Sierra 780 Series User manual

Series 780-CT Instruction Manual Table of Contents
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Sierra Series 780
Custody Transfer
Mass Flow Monitoring System
Instruction Manual
Part Number IM-78-CT
10.97 Revision B
5 Harris Court, Building L Monterey, CA 93940
[phone] [phone] Fax [phone]
http://www.sierrainstruments.com
Sierra Instruments b.v. Bolstoen 30A 1046 AV Amsterdam The Netherlands
31(0)20-6145810 Fax [phone]

Table of Contents Series 780-CT Instruction Manual
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Customer Notice
Unless you have specifically ordered Sierra’s optional O2cleaning, this flow meter
may not be fit for oxygen service. Sierra Instruments, Inc., is not liable for any dam-
age or personal injury, whatsoever, resulting from the use of Sierra Instruments
standard mass flow meters for oxygen gas. You are responsible for cleaning the
mass flow meter to the degree required for your oxygen flow application.
© COPYRIGHT SIERRA INSTRUMENTS 1997
No part of this publication may be copied or distributed, transmitted, transcribed, stored in
a retrieval system, or translated into any human or computer language, in any form or by
any means, electronic, mechanical, manual, or otherwise, or disclosed to third parties
without the express written permission of Sierra Instruments. The information contained in
this manual is subject to change without notice.
TRADEMARKS
Steel-TrakTM Collector-BoxTM and Flo-BoxTM are trademarks of Sierra Instruments Inc.
Other product and company names listed in this manual are trademarks or trade
names of their respective manufacturers.

Series 780-CT Instruction Manual Table of Contents
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Table of Contents
Chapter 1 Introduction
Series 780-CT Mass Flow Monitoring System ....................1-1
Using this Manual.................................................1-1
Notes and Safety Information....................................1-1
Receipt of System Components .................................1-2
Technical Assistance..............................................1-2
How the Flow Monitoring System Works..........................1-3
Series 780-CT Mass Flow Meter Features.....................1-4
Series 900 Collector-Box Features..............................1-4
Chapter 2 Installation
Installation Overview..................................................2-1
Installing the Flow Monitoring Components.......................2-1
Flow Meter Installation Requirements..........................2-2
Flow Meter Orientation...........................................2-3
Flow Meter Installation...........................................2-3
Collector-Box Installation........................................2-4
Wiring Connections ...................................................2-5
Collector-Box Input Power Wiring .............................2-5
Sensor Wiring .....................................................2-6
Collector-Box Outputs ................................................2-7
Chapter 3 Operating Instructions
Facility Start Overview................................................3-1
Collector-Box Controls and Indicators..............................3-1
Display Selections.................................................3-2
Totalizer Reset.....................................................3-3
MODE Selections..................................................3-3
Function Selections ...............................................3-4
Numeric Keypad ..................................................3-4
Alarm Acknowledge ..............................................3-5
Status LEDs........................................................3-5
Operating the Flow Monitoring System.............................3-6
First Time Start Up................................................3-6
System Configuration.................................................3-7
Configuration Procedure .........................................3-7
Access Code Information........................................3-11

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Chapter 4 Validation and Maintenance Procedures
Field Validation Procedures ..........................................4-1
Sensor Test Procedures...........................................4-1
Electronic Test Procedures.......................................4-2
Entering Bias Factors..................................................4-4
Bias Factor Procedure ............................................4-5
Maintenance Procedures ..............................................4-6
Obtaining an RMA.....................................................4-7
Chapter 5 Troubleshooting
System Diagnostics....................................................5-1
Troubleshooting Procedures..........................................5-2
Appendix A Product Specifications
Specifications and Drawings .........................................A-1
List of Figures
1-1. Flow Monitoring System Block Diagram..................1-3
2-1. Correct Flow Meter Orientation.............................2-3
2-2. Collector-Box Mounting Dimensions ......................2-4
2-3. Flow Meter Wiring ...........................................2-6
2-4. Motherboard Terminal Block Layout/Output Wiring.....2-7
2-5. Relay Board Terminal Block Designations ................2-8
3-1. Collector-Box Front Panel Controls........................3-1
A-1. Collector-Box Critical Component Locations .............A-3
A-2. Collector-Box Standard Wiring.............................A-4
A-3. Collector-Box Optional Rack Mount Wiring ..............A-4
A-4. Digi-Bridge Board Critical Component Locations........A-5
List of Tables
2-1. Required Minimum Pipe Lengths for Installation.........2-2

