Dwyer Instruments TFP-GI Series Document technique

Manual F-20-TFP-G

June 2008

Revision 1

MODEL TFP-GI

MODEL TFP-GV

Flow Sensors and Flow Meters For Gases

Installation Manual & Operating Instructions

READ THIS MANUAL COMPLETELY BEFORE ATTEMPTING TO CONNECT

OR OPERATE YOUR FLOW SENSOR. FAILURE TO DO SO MAY RESULT

IN INJURY TO YOU OR DAMAGE TO THE FLOW SENSOR.

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F-20-TFP-G, pg. 2 of 27

T A B L E O F C O N T E N T S

A. Introduction ..............................................................................3

1. Unpacking ....................................................................................3

2. Product Overview And Principle Of Operation ................................4

B. Installation................................................................................5

1. General Considerations.................................................................5

2. Mounting The Flow Sensor Or Flow Meter ....................................5

3. Tubing Connections.......................................................................6

4. Electrical Connections....................................................................8

a) Overview ................................................................................8

b) Connecting A Cable Assembly....................................................8

c) Electrical Connections - Voltage Output Units ..............................9

d) Using A 0-5VDC Output Power Adapter Package ......................10

C. Operation...............................................................................11

1. Start-Up......................................................................................11

2. Flow Readings.............................................................................11

a) 0-5VDC Analog Outputs ..........................................................11

b) Units With An Integral Display ..................................................12

3. Operating At Flow Rates Outside The Calibrated Flow Range ........12

a) Flows Above The Maximum Rated Flow .....................................12

b) Flows Below The Minimum Rated Flow ......................................13

4. Zero Adjustments ........................................................................13

5. Recalibration...............................................................................13

6. Using Flow Sensors Or Flow Meters With Different Gases..............13

D. Maintenance And Product Care ................................................15

1. General ......................................................................................15

2. Cleaning And Flushing ................................................................16

3. Returning Units For Repair Or Recalibration..................................16

E. Specifications ..........................................................................17

F. Connector Pin And Wire Color Cross Reference .........................18

G. Dimensions.............................................................................19

H. Trouble Shooting Guide ...........................................................25

I. Limited Warranty.....................................................................27

J. Contacting Dwyer....................................................................27

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F-20-TFP-G, pg. 3 of 27

A. Introduction

1. Unpacking

All sensors are suitably packaged to prevent damage during shipping. If

external damage is noted upon receipt of the package, please contact

the

shipping company

immediately. Dwyer Instruments 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 Dwyer

Instruments to resolve the problem.

Typical Contents of Box

Sensor, Calibration Certificate & Instruction Manual

(Model TFP-GV 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 27 for

more details).

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F-20-TFP-G, pg. 4 of 27

2. Product Overview and Principle of Operation

TFP Series Flow Meters and Flow 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

while maintaining fast response and linear outputs with virtually no

maintenance.

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 flow 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 affect the

calibration.

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F-20-TFP-G, pg. 5 of 27

B. Installation

CAUTION: Do not exceed the pressure, temperature or power

operating ranges detailed in the Specifications section of this

manual. Dwyer Instruments 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 of

(before) the sensor.

All wetted parts should be checked for compatibility with the gas to be used.

If there are any incompatibilities e.g. 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 Flow Sensor Or Flow Meter.

CAUTION: On high flow units (2.0-10.0 L/min and above) DO

NOT disassemble the shunt / mounting plate assembly or the unit

will not operate correctly and the warranty will be void.

The TFP Series of Flow Sensors and Flow 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 Dwyer Customer Service 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.

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F-20-TFP-G, pg. 6 of 27

Mounting The Sensor

(Mounting hardware not included with sensor)

3. Tubing Connections

CAUTION: DO NOT FLOW ANY LIQUID THROUGH A GAS

FLOW SENSOR OR FLOW METER. THIS WILL SERIOUSLY

AFFECT 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 specifications 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 Dwyer Instruments 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.

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F-20-TFP-G, pg. 7 of 27

Connecting and tightening the Fittings

CAUTION: DO NOT over tighten the fittings into the sensor

body. Excessive force may damage the sensor body. This type of

damage will NOT be repaired under warranty.

The flow direction for the unit is clearly marked on the label. Do not reverse

the flow direction or the unit will not function.

Close Up of Label Showing Flow Directions

(All 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.

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F-20-TFP-G, pg. 8 of 27

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

The TFP-GV Series provides a 0-5VDC output proportional to the volumetric

flow rate. This output may be connected to a display, data acquisition

system or voltmeter.

The TFP-GI Series features 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.

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 F (Page 18) of this manual.

b) Connecting a Cable Assembly

The connector on 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

(All models similar)

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F-20-TFP-G, pg. 9 of 27

c) Electrical Connections – Voltage Output Units

The cable assembly should be connected to the sensor as detailed in section

4(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!

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F-20-TFP-G, pg. 10 of 27

d) Using a 0-5VDC Output Power Adapter Package.

An optional 0-5VDC Output Power Adapter Package is available for use

with the TFP Series.

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

(All other models similar)

Electrical connections to the cable assembly should be made as follows:

YELLOW WIRE: This provides the 0-5VDC signal output and should be

connected to the positive terminal of the display, data acquisition system or

voltmeter with an impedance of greater than 2500Ω(Ohms).

GREEN WIRE: This is not used.

WHITE WIRE: This 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!

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