McMillan Model 106 Series Instruction Manual

McMillan Model 106 Series Instruction Manual
Manual 106-M001
March 2006
Revision 1
www.mcmflow.com
MODEL 106
MODEL 106F
MODEL 106S
FLO-SENSORS®
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 2006 R.D. MCMILLAN COMPANY, INC.
106-M001, pg. 1 of 38
TABLE
OF
CONTENTS
A. Introduction
3
1. Unpacking........................................................................................................................ 3
2. Product Overview And Principle Of Operation....................................................................... 4
3. Non-Standard Products (Z Suffixes) ...................................................................................... 5
B. Installation............................................................................................................................ 5
1. General Considerations ..................................................................................................... 5
2. Mounting The FLO-SENSOR® .......................................................................................... 7
a) Mounting The Model 106 FLO-SENSOR® ................................................................ 7
b) Mounting The Model 106 Using An Optional Base Plate............................................. 8
c) Mounting The Model 106F and Model 106S ......................................................... 8
3. Tubing Connections........................................................................................................... 9
a) General .............................................................................................................. 9
b) Special Considerations For The Model 106 ............................................................... 9
4. Electrical Connections ...................................................................................................... 10
a) Overview............................................................................................................ 10
b) Pulse Output Units (“A” and “E” Suffixes) ................................................................ 11
i) NON ISOLATED Output ................................................................................. 11
ii) ISOLATED Output ......................................................................................... 12
c) Voltage Output Units (“B”, “D”, “J” and “K” Suffixes) ................................................ 14
d) Current Output Units (“C” Suffix) ........................................................................... 15
C. Operation .......................................................................................................................... 16
1. Start-Up ......................................................................................................................... 16
2. Entrapped Air or Gas ....................................................................................................... 16
3. Flow Readings................................................................................................................. 16
a) Pulse Output Units ............................................................................................... 16
b) 0-5VDC Analog Output Units................................................................................ 17
c) 0-10VDC Analog Output Units .............................................................................. 17
d) 4-20mA Output Units........................................................................................... 18
4. Operating at Flow Rates Outside the Calibrated Flow Range ................................................. 18
a) Flows Above the Maximum Rated Flow ................................................................... 18
b) Flows Below the Maximum Rated Flow.................................................................... 19
5. Zero Adjustments............................................................................................................. 19
6. Checking the Calibration.................................................................................................. 19
7. Calibrating FLO-SENSORS® for different Liquids .................................................................. 20
D. Maintenance And Product Care............................................................................................. 21
1. General ......................................................................................................................... 21
2. Cleaning and Flushing ..................................................................................................... 21
3. Returning Units For Repair Or Recalibration ........................................................................ 22
E.
Part Number Information ...................................................................................................... 23
F.
Accessories......................................................................................................................... 24
G. Specifications...................................................................................................................... 25
H. Dimensions ........................................................................................................................ 26
I.
Limited Warranty ................................................................................................................. 32
J.
Trouble Shooting Guide ....................................................................................................... 34
K. Contacting McMillan ........................................................................................................... 36
106-M001, pg. 2 of 38
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 106F shown, 106 and 106S Similar).
Caution: Take care not to drop your sensor. 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 32 for more details).
106-M001, pg. 3 of 38
2. Product Overview and Principle of Operation
McMillan Micro Turbine Wheel FLO-SENSORS® for liquids are capable of measuring
flows as low as 15-100 ml/min or as high as 7.0-50.0 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.
McMillan’s patented technology
measures flow using a miniature
turbine wheel approximately 0.8
inches (20 mm) in diameter. The
micro-turbine wheel is supported on a
very small sapphire shaft that is held
in position by two sapphire bearings.
The micro-turbine assembly is so light
that it virtually floats in the liquid. This
relieves force on the bearings and
eliminates wear.
As flow passes through the FLOSENSOR®, a precision machined
nozzle directs the fluid onto the very
small teeth of the micro-turbine wheel. This causes the wheel to spin at a speed
proportional to the flow rate.
The micro-turbine wheel is opaque except for 8 small translucent windows. An
infrared light beam is directed onto the wheel through a thin section of the PTFE
body. As the wheel rotates the infrared beam passes
through each translucent section and is electro optically
detected on the other side of the wheel. The detected
light is converted to 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 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 deionized water as the reference media.
Flowing liquids with different specific gravities or viscosities may yield results
differing from the original calibration.
106-M001, pg. 4 of 38
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® has a “Z” suffix (e.g. 106-Z0123) then your unit is nonstandard. 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 FLOW ANY GAS THROUGH A LIQUID FLOSENSOR®. THIS WILL DAMAGE THE MICRO-TURBINE
ASSEMBLY AND VOID THE WARRANTY.
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 of (before) the
sensor.
All wetted parts should be checked for compatibility with the liquid to be used. If
there are any incompatibilities eg. highly corrosive liquid, 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 liquid to be used may contain particles larger than 20 microns then a filter (20
microns or less) should be installed upstream of (before) the unit.
If there is any possibility that there may be bubbles or entrapped gas in the system
then the outlet tubing should be elevated above the inlet port. This will enable any
gas that may become entrapped in the unit to escape.