Series 780-CT Instruction Manual Table of Contents
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Warnings and Cautions
Agency approval for hazardous location installations varies between flow
meter models. Consult the factory for specific flow meter approvals be-
fore any hazardous location installation. For explosion proof installations,
you must use solid metal conduit and follow NFPA (or your local code)
approved wiring methods.
All installation procedures must be performed with the power Off.
All maintenance operations must be performed with the power Off. Be-
fore attempting any maintenance, verify no pressure is present in the
line. Gas leaks are possible during probe maintenance. Make sure the
lines are completely purged before removing the probe.
Calibration must be performed by qualified personnel. Sierra Instru-
ments, Inc. strongly recommends that you return your flow meter to the
factory for calibration.
The flow meter requires four wiring connections; two for power and two
for signal. The flow meter is not a 24 VDC, 4-20 mA loop powered trans-
mitter.
For all flow meter installations, standard industrial wiring practices apply.
Local codes may require the use of conduit. In general, we recommend
the use of conduit as a good wiring practice.
Although the meter will indicate flow in the opposite direction, it is calibrated
with flow in the direction indicated on the label. Confirm the meter is in-
stalled with flow in the same direction as the label. Measuring flow opposite
the calibration direction will result in inaccurate readings.
Before applying power for the first time, make sure all wiring is in compli-
ance with the instructions listed in Chapter 2.
The electronics, sensors and interconnecting wires supplied by Sierra In-
struments are calibrated as a single precision mass flow meter. Each
component is an integral part of the flow measurement circuit. Changing
the length of wires or interchanging sensors or sensor wiring will affect
the accuracy of the flow meter.

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Series 780-CT Instruction Manual Chapter 1 Introduction
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Chapter 1 Introduction
Series 780-CT Mass Flow Monitoring System
The Sierra Series 780-Custody Transfer (CT) Mass Flow Monitor-
ing System precisely monitors the total accumulated mass flow of air
and process gases. The 780-CT Monitoring System features dual
level totalizing for tracking standard and premium flow rates. The
field-programmable totalizer automatically switches between normal
and premium billing rates based on the measured flow rate.
780-CT system components include a Sierra Series 780-CT Mass
Flow Meter with built in flow conditioning plates and a Sierra Series
900 Collector-Box™for computing totalized flow.
Using This Manual
This manual provides the information you need to install and operate
the 780-CT Mass Flow Monitoring System. The five chapters of
this manual cover these areas:
• Chapter 1 includes the introduction and product description
• Chapter 2 provides information needed for installation
• Chapter 3 describes system operation
• Chapter 4 covers system diagnostics and validation
• Chapter 5 outlines troubleshooting procedures
The product specifications and dimensional drawings are found in
Appendix A.
Note and Safety Information
We use note, caution and warning statements throughout this book
to draw your attention to important information.
Warning! Caution! Note
This statement appears with
information that is important to
protect people and equipment
from damage. Pay very close
attention to all warnings that
apply to your application.
This statement appears with
information that is important
for protecting your equipment
and performance. Read and
follow all cautions that apply
to your application.
This statement appears with
a short message to alert you
to an important detail.

