Sierra BioTrak 645i User manual

831.373.0200 | 5 Harris Court Building L, Monterey, CA 93940 | sierrainstruments.com
Instruction Manual
Document: S-IM-645i/745i
Rev C_PN 109637
Thermal Mass Flow Meter for Wastewater Processes
TM

| 2

Disclaimer | 3
Disclaimer
BioTrak 645i/745i
GLOBAL SUPPORT LOCATIONS: WE ARE HERE TO HELP!
For Global Service Centers, go to http://www.sierrainstruments.com/facilities.html
CORPORATE HEADQUARTERS
5 Harris Court, Building L Monterey, CA 93940
Phone [phone] +1.800.866.0200
[email protected]
www.sierrainstruments.com
EUROPE HEADQUARTERS
Bijlmansweid 2 1934RE Egmond aan den Hoef
The Netherlands
Phone [phone] Fax [phone]
[email protected]
ASIA HEADQUARTERS
Second Floor Building 5, Senpu Industrial Park
25 Hangdu Road Hangtou Town
Pu Dong New District, Shanghai, P.R. China
Postal Code 201316
Phone: + 8621 5879 8521 Fax: [phone]
© COPYRIGHT SIERRA INSTRUMENTS 2023
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
BioTrak™, BioCal™, BioSelect™, FlowTrak™, BioView™ and DigiSense™ are trademarks
of Sierra Instruments, Inc. Other product and company names listed in this manual are
trademarks or trade names of their respective manufacturers.

Disclaimer | 4
Disclaimer
BioTrak 645i/745i
Warnings and Cautions
General Safety Information
We use caution and warning statements throughout this book to draw your attention to
important information.
Symbol Key
Symbol Symbol Meaning Description
Warning
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.
Caution/Note
This statement appears with
information that is important
for protecting your equipment’s
performance. Read and follow
all cautions that apply to your
application.


hazardous location installation.
• Warning! Hot tapping must be performed by a trained professional. U.S. regulations often
require a hot tap permit. The manufacturer of the hot tap equipment and/or the contractor
performing the hot tap is responsible for providing proof of such a permit

• Warning! To avoid potential electric shock, follow National Electric Code safety practices or your
local code when wiring this unit to a power source and to peripheral devices. Failure to do so
could result in injury or death. All AC power connections must be in accordance with published
CE directives.


WARNING

Disclaimer | 5
Disclaimer
BioTrak 645i/745i
CAUTION
• 
actively monitoring or reporting to any master control system. Adjustments to the

 
have the same or higher pressure rating as the main pipeline.
• Caution! Serial Numbers: If you have more than one meter, you must ensure that the

match one another. These items have been manufactured and calibrated to operate as
a unit and cannot be mismatched.
• Caution! Printed circuit boards are sensitive to electrostatic discharge. To avoid
damaging the board, follow these precautions to minimize the risk of damage:
• before handling the assembly, discharge your body by touching a grounded,
metal object
• handle all cards by their edges unless otherwise required
• when possible, use grounded electrostatic discharge wrist straps when handling
sensitive components

Disclaimer | 6
Disclaimer
BioTrak 645i/745i
Receipt of System Components

incurred in shipment. If the carton is damaged, notify the local carrier and submit a report to the
factory or distributor. 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

Technical Assistance

of the installation, operation, and setup procedures. Verify that your settings and adjustments are
consistent with factory recommendations. Installation information can be found in Chapter 2 of this
manual.
If the problem persists, contact Sierra Instruments by e-mail (see inside front cover). For urgent phone
support you may call [phone] between 8:00 a.m. and 5:00 p.m. PST. In Europe, contact Sierra

[phone]. When contacting Technical Support, make sure to include this information:
• The serial number (marked on the meter's label)
 
• The problem you are encountering and any corrective action taken
 
Using This Manual
This manual provides information needed to install and operate the Series BioTrak 645i/745i Mass Flow
Meter.
Additional Resources
Visit Sierrainstruments.com for additional resources. Note: the most current versions of the 645i/745i
documents can be found at https://www.sierrainstruments.com/products/downloads.html.