106-M001, pg. 5 of 38
The required differential pressure (or pressure drop across the unit) decreases
exponentially with decreases in flow rate. The specific pressure drop at 100% of the
rated flow is detailed on the calibration certificate for each unit.
To calculate the pressure drop at a certain flow rate use the formula
PD = (YourFlow / MaxFlow)2 x PDmax
PD = Pressure drop at YourFlow.
YourFLow = flow rate (ml/min or l/min)
MaxFlow = 100% rated flow for the sensor (in same units as YourFlow)
PDmax = Pressure drop at 100% rated flow (see calibration certificate)
If the pressure available for the flow sensor is BELOW the pressure drop at the
required flow then flow through the unit will not be possible.
Typical Pressure Drop vs. Percentage of the Full Scale
Rated Flow for the Model 106 Series
Values may vary +/-10%
12
10
Delta P psid
8
Delta P
6
4
2
0
10
20
30
40
50
60
70
80
90
100
% of rated flow
For example: You have a sensor with a 50-500 ml/min flow range (Range 5) and
want to know the pressure drop (or minimum differential pressure required) at 300
ml/min. According to the calibration certificate, the pressure drop at 100% of flow is
approx 10 psi. Using the formula above:
PD = (300 / 500)2 x 10 = 3.6 psid
Therefore, at 300 ml/min the minimum required differential pressure for this unit is
3.6 psid. This means that if the available pressure is below 3.6 psid then flow
106-M001, pg. 6 of 38
through the unit will not be possible.
Pressure drop through a system is cumulative. If the total pressure drop across all
the components in a system exceeds the minimum pressure available then flow will
not be possible.
For example: A system has a pressure of 30-40 psi. There are several components
and the sum of their pressure drops at the required flow rate is 32 psid. If the
system is operating at 30 psi flow would not be possible as the total of the pressure
drops would be greater than the pressure available. The system will only operate if
the system pressure is above 32 psi.
2. Mounting the FLO-SENSOR®.
McMillan FLO-SENSORS® have no particular installation requirements so may be
mounted in any convenient position. It is recommended that the outlet of the FLOSENSOR® is parallel with, or elevated above the inlet. This will enable entrapped air
in the system to pass through the unit more easily.
a) Mounting The Model 106
It is recommended that units be fixed to a suitable substrate with #4 screws using
the two mounting holes provided.
Mounting View From Bottom
(Mounting hardware not included with sensor).
106-M001, pg. 7 of 38
b) Mounting The Model 106 Using an Optional Base-plate .
An optional mounting base-plate (Part Number suffix “MT”) is available for the Model
106 FLO-SENSOR®. This enables easy installation on flat, level surfaces.
The Model 106 FLO-SENSOR® and base-plate are pre-assembled at the factory. This
assembled unit should be mounted on a suitable substrate using the two mounting
holes provided.
Mounting View From Side
(Mounting hardware not included with sensor).
c) Mounting The Model 106F and Model 106S
The Model 106F and 106S FLO-SENSORS® have an integral base plate. Units should
be mounted on a suitable substrate using the holes provided.
Mounting View From Bottom
Model 106S Shown, 106F is similar
(Mounting hardware not included with sensor).
106-M001, pg. 8 of 38
3. Tubing Connections
a) General
CAUTION: DO NOT FLOW ANY GAS THROUGH A LIQUID FLOSENSOR®. THIS WILL DAMAGE THE MICRO-TURBINE
ASSEMBLY AND VOID THE WARRANTY.
All tubing must be clean, dry and without crimps, burrs or scratches.
The flow direction for the FLO-SENSOR® is clearly marked on the label. Do not
reverse the flow direction or the unit will not function.
Close Up Of Label Showing Flow Direction
(Model 106 shown, 106F and 106S Similar).
For the best results, the tubing ID should be as large as possible to avoid restrictions
and turbulence. Straight lengths of tubing before or after the unit are not required.
b) Special Considerations For The Model 106.
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.
Caution: DO NOT over tighten the fittings into the FLOSENSOR® body. Excessive force may damage the sensor body
and will NOT be repaired under warranty.
106-M001, pg. 9 of 38
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
(Model 106 only).
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® provide a 0-5 V DC, or 0-10 V DC, or 4-20 mA, or pulse
output proportional to the flow rate. This output may be connected to a display, data
acquisition system or voltmeter / current meter.
A regulated, stable and low noise D.C. power supply is recommended for powering
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
conductor cable should be used if the length of the power wires is to be longer than
1 meter.
Units are supplied with an integral cable terminated with pigtail leads. Electrical
connections to the unit should be made as detailed in the following sections.
106-M001, pg. 10 of 38
Integral Cable Terminated with Pigtail Leads
(Model 106 shown, 106F and 106S Similar).
b) Pulse Output Units (“A” or “E” Suffix )
i) NON ISOLATED Output
If a NON ISOLATED output is required the same power supply as used for the flow
sensor may be used to power the output. Connections should be made as follows:
Wiring Schematic For Non Isolated Pulse Output. “A” or “E” Suffixes Only
106-M001, pg. 11 of 38
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 pulse output and should be connected to the negative
terminal of the power supply.