Chapter 1 Introduction Series 780-CT Instruction Manual
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Receipt of System Components
When receiving the components of the Sierra Flow Monitoring
System, carefully check the outside packing carton for damage in-
curred in shipment. If any carton is damaged, notify the local carrier
and submit a report to the factory.
Remove the packing slip and check that all ordered components are
present. Make sure any spare parts or accessories are not discarded
with the packing material. Do not return any equipment to the fac-
tory without a Return Material Authorization (RMA, see Chapter 4).
Technical Assistance
If you encounter a problem with your flow monitoring system, re-
view the configuration information for each step of the installation
and operation procedures. Verify that your settings and adjustments
are consistent with factory recommendations. Refer to Chapter 5,
Troubleshooting, for specific information and recommendations.
If the problem persists after following the troubleshooting proce-
dures outlined in Chapter 5, contact Sierra Instruments, Technical
Support at [phone] or [phone] between 8:00 a.m.
and 5:00 p.m. PST. When calling technical support, have the fol-
lowing information on hand:
•the flow meter serial number
•the Collector-Box serial number
•the flow range of the meter
•the software version number
•your Instruction Manual
•the problem you are encountering

Series 780-CT Instruction Manual Chapter 1 Introduction
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How the Flow Monitoring System Works
Collector-Box
Series 780-CT
Mass Flow Meter
Series 900 Collector-Box
Flow Sensors
(Aligned 90-degrees to flow)
Heat
Gas Flow
Sensor Detail
Ts Ta
Figure 1-1. Flow Monitoring System Block Diagram
The 780-CT Mass Flow Meter measures gas flow using two sensing
elements–a velocity sensor and a temperature sensor that automati-
cally correct for changes in gas temperature. The digital sensor
bridge, Digi-bridge circuit heats the velocity sensor (Ts) at a con-
stant temperature differential above the gas temperature (Ta) and
measures the cooling effect of the gas flow. When heat is carried
away by the molecules in the gas, the heated sensor directly meas-
ures mass velocity (Ts-Ta), referenced to standard conditions of
70°F (21.1°C) and one atmosphere.
A supplied 5-wire cable connects between the flow meter sensor and
the Digi-bridge board inside the Collector-Box enclosure. This ca-
ble makes all the necessary power and signal connections.
Using data from the mass flow meter, the 900 Series Collector-Box
calculates the mass flow rate based on the power required to maintain
the constant temperature differential. The Collector-Box displays the
flow rate and totalized mass flow on a 2 x 16 digit LCD readout
screen. The Collector-Box provides both a 4-20 mA and 0-5 VDC
output signal proportional to mass flow.

Chapter 1 Introduction Series 780-CT Instruction Manual
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Series 780-CT Mass Flow Meter Features
Series 780-CT mass flow meter bodies are constructed of 316L
stainless steel tubing. The 780 flow body incorporates special flow
conditioning plates welded into the body between the sensor and the
inlet connection. This unique dual-plate design eliminates velocity
profile distortions, swirl and temperature stratification in the gas
stream and greatly reduces upstream piping requirements.
Series 780-CT mass flow meters are available in a variety of process
connections depending on the flow meter ordered. Compression
fittings allow easy removal of the flow meter sensor probe for serv-
ice or maintenance procedures. The flow meter can be installed at a
remote location up to 350 feet from the Collector-Box.
Series 760HP/UHP and Series 780HP/UHP Mass Flow Meters are
also available with the Flow Monitoring System. The flow bodies
are constructed of 316L electropolished stainless steel tubing. The
“UHP” has a 7-10 Ra internal finish; the “HP” has 20-25 Ra. The
tubing’s smooth, level surface eliminates turbulence and erosive ac-
tion, which generates particulates. The Model 780HP/UHP flow
body incorporates flow conditioning plates that reduce upstream
piping requirements and improve measurement accuracy in con-
strained installations.
Series 900 Collector-Box Features
The Collector-Box’s flexible features allow you to customize your
flow monitoring and totalizing requirements. Local programming is
available via the 20-button, menu driven keypad along with the 2 x
16 character LCD display. The Collector-Box displays velocity,
standard volumetric flow, mass flow, total mass and time in user-
selectable engineering units. Comprehensive self-diagnostics, pro-
grammable testing and field calibration capabilities ensure accurate
flow rate monitoring.
The dual-totalizing feature allows you to set standard and premium
levels of flow monitoring. Pressing TOTAL on the front panel in-
terface displays the total units of flow. Press TOTAL a second time
to show the time elapsed. When pressing the TOTAL button a third
and fourth time, the same data is displayed for the premium level
totalizer showing the total premium flow and elapsed premium bill-
ing time.