Disclaimer | 7
BioTrak 645i/745i
Table of Contents
1. Introduction p. 11-21
a. Quick Start Guide .........................................................................p. 9
b. Menu Trees .............................................................................p. 11
c. General ................................................................................p. 19
2. Installation (Mechanical) p. 22-33
a. Lateral Placement ........................................................................p. 23
b. Welding Branch Outlet ...................................................................p. 25
c. Installation Depth ........................................................................p. 26
d. Mounting Instructions....................................................................p. 28
e. Orientation .............................................................................p. 29
f. Retractor Installation......................................................................p. 31
3. Wiring (Electrical) p. 35-48
a. Wiring Access ...........................................................................p. 35
b. Input Power .............................................................................p. 37
c. Signal Wiring and HART Communication Option.............................................p. 39
d. Pulse/Alarm Wiring (optional feature) ......................................................p. 41
e. RS485 Wiring............................................................................p. 44
f. HART Handheld Wiring ...................................................................p. 45
g. Remote Wiring ..........................................................................p. 46
4. Operation (Standard Operation) p. 49-73
a. Start Up ................................................................................p. 49
b. Programming ...........................................................................p. 51
c. BioCal™.................................................................................p. 67
d. BioSelect™ ..............................................................................p. 70
5. Communication Protocols p. 74-86
a. Modbus RTU (RS485).....................................................................p. 74
b. HART with DDL ..........................................................................p. 83

BioTrak 645i/745i
Table of Contents | 8
Table of Contents
6. Maintenance p. 87-96
a. Safe Removal of Meter from Retractor......................................................p. 89
b. Troubleshooting .........................................................................p. 93
7. Appendices p. 97-115
 ...........................................................................p. 97
b. Agency Approvals ......................................................................p. 100
c. Dimensions ............................................................................p. 101
d. Terms and Conditions of Sale ............................................................p. 112
e. Returning your meter ...................................................................p. 112
 
9. Index p. 115

1. Record inside diameter (ID). Ensure the actual pipe ID
matches the pipe ID shown on the factory calibration


2.
Record up/downstream straight-pipe requirements
based on Pipe ID and meter style (insertion or inline).
[refer to p. 23]
3. The Flow Direction Indicator must point in the

The housing can be rotated for a better view of the
meter's display. Note that the 2 set screws must be
loosened before the housing will turn. [refer to p.
29]
4.

pipe, please see note on p. 26.
5.
If needed, the orientation of display can be rotated in
90° increments for a better view.
[refer to p. 30 for more information]
6.
Ensure power wiring [p. 37] and 4-20mA wiring [p.
39 - p. 40] properly connected. [refer to Wiring
section p. 35 for more information]
7.
Ensure remote wiring is correct if remote option
ordered.
[refer to p. 46 - p. 48 for more information]
8.
Verify you have the proper output signal wiring
[refer to p. 39 - p. 45 for more information]
9.