The GREEN wire is the pulse output and should be connected to the data
acquisition system. A connection to the positive terminal of the power supply should
be made using a resistor as shown above. For 12-15 VDC (A suffix) models, a 1000
ohm, 1/4 Watt minimum resistor should be used. For 18-24 VDC models, a 2000
ohm, 1/2 Watt minimum resistor should be used.
The BARE wire is the shield. For noisy environments this should be connected to
ground (earth).
ii) ISOLATED Output
If an ISOLATED output is required a low impedance, low noise power source needs
to be connected to the pulse output wires. This should be isolated from the sensor
power supply. Connections should be made as follows:
Wiring Schematic For Isolated Pulse Output. “A” or “E” Suffixes Only
106-M001, pg. 12 of 38
The RED wire should be connected to the Positive of the FLO-SENSOR® power
source (V1).
The BLACK wire should be connected to the Negative ( Ground ) of the FLOSENSOR® power source (V1).
The GREEN wire provides the pulse output and should be connected to the positive
terminal of the data acquisition system. A connection to the positive terminal of the
pulse output power supply (V2) using a resistor (R1) should also be made as shown
above.
The WHITE wire is the pulse output and should be connected to the negative
terminal of the data acquisition system using a resistor (R2). A connection to the
negative terminal of the pulse output power supply (V2) should also be made as
shown above.
The BARE wire is the shield. For noisy environments this should be connected to
ground (earth).
The power supply (V2) connected to the pulse output should be less than 36VDC. Do
not exceed a current of 20 mA through the FLO-SENSOR® BOSFET Pulse output.
The pulse output peak voltage may be calculated using the following formula:
VOUT = V2 (R2 / ( R1 + R2 ))
VOUT is the pulse output peak voltage
V2 is voltage applied to the output
R1 and R2 are the resistance values of the resistors connected as shown
above
Standard 5% composition type resistors may be used to provide the desired pulse
voltage.
The resistor, R2 is not required if the frequency output voltage (VOUT) can be the
same as the supply voltage, V2.
If output isolation is not required then the sensor power supply (V1) can be used to
power the pulse output (V2) as detailed in the previous section.
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!
106-M001, pg. 13 of 38
c) Voltage Output Units (“B”, ”D”, ”J” and ”K” Suffixes)
Wiring Schematic Voltage Outputs. “B”, “D, “J” or “K” Suffixes Only
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.
The GREEN wire is the signal negative (ground) and should be connected to the
negative (Ground) terminal of the display, data acquisition system or voltmeter.
The BARE wire is the shield. For noisy environments this should be connected to
ground (earth).
For 0-5 VDC units (“B” and “D” suffixes) the display, data acquisition system or
voltmeter should have an impedance of greater than 2500Ω (Ohms).
For 0-10 VDC units (“J” and “K” suffixes) the display, data acquisition system or
voltmeter should have an impedance of greater than 5000Ω (Ohms).
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!
106-M001, pg. 14 of 38
d) Current Output Units (“C” Suffix)
Wiring Schematic For 4-20 mA Current Output. “C” Suffix Only
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 current meter.
The GREEN wire is the signal negative (ground) and should be connected to the
negative (Ground) terminal of the display, data acquisition system or current meter.
The BARE wire is the shield. For noisy environments this should be connected to
ground (earth).
For 4-20 mA units (“C” suffix) the resistance of the external current loop should be
less than 500 Ω (Ohms).
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!
106-M001, pg. 15 of 38
C.
Operation
CAUTION: USE WITH LIQUIDS ONLY. FLOWING GAS OR AIR
THROUGH YOUR FLO-SENSOR® WILL DAMAGE THE MICROTURBINE ASSEMBLY. THIS TYPE OF DAMAGE WILL NOT BE
REPAIRED UNDER WARRANTY.
1. Start Up
Before applying power to the unit check all tubing and electrical connections. Once
correct installation is verified switch on the power.
2. Entrapped Air or Gas
There may be a lot of air or gas trapped in your FLO-SENSOR® after installation.
This will usually escape the unit when flow (within the range of the unit) is first
started.
If gas remains entrapped in the unit it may be necessary to elevate the outlet tubing
above the inlet of the FLO-SENSOR®. This should enable the trapped gas to escape
the unit. The tubing may be returned to its original position once all the gas has
escaped.
If elevating the outlet tubing does not work, block or pinch the outlet tube whilst
there is flow in the system. After approximately 5 seconds, release the restriction to
allow normal flow. Doing this will build up pressure in the flow path that when
released will help remove the entrapped gas. Repeat this several times until it is
certain that all the entrapped gas has been removed from the unit. This can take
some time for units with full scale flow rates of 500 ml/min and below (ranges 3, 4
and 5).
3. Flow Readings
McMillan FLO-SENSORS® provide a 0-5 VDC, or 0-10 VDC, or 4-20 mA, or pulse
output proportional to the flow rate. The type of output signal is detailed in the part
number reference and on the calibration certificate.
