McMillan FLO-SENSOR 100 Technical Document

Manual 100-M004

July 2007

Revision 4

www.mcmflow.com

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

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.

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!

This manual suits for next models

Table of contents

Other McMillan Measuring Instrument manuals

McMillan

McMillan 101 Technical Document

Popular Measuring Instrument manuals by other brands

Suaoki

Suaoki D40 user manual

Elster

Elster BK-G1.6 operating instructions

Endress+Hauser

Endress+Hauser Deltabar FMD71 technical information

Duratool

Duratool D03128 manual

Vega

Vega VEGAPULS 65 Quick setup guide

Tonghui

Tonghui TH2618B Operation manual

Tenmars

Tenmars TM-801 user manual

MSR

MSR 145 user manual

TPS

TPS WP-82 manual

ELMETRON

ELMETRON CP-511 user manual

PCB Piezotronics

PCB Piezotronics 003C30 Installation and operating manual

Tenma

Tenma 72-10465 manual

Endress+Hauser

Endress+Hauser Proline Promag 50 Brief operating instructions

Siemens

Siemens SITRANS F Coriolis FCT030 Function manual

KLINGER

KLINGER CMF V Series instruction manual

EXFO

EXFO FTB-2 Notice

Keysight

Keysight M8290A Getting started guide

ADTEK

ADTEK MW-5 operating manual