10. 
of the display or by using the BioViewTM Software. Record the settings in the spaces given for items A -
F on the following page.
Use the table below as a guide while using the worksheet on the next page to record your notes.
NOTE! Please read the entire quick-start procedure before beginning installation.
ID OUTER
DIAMETER
FLOW
4X = INLINE
10X = INSERTION
8X = INLINE
15X = INSERTION
PIPE ID MIN.
INDICATOR:
- POINT IN DIRECTION
OF FLOW
- LOOSEN SET SCREWS TO
ROTATE HOUSING ±90º, ±180º
- TIGHTEN SET SCREWS
WHEN DONE
FLOW
FLOW
PIPE
0.73"
(18.5 mm)
L
C
F1 F2 F3 F4
ACCESS THE
DISPLAY BY
UNSCREWING
COVER
REMOVE SCREWS
ON DISPLAY TO
ROTATE DISPLAY
±180°
3 PULSE (+)
4 PULSE (-)
7 COMMON
6 Tx/Rx (-)
5 Tx/Rx (+)
2 SWITCH INPUT (-)
1 SWITCH INPUT (+)
POWER (+) 1
POWER (-) 2
4-20mA #1 (+) 3
4-20mA #1 (-) 4
4-20mA #2 (+) 5
4-20mA #2 (-) 6
TS2
TS1
F1
J1
USB
0.75A
W1
TERMINATION
TP1
TP2
EARTH GROUND
POWER
#4
#6
#3
#5
#2
Cable Shield
Electronics Enclosure
RED WHT
BLU YEL
Probe Sensor Wired By Fox
SENSOR
Remote Enclosure
#7
#8
#1
Splice
Green Wire
Shield Wire (insulate)
F1 F2 F3 F4
Initializing...
3 PULSE (+)
4 PULSE (-)
7 COMMON
6 Tx/Rx (-)
5 Tx/Rx (+)
2 SWITCH INPUT (-)
1 SWITCH INPUT (+)
POWER (+) 1
POWER (-) 2
4-20mA #1 (+) 3
4-20mA #1 (-) 4
4-20mA #2 (+) 5
4-20mA #2 (-) 6
TS2
TS1
F1
J1
USB
0.75A
W1
TERMINATION
TP1
TP2
645i/745iCustomer PLC or DCS
+12 TO 24VDC
PULSE OR ALARM OUTPUT
12 TO 24VDC RETURN
+
-
2.4K OHM TYPICAL WITH 24VDC POWER
1.2K OHM TYPICAL WITH 12VDC POWER
BioTrak 645i/745i
Quick Start Guide | 9
Quick Start Guide

Item to verify
Serial Number: Serial Number: Serial Number: Serial Number:
1. What is the Pipe ID? ID = ID = ID = ID =
2. Calculate the Upstream/
Downstream straight-pipe
requirements
UP =
DN =
UP =
DN =
UP =
DN =
UP =
DN =
3. 

Must the housing be rotated for
easy viewing?
Y / N
Y / N
Y / N
Y / N
Y / N
Y / N
Y / N
Y / N
4. Is the probe depth setting correct? Y / N Y / N Y / N Y / N
5. Have you rotated the display for
easier viewing?
Y / N Y / N Y / N Y / N
6. Verify proper power wiring
7. Verify proper remote wiring (if
ordered)
8. Verify proper input/output wiring
After applying power to your meter, check items A - F below by accessing the meter settings either through
the front panel of the meter's display or by using the BioViewTM Software.
A. 
meter? (SCFM, KG/H, etc..)
B. Correct values for reference
temperature and pressure?
Y / N Y / N Y / N Y / N
C. 

D. Verify the 1st 4mA and 20mA
meter settings
4mA =
20mA =
4mA =
20mA =
4mA =
20mA =
4mA =
20mA =
E. Verify the 2nd 4mA and 20mA
meter settings
4mA =
20mA =
4mA =
20mA =
4mA =
20mA =
4mA =
20mA =
F. 
selected for your application in
theBioSelect™ menu
Your Notes:
Before applying power to your meter, use this worksheet to record your notes.
If you are experiencing any problems after completing this procedure, please call the Sierra
Instruments Service Department at 831-373-0200 to review this information.
BioTrak 645i/745i
Quick Start Guide | 10
Quick Start Guide

MAINMENU
I/OFLODSPEXIT
Comm=Modbus
NXTOK
None
Modbus
HART
mA=Temp
NXTOK
20mACnt=52921
CHGOK
4mACnt=2515
CHGOK
20mA=200°F
CHGOK
4mA=10°F
CHGOK
Temp
Flow
AnalogOutputs
Baud=9600
NXTOK
Parity=NONE
NXTOK
Address=02
CHGOK
1200
2400
4800
9600
19200
38400
57600
76800
115200
NONE
ODD
EVEN
01‐247
Entermenubyscollingtodisplay4
andenteringthepassword
mAFault=Notuse
NXTOK
Notuse
3.6mA
21mA
Communication
Level2
password
I/OMENU
I/OCOM420EXIT
Comm=Hart
OK
Address=0
CHGOK
0‐63
Modbus
Only
HART
Only
SET4‐20mA
CH1CH2EXIT
20mACnt=52921
CHGOK
4mACnt=2515
CHGOK
20mA=2345.6SCFM
CHGOK
4mA=0SCFM
CHGOK
mAFault=Notuse
NXTOK
Notuse
3.6mA
21mA
Level2
password
NOTE! Some menus will only be available
with a level 2 password.
NOTE! Menu tree boxes are populated
with example values.
Display Menu, p. 15
Flow Menu 1, p. 13
Digital Output
Menu, p. 12
BioTrak 645i/745iBioTrak 645i/745i
Introduction | 11
Introduction
Fig. 1.1: 645i/745i Menu Tree - Main Menu