Each FLO-SENSOR® is factory calibrated for a specific flow range. The flow range is
shown on the unit’s label and calibration certificate. Units are calibrated using
deionized water as the reference media.
a) Pulse Output Units
By monitoring the Pulse output frequency it is possible to determine the flow rate of
the liquid. The pulse frequency for maximum flow through the unit (i.e. full scale
106-M001, pg. 16 of 38
flow) is detailed on the calibration certificate. This differs from unit to unit. This
output is approximately linear and scaleable within the sensor’s range. For example:
For a flow range of 1.0-10.0l/min (Range 9) :
At 10.0l/min the pulse output signal detailed on the calibration
certificate is 312Hz
If the output signal were 120Hz then the flow rate would be:
10.0 ÷ 312 × 120 = 3.85l/min
b) 0-5VDC Analog Outputs
By monitoring the voltage output signal it is possible to determine the flow rate of
the liquid. 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 within the sensor’s
range. For example:
For a flow range of 50-500ml/min (Range 5) :
At 500ml/min the output signal would be 5VDC
If the output signal were 3.5VDC then the flow rate would be:
500 ÷ 5 × 3.5 = 350ml/min
If the maximum flow rate is exceeded non-linear and inaccurate readings will result.
c) 0-10VDC Analog Outputs
By monitoring the voltage output signal it is possible to determine the flow rate of
the liquid. Units are configured so that an output signal of 10.0VDC 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 within the sensor’s
range. For example:
For a flow range of 500-5000ml/min (Range 8) :
At 5000ml/min the output signal would be 10VDC
If the output signal were 6.9VDC then the flow rate would be:
5000 ÷ 10 × 6.9 = 3450ml/min
106-M001, pg. 17 of 38
If the maximum flow rate is exceeded non-linear and inaccurate readings will result.
d) 4-20mA Output Units
By monitoring the current output signal it is possible to determine the flow rate of
the liquid. Units are configured so that an output signal of 20mA is provided when
the maximum flow (i.e. Full Scale flow) is passing through the unit. The output
signal is 4mA when there is zero flow through the unit. The output signal is linear
and scaleable enabling calculation of flow rates within the sensor’s range. For
example:
For a flow range of 20-200 ml/min (Range 4) :
At 200 ml/min the output signal would be 20 mA
If the output signal were 9 mA then the flow rate would be:
200 ÷ (20-4) × (9-4) = 62.5ml/min
4. Operating at Flow Rates Outside the Calibrated Flow Range
CAUTION:. If the flow through the unit exceeds 120% of the
maximum rated (full scale) flow the unit will be damaged.
This type of damage will not be repaired under warranty.
Flow measurement is only accurate within the calibrated flow range for the unit. This
is detailed on the calibration certificate. The unit will still operate, to some degree,
outside this flow range.
Results obtained when operating outside the specified range of the unit are not
accurate but may be considered repeatable.
a) Flows Above the Maximum Rated Flow.
If the flow rate is above the maximum rated (or full scale) flow, the unit will still
operate and provide an output signal proportional to the flow rate.
Flows must not exceed 120% of the maximum rated flow or the unit may be
damaged.
106-M001, pg. 18 of 38
b) Flows Below the Minimum Rated Flow.
Signal outputs may be obtained at flow rates below the minimum specified for your
unit. The amount of flow that may be measured below the minimum specified varies
from unit to unit.
5. Zero Adjustments
It is impossible for there to be any zero drift so zero adjustments are never required.
NOTE: Units with a 4-20 mA output signal (part number suffix C )
may have a slight offset at 4 mA. This is preconfigured at the factory
during calibration and does not need adjustment.
6. Checking the Calibration
The calibration of the FLO-SENSOR® may be easily verified using empirical methods.
It should be noted that the use of empirical methods outside a certified calibration
laboratory is subject to inaccuracy and error. These methods should only be used to
gain an indication of a sensor’s performance. Please contact the McMillan Service
Department if accurate, certified recalibration is required.
A typical empirical calibration check may be carried out as follows:
Carefully adjust the flow rate so that the maximum output signal is obtained. With
the flow rate constant, liquid flowing through the unit should be gathered in a
container over a timed interval. The total volume flowed over the timed period
should then be measured using a measuring cylinder. The actual flow rate (in the
same units as the flow sensor calibration certificate) may then be calculated. The
actual maximum flow rate should then be compared to the specified maximum flow
rate to determine the error in calibration. For example:
For a flow range of 20-200ml/min (Range 4) with a 0-5VDC output:
With a constant flow and constant 5VDC output the actual volume measured
over 30 seconds was 102ml.
Therefore the actual flow rate is:
(102 / 30) x 60 = 204ml/min
The error is therefore 204 – 200 = 4ml/min or 2%
106-M001, pg. 19 of 38
Once the error in flow reading at maximum flow has been calculated, there are two
options:
i.) Adjust the scaling endpoints in the display or data acquisition system. For
example:
For a flow range of 50-500ml/min (Range 5) with a 0-5VDC output:
With a constant flow and constant 5VDC output the actual volume measured
over 60 seconds was 405ml.
