltage to 10% of full scale and allow the flow to stabilize.
3) Step change the command voltage to 100% and observe the flow through the controller.
If the overshoot is tolerable, make no further changes. Else, remove the jumper and to prevent losing
the unused jumper, place it over only one pin of J15 (one of the pins of J8 for 24 V boards).
Range Changing
The range of the flow controller can be changed in the field if recalibration facilities are available. The flow
controller may require a different orifice, which can be purchased separately from the factory. A listing of the
orifices available can be found in Section 3.7. A brief description of the steps needed to adjust the flow range
of a Hastings flow instrument can be found in Section 3.3.
NOTICE: It is strongly recommended that adjustments to the span/calibration of a Hastings flow
instrument be made by Hastings personnel with the appropriate equipment and training. Improper
adjustments to the flow instruments will result in inaccurate data and poor instrument function.
Valve-Override Control
The valve override control line (pin 8 on 15 V boards, pin 6 on 24 V boards) provides a method to override the
valve open or closed regardless of the flow or command signals. During normal operation this line must be
allowed to float freely (no voltage source connected). This will allow the loop control to open and close the
valve as it requires to meet the issued setpoint. If the valve override line is forced high (> +10 Volts) the valve
will be forced full open. If the valve-override line is forced negative (< 0 Volts) the valve will be forced closed.