OUT= Pulse
NXT OK
Not used
Pulse
HiFloAlm
LoFloAlm
HiTempAlm
LoTempAlm
System Alarm
PULSE OUTPUT
P/U U/P FEQ EXIT
PLS/UNT=2
CHG OK
UNT/PLS=0.5
CHG OK
MaxFreq=100Hz
CHG OK
MaxFlo=5000 SCFM
CHG OK
HiFloAlm=500 SCFM
CHG OK
LoFloAlm=100 SCFM
CHG OK
HiTmpAlm=250° F
CHG OK
LoTmpAlm=10 F
CHG OK
High Flow Alarm
Low Flow Alarm
High Temp Alarm
Low Temp Alarm
Select 1 of 3
methods to scale
the pulse output
Pulse
OUT= HiFloAlm
NXT OK
OUT= LoFloAlm
NXT OK
OUT= HiTempAlm
NXT OK
OUT= LoTempAlm
NXT OK
System Alarm
OUT= System Alm
NXT OK
Set I/O
OUT INP EXIT
Alarm output
MAIN MENU
I/O FLO DSP EXIT
Inp= Not Used
NXT OK
Not used
Tot Reset
I/O MENU
I/O COM 420 EXIT
(See Flow Menu 2, p. 14, for more alarm settings)
NOTE! A value of 0 disables the alarms
BioTrak 645i/745iBioTrak 645i/745i
Introduction | 12
Introduction
Fig. 1.2: 645i/745i Menu Tree - Digital Outputs and Input

FLOWMENU1
DGNUNTFM2EXIT
DIAGNOSTIC
SIMBioCalEXIT
FloSim=0SCFM
CHG OK
TmpSim=0°F
CHG OK
ENABLESIM?
YES NO
FLOUNT=SCFM
NXT OK
SCFM
SCFH
NM3/H
NM3/M
KG/H
KG/M
KG/S
LBS/H
LBS/M
LBS/S
NLPH
NLPM
MMSCFD
LBS/D
SLPM
NLPS
MSCFD
SM3/H
MT/H
NM3/D
MMSCFM
SCFD
MCFD
SM3/M
SM3/D
TMPUNT=°F
NXT OK
DegF
DegC
TmpRef=60°F
CHG OK
PRESUNT=Psia
NXT OK
PresRef=14.73
CHG OK
mmHG
Psia
bara
SimulateFlow?
YES NO
SimulateTemp?
YES NO
MAINMENU
I/OFLODSPEXIT
Flow Menu 2 Menu, p. 14
BioCal™ Menu, p. 16
BioTrak 645i/745iBioTrak 645i/745i
Introduction | 13
Introduction
Fig. 1.3: 645i/745i Menu Tree - Flow Menu 1

FLOWMENU2
GASSPCPRMEXIT
Kfact=0%
CHG OK
RESETCRC?
YES NO
Cutoff=12.5SCFM
CHG OK
Pipe_id=4.026In
CHG OK
Filter=0.8Sec
CHG OK
Parameters
Flowcutoffinselectedunits
Pipeidininchesormm
FlowFilterinseconds
Min=0.8,max=10
HiFloAlm=0SCFM
CHG OK
LoFloAlm=0SCFM
CHG OK
HiTmpAlm=0°F
CHG OK
LoTmpAlm=0°F
CHG OK
Level2
RESTOREDATABASE?
YES NO
MAINMENU
I/OFLODSPEXIT
FLOWMENU1
DGNUNTFM2EXIT
 Thesealarmscanbeusedwithoutthedigitaloutputassignedto
thealarm.
 Ifthatisthecase,thealarmstatuswillonlybeshownonthe
display,throughserialcommunicationorBioViewTM.
 Ifthedigitaloutputisassignedtoanalarm,changingthevalue
herewillchangethatsetting.
 Avalueof0disablesthealarm.
BioSelect
®
Menu, p. 17
BioTrak 645i/745iBioTrak 645i/745i
Introduction | 14
Introduction
Fig. 1.4: 645i/745i Menu Tree - Flow Menu 2