Therefore the actual flow rate is:
(405 / 60) x 60 = 405ml/min
The display or data acquisition system may now to configured as follows:
0 VDC = Zero flow
5VDC = 405ml/min
ii.) Apply the error factor to each flow reading taken. For example:
For a flow range of 0.2-2.0l/min (Range 7) connected to a display:
With a constant flow rate of 2.0 l/min on the display, the actual volume
measured over 20 seconds was 0.7l
Therefore the actual flow rate is:
(0.7 / 20) x 60 = 2.1 l/min
The error is therefore 2.1 – 2.0 = 0.1 l/min or 5%
If the display shows an uncorrected flow rate of 1.4 l/min then :
Corrected flow rate = Uncorrected flow rate + error = 1.4 + 5% = 1.47 l/min
7. Calibrating FLO-SENSORS® for Different Liquids
McMillan FLO-SENSORS® will operate with most translucent liquids subject to
compatibility of the wetted parts. Best results are obtained with low viscosity (less
than 10 centistokes) liquids. For information regarding higher viscosity liquids,
contact the McMillan Service Department.
106-M001, pg. 20 of 38
Units are calibrated with deionized water as the reference media. Using other liquids
will effect the calibration. The amount of calibration error will depend on the
characteristics of the liquid being flowed.
The error in flow reading (or calibration) should be calculated and utilized as detailed
in section 6 above.
NOTE: Some higher viscosity liquids may yield non linear results
across the flow range. The calibration offset should be determined at
several different flow rates across the range of the unit.
D.
Maintenance and Product Care
1. General
CAUTION: Do not disassemble your FLO-SENSOR® for any
reason. If the unit appears to be malfunctioning please
contact the McMillan Service Department.
McMillan FLO-SENSORS® require no periodic maintenance if used within the
recommended specifications.
Inlet filters should be periodically checked and cleaned / 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 store a FLO-SENSOR® with any chemical other than water (or air) inside it
over an extended period of time. Prolonged exposure to chemicals other than water
may lead to precipitation or corrosion.
2. Cleaning and Flushing
If there is a build up of deposits or residues from the measured chemicals it may be
necessary to clean or flush the unit. This should be done by flowing clean, particle
free water through the unit at a flow rate, pressure and temperature within the
specifications of the unit. If necessary, flow may be reversed to assist flushing.
Under no circumstances should gas or air be flowed through the unit. This will cause
severe damage.
106-M001, pg. 21 of 38
3. 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
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:
Fax:
U.S.A. (512) 863-0231
U.S.A. (512) 863-0671
Email:
[email protected]
Website:
www.mcmflow.com
106-M001, pg. 22 of 38
E.
Part Number Information
DESCRIPTION
Model 106 FLO-SENSOR®
Model 106F FLO-SENSOR®
Model 106S FLO-SENSOR®
Flow Range (ml/min of water)
15-100 ml/min
20-200 ml/min
50-500 ml/min
100-1000 ml/min
200-2000 ml/min
500-5000 ml/min
1000-10000 ml/min
2.0-20.0 l/min
3.0-30.0 l/min
7.0-50.0 l/min
Power / Output Signal
12.0-15.0 VDC / Pulse Output
22.0-25.0 VDC / 0-5 VDC Output
15.0-25.0 VDC / 4-20mA Output
12.0-15.0 VDC / 0-5 VDC Output
22.0-25.0 VDC / Pulse Output
22.0-25.0 VDC / 0-10 VDC Output
12.0-15.0 VDC / 0-10 VDC Output
Fittings
1/8” PFA compression tube
¼” PFA compression tube
3/8” PFA compression tube
1/4” male flare (Flaretek® compatible)
3/8” male flare (Flaretek® compatible)
1/2” male flare (Flaretek® compatible)
3/4” male flare (Flaretek® compatible)
1/4” Super 300 (Pillar® compatible)
3/8” Super 300 (Pillar® compatible)
1/2” Super 300 (Pillar® compatible)
3/4” Super 300 (Pillar® compatible)
1” Super 300 (Pillar® compatible)
Cable Length
3 feet (0.92m)
6 feet (1.85m)
10 feet (3.1m)
15 feet (4.6m)
20 feet (6.2m)
25 feet (7.7m)
Options
High Fluid Temperature Operation
Add pair of PVDF Flare Nuts (Not Super 300)
Upgraded Microturbine Wheel
Mounting Plate (Model 106 only)
Exterior Teflon Coated (Model 106 only)
CODE
106
106F
106S
3
4
5
6
7
8
9
20
30
50
A
B
C
D
E
J
K
T2
T4
T6
F4
F6
F7
F8
S4
S6
S7
S8
S9
C3
C6
C10
C15
C20
C25
HT
FN
U
MT
TX
Note: Please refer to the product datasheet for the availability of specific options.
106-M001, pg. 23 of 38
F.
Accessories
DESCRIPTION
CODE
Cables and Power Adapters
(Ordered Separately)
110VAC Power Adapter
For 15VDC Models with 0-5VDC output
106-10-08
230VAC Power Adapter
For 15VDC Models
106-10-18
Displays
(Ordered Separately, More Information Available)
210R Rate Display, 3½ digit, 5-30 VDC Power
250 Multi-Function Display, 115 VAC Power, Analog Input
250E Multi-Function Display, 230 VAC Power, Analog Input
251 Multi-Function Display, 115 VAC Power, Pulse Input
251E Multi-Function Display, 230 VAC Power, Pulse Input
210R
250
250E
251
251E
106-M001, pg. 24 of 38
G.