DISPLAY/PASSWORD
DSP PSWEXIT
DSP1L1=FLorate
NXT OK
FLorate
Total
Elps
Temp
Alarm
DSP1L2=Total
NXT OK
DSP2L1=Temp
NXT OK
DSP2L2=Elps
NXT OK
ALTERNATE=Off
NXT OK
On
Off
PASSWD=1234
CHG OK
FLorate
Total
Elps
Temp
Alarm
FLorate
Total
Elps
Temp
Alarm
FLorate
Total
Elps
Temp
Alarm
Whenalternate
"ON",flashes
betweenthe2
displays
Display1
Line1
Display2
Line1
Display2
Line2
MAINMENU
I/OFLODSPEXIT
Display1
Line2
BioTrak 645i/745iBioTrak 645i/745i
Introduction | 15
Introduction
Fig. 1.5: 645i/745i Menu Tree - Display Menu
NOTE! All readings updated every second
• Flo Rate = Flow rate of process gas
• 
• 
• Temp = Temperature of process gas
• 

DIAGNOSTICMENU
SIMBioCalEXIT
BioCalMENU
VER EXIT
VerifyingBioCal
PleaseWait
VerifyingBioCal
0.512 T=123
BioCal=0.259
Pass OK
Displaysthetest’s
countdowntimer
Displaysanumbervalue
duringtest
VERIFYBioCal?
YES NO
BioCal=0.911
Warning OK
BioCal=2.321
Fail OK
FLOWMENU1
DGNUNTFM2EXIT
MAINMENU
I/OFLODSPEXIT
Flo:HoldValue
NXT EXITOK
HoldValue
Gotozero
TakeControl
off‐lineEXITOK
BioCalFail
Greaterthan±1.0
BioCalPass
Lessthan±0.80
BioCalWarning
Between±0.80to±1.0
Choosing“HoldValue”will
retainthelastflowvaluewhile
testisbeingperformed.
BioTrak 645i/745iBioTrak 645i/745i
Introduction | 16
Introduction
Fig. 1.6: 645i/745i Menu Tree - BioCal™ Menu

FLOWMENU2
GASPRMEXIT
GAS=DigesterGas
NXT OK
Air
Methane
GasMix(100%)
OK
Onlyfor
Digester
Gasmix
Showsonlyifgasmix
doesnotequal100%.
PressingOKreturnsto
gasentry.
CO2=25.5%
UPDN OK
MAINMENU
I/OFLODSPEXIT
FLOWMENU1
DGNUNTFM2EXIT
Err:Mix=(110%)
OK
Methane=65.5%
UPDN OK
Showsonlyifnoerroris
detected.PressingOK
allowsexittomenu.
Besuremixtureequals100%.
OR
GAS=Methane
NXT OK
Air
Methane
DigesterGas
BioTrak 645i/745iBioTrak 645i/745i
Introduction | 17
Introduction
Fig. 1.7: 645i/745i Menu Tree - BioSelect™ Menu

BioTrak 645i/745iBioTrak 645i/745i
Introduction | 18
Introduction
3124.6 SCFM
csv = 0.3432 Volt
Press F1 and F2 at the same me to enter the Engineering Screens
Press F4 to return to normal mode
Display 10
Display 19
Pulse=1234.5 cnt
mA_420=234 cnt
Elp=12.5 HR
Stat(hex)=2800
Alarm=None
645i v8.2
MB_Sn=P23949
BB_Sn=P23945
MTR_Sn=123456
SNS_Sn=234567
TmpHi=