Specifications
Model 106
Model 106F
Accuracy (including linearity)
Model 106S
±1.0% Full Scale*
±3.0%* Full Scale for Pulse Output Units
Repeatability
±0.2% Full Scale*
Max Working Pressure
60 psig (4.2 bar)
80 psig (5.4 bar)
Max Over Pressure Limit
80 psig (5.4 bar)
100psig (6.8bar)
Temperature Rating (Fluid)
Operating Range: 5 to 55ºC
”HT” Option: 5 to 90ºC
Temperature Rating (Environment)
Operating: 5 to 55ºC
Storage: 0 to 70ºC
Temperature Sensitivity
Wetted Materials
±0.2% F.S.* or less per ºC
PTFE
Sapphire
PFA
PTFE
Sapphire
O-Ring Material
Non Wetted Materials
Recommended Filtration
Perfluoroelastomer
PTFE, Ryton, Viton,
Polypropylene, Anodised
Aluminum, Stainless
Steel, PVC Jacketed
Cable.
PTFE, Ryton, Viton, Polypropylene, Stainless Steel,
PVC Jacketed Cable.
25 microns or less
Compatible Liquids
Low viscosity (ideally <10cS)
Translucent or transparent
Minimum amount of entrapped air or gas
Pulse Output Signal
BOSFET
Opto isolated passive pulse
Isolation 2500 volts
Typically 0-200Hz for lower flow rates and 0-500Hz for higher flows
Pulse height selectable using external voltage source
0-5VDC Output Signal
0-10VDC Output Signal
4-20mA Output Signal
Typical Power Consumption
Response Time
Reliability
Certifications
Ratings
Warranty
Non Isolated
Minimum 2.5 KΩ load
Non Isolated
Minimum 5 KΩ load
Non Isolated
Current loop should be <500Ω
12-15VDC units : 50mA
15-25 VDC units: 75mA
22-25VDC units: 50mA
Analog Outputs: Typically <1 second for 97% of final value
Pulse Outputs: Typically <300 milliseconds for 97% of final value
100,000 hours MTBF
CE Approved
89/336/EEC (EN 55011 & EN 50082-1)
73/23/EEC Low Voltage Directive
IP53 (NEMA 2)
1 year limited
*Specifications from 10-100% of rated flow. Linearity is best fit straight line. All calibrations performed with
deionized water unless otherwise stated on calibration certificate.
106-M001, pg. 25 of 38
H.
Dimensions
1. Model 106 With 1/8” Compression Fittings
2. Model 106 With 1/4” Compression Fittings
106-M001, pg. 26 of 38
3. Model 106 With 3/8” Compression Fittings
4. Model 106 With 1/4” Male Flare Fittings
106-M001, pg. 27 of 38
5. Model 106 With 3/8” Male Flare Fittings
6. Model 106 “MT” Mounting Plate
106-M001, pg. 28 of 38
7. Model 106F With 1/4” Or 3/8” Male Flare Fittings
8. Model 106F With 3/4” Male Flare Fittings
106-M001, pg. 29 of 38
9. Model 106S With 1/4”, 3/8” or 1/2” Male Flare Fittings
10.
Model 106S With 3/4” Male Flare Fittings
106-M001, pg. 30 of 38
11.
Model 106S With Super 300 Fittings
Fitting Size
P/N
Suffix
Dimension
A
B
C
D
1/4” Super 300
S4
2 x 0.4”
(2 x 11.43mm)
3.40”
(86.36mm)
1.00”
(25.40mm)
3.36”
(85.45mm)
3/8” Super 300
S6
2 x 0.6”
(2 x 13.97mm)
3.60”
(91.44mm)
1.00”
(25.40mm)
3.36”
(85.45mm)
1/2” Super 300
S7
2 x 0.7”
(2 x 17.78mm)
3.90”
(99.06mm)
1.10”
(27.94mm)
3.36”
(85.45mm)
3/4” Super 300
S8
2 x 1.0”
(2 x 25.40mm)
4.50”
(114.30mm)
1.10”
(27.94mm)
3.36”
(85.45mm)
1” Super 300
S9
2 x 0.8”
(2 x 20.32mm)
4.10”
(104.14mm)
1.25”
(31.75mm)
3.49”
(88.62mm)
106-M001, pg. 31 of 38
I.
Limited Warranty
DURATION OF LIMITED WARRANTY, MATERIALS & WORKMANSHIP
R.D. McMillan Co., Inc., hereinafter referred to as “McMillan”, warrants these products and their associated standard accessories manufactured by
McMillan and supplied hereunder, to be free from defects in materials and workmanship for a period of twelve (12) months from the date of
shipment to the customer when installed, serviced and operated in its recommended environment. This warranty is not affected in any part by
McMillan providing technical support or advice.
Replacement parts are warranted to be free from defects in material or workmanship for ninety (90) days or for the remainder of the Limited
Warranty period of the McMillan product in which they are installed, whichever is longer. Parts not installed by factory authorized service centers
may void the warranty.
PRODUCT RETURNS
(a) General Policy:
Any product or parts determined by McMillan’s inspection to have failed per this warranty, will at McMillan’s option, be repaired
or replaced with an equivalent or comparable product without charge. McMillan’s obligation hereunder shall be limited to such
repair and/or replacement and shall be conditional upon McMillan’s receiving written notice of any alleged defect within ten (10)
days of its discovery. The customer will, however, be responsible for returning the product to McMillan’s manufacturing facility in
Georgetown, Texas, U.S.A., and for assuming the cost of removing the original product and reinstalling the repaired or replaced
product. A written specific explanation of the problem must be included with each returned product. Returned goods should be
properly packaged to prevent shipping damage and shipped prepaid to McMillan.
(b) Safety Requirements:
For safety reasons, McMillan must be advised of any hazardous fluid or toxic materials that were in or on the product to be
returned. Customer must certify in writing that all such hazardous, corrosive or toxic substances have been completely removed,
cleaned or neutralized from the returned product prior to shipment to McMillan. McMillan shall hold the returned items pending
receipt of customer’s statement for defect and certification of cleanliness of returned items, provided that, prior to such receipt,
risk of loss of returned items shall remain with customer. Flow sensors, flow meters and flow controllers must be thoroughly
cleaned to remove any toxic, corrosive or hazardous fluids that may internally remain therein before shipping product to
McMillan.
(c) Shipping Requirements:
Customer is responsible for all shipping charges (except for those products under warranty, in which cases customer shall bear the
cost of inbound shipping as described herein below, and McMillan shall bear the cost of outbound shipping). Customer is
responsible for the costs of out of warranty repairs and/or recalibration. McMillan will ship items repaired under warranty back to
customer by the most economical shipping means. Expedited shipping methods may be available at customer’s expense. All
returned items shall be returned to a McMillan authorized service center., freight prepaid, accompanied or preceded by a
particularized statement of the claimed defect and with a clearly readable Returned Material Authorization (“RMA”) number
affixed to the shipping label. Contact McMillan Customer Service Department for RMA number. Warranty claims shall be made
only by using the McMillan’s Returned Material Authorization form, completely filled out and returned to McMillan in accord with
McMillan’s Product Return Policy and Procedure Form.
Contact McMillan’s Customer Service Department as follows for instructions:
Telephone calls in U.S.A. ( CST ) 1-800-861-0231 or Outside U.S.A.
512-863-0231 Or Fax: 1-512-863-0671 or e-mail: [email protected]
DESIGN, PROCESS and MANUFACTURING CHANGES
McMillan may make changes in the design or manufacture of any products sold hereunder without incurring any obligation to incorporate such
changes into products manufactured prior to incorporation of such design or manufacturing changes. McMillan reserves the right to make design or
manufacturing changes without prior notice. McMillan products and replacement parts are manufactured using new materials or new and
equivalent to new in appearance, performance and reliability. Due to continuous research, testing, product improvements and enhancements,
McMillan reserves the right to change product specifications without notice, except to the extent an outstanding bid obligation exists.
LIMITATION of LIABILITY
Except as expressly set forth in this limited warranty, McMillan makes no other warranties or conditions, express or implied, including any implied
warranties of merchantability and fitness for a particular purpose. McMillan expressly disclaims all warranties and conditions not stated in this limited
warranty. Any implied warranties that may be imposed by law are limited in duration to the limited warranty period. Buyer/customer agrees that
models or samples shown to buyer/customer were merely used to illustrate the purchased product and not to represent, promise or guarantee that
any purchased products delivered hereunder would conform to such models or samples. McMillan’s distributors or sales representatives have no
authority to give warranties beyond those provided in this limited warranty.
If customer’s product fails to work as warranted herein, customer’s sole and exclusive remedy shall be the repair or replacement at McMillan’s
option. McMillan is not liable for any damages caused by the product or the failure of the product to perform, including any lost profits or savings,
incidental or consequential damages. McMillan is not liable for any claim made by a third party or made by a buyer for a third party. No actions
arising out of sale of the products sold hereunder or this limited warranty may be brought by either party more than two (2) years after the cause of
action accrues. This limitation of liability applies whether damages are sought, or a claim made, under this limited warranty or as a tort claim
(including negligence and strict product liability), a contract claim, or any other claim. This limitation of liability cannot be waived or amended by
106-M001, pg. 32 of 38
any person. This limitation of liability will be effective even if customer has advised McMillan or an authorized representative or distributor of
McMillan of the possibility of any such damages
This limited warranty gives customer specific legal rights. Customer may also have other rights that may vary from state to state or country to country.
Customer is hereby advised to consult applicable state or country laws for a full determination of customer’s rights.
EXCLUSIONS FROM WARRANTY
This limited warranty provided herein shall not apply to any product which:
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
has been repaired or altered outside of McMillan’s factory (or authorized service center) in any way so as, in McMillan’s judgment, to
affect such purchased item’s reliability or performance.
has been subject to misuse, mishandling, negligence, accident, or acts of God.
has been operated other than in accordance with the printed instructions prepared by McMillan and provided by McMillan with the
product.
has been returned to McMillan after more than thirty (30) days following the date of the alleged product failure.
has been returned to McMillan without complying with the Safety Requirements or the Shipping Requirements contained herein.
requires calibration and/or routine maintenance, unless this calibration or routine maintenance is required as a result of a product
failure that is covered under terms of this warranty.
are consumable parts, such as filter elements, batteries or tube fittings.
requires replacement or repairs resulting from buyer’s improper choice of product flow range, or require repair or replacement due to
buyer subjecting product to corrosive fluids or other fluids not suited for use in product
has flow passages clogged due to failure to use a filter to protect product from particulates in fluid flow stream, or other cause to
produce clogged passages
has been operated outside of recommended specifications (such as voltage, temperature, or flow range, etc.)
has been damaged or cracked due to negligence in failing to follow printed instructions to prevent excessive torque from being applied
to product housing ( generally polyphenylene sulfide plastic )
has been damaged as a result of gross over-speeding, or prolonged over-speeding of the micro-turbine wheel
has been damaged as a result of severe sudden impact forces (example: dropping the product)
METHOD OF SETTLEMENT OF ANY CLAIMS, DISPUTES AND CONTROVERSIES
The provisions of this warranty are severable and if one or more provisions are deemed invalid, the remaining provisions shall remain in effect.
Further, in the event that any provision is held to be over broad as written, such provision shall be deemed amended to narrow its application to the
extent necessary to make the provision enforceable according to applicable law and shall be enforced as amended. This warranty shall be construed
and interpreted in English.
All claims, disputes and controversies arising out of or relating in any way to claims under any warranties, either express or implied (including
implied warranty of merchantability), or claims based on any consumer protection act or deceptive trade practice act, contract, tort, statute, or
common law, or any alleged breach, default, and/or misrepresentation, will be resolved by means of final and binding arbitration. This limited
warranty, including any contests to the validity or enforceability of this limited warranty, shall be finally settled by arbitration under the Rules of
Conciliation and Arbitration of the International Chamber of Commerce by one or more of its arbitrators appointed in accordance with the Rules,
and judgment upon award rendered may be entered in any court having jurisdiction thereof. The place of arbitration shall be Austin, Texas U.S.A.,
and the Texas Uniform Commercial Code, as then enacted shall govern the rights and duties of the parties of this agreement without regard to
conflicts-of-law principles. The arbitration shall be conducted in English. The UN Convention on Contracts for the International Sale of Goods shall
not apply to this Limited Warranty.
R. D. McMillan Company, Inc.
7075 R.R. 2338
P. O. Box 1340
Georgetown, Texas U.S.A. 78627
106-M001, pg. 33 of 38
J.
Troubleshooting Guide
Symptom
Possible Cause
Method of Correction
Unit Leaks
Fittings not tight enough
Tighten fittings (see section B4)
Sensor assembly damaged
Unit must be returned for repair
(see Section J)
No power or low power
Apply correct power
No flow passing through unit
Display or output should read
zero
Output shorted or overloaded
Check electrical connections
(see section B5)
Improper connection
Check electrical connections
(see section B5) and ensure
connector is correctly plugged
in
Output circuitry damaged
Unit must be returned for repair
(see Section J)
Liquid not translucent
enough.
Contact the McMillan Service
Department for assistance
Attempting to measure flows
below the specified minimum
for the unit
Use higher flow rates
Flow is actually fluctuating
Correct flow source to obtain
steady flow
Not using the fittings
supplied by the manufacturer
Use the supplied fittings
Entrapped air or gas
Remove entrapped air (see
section C2)
Turbulence in tubing or
sensor
Straighten the inlet tubing or
lengthen it to at least 6”
(150mm)
Fluctuating input power
Correct the power source or
change to a regulated supply
Mechanical sensor assembly
damaged
Unit must be returned for repair
(see Section J)
No output signal or flow
indication
Flow indication “bounces”
or fluctuates
106-M001, pg. 34 of 38
Symptom
Possible Cause
Method of Correction
Flow indication is not linear
and output too low at lower
flows
Attempting to measure flows
below the specified minimum
for the unit
Use higher flow rates
Liquid is too viscous
Best results are obtained with
liquids that have a viscosity of
10cS or less. Contact the
McMillan Service Department for
further information
Entrapped air or gas
Remove entrapped air (see
section C2)
Mechanical sensor assembly
damaged
Unit must be returned for repair
(see Section J)
Liquid has a different
viscosity and / or specific
gravity than water at 20°C
Calculate the flow reading error
/ offset as explained in section
C7
Entrapped air or gas
Remove the entrapped air (see
section C2)
Mechanical sensor assembly
damaged
Unit must be returned for repair
(see Section J)
The maximum rated flow for
the unit is being exceeded
Reduce the flow
Output circuits may be
damaged
Unit must be returned for repair
(see Section J)
Flow reading accuracy is
outside the specification
Flow indication is fixed at
one value
106-M001, pg. 35 of 38
K.
Contacting McMillan
Website:
Email:
www.mcmflow.com
[email protected]
Mailing address:
McMillan Company
P.O. Box 1340
Georgetown, TX 78627
U.S.A.
Shipping address: McMillan Company
7075 RR 2338
Georgetown, TX 78628
U.S.A.
Phone:
Fax:
(512) 863-0231
(512) 863-0671
For repairs and/or return information, please contact our service department any of the
ways shown above.
106-M001, pg. 36 of 38
THIS PAGE INTENTIONALLY LEFT BLANK.
Manual 106-M001
March 2006
Revision 1
www.mcmflow.com
THIS PAGE INTENTIONALLY LEFT BLANK.
Manual 106-M001
March 2006
Revision 1
www.mcmflow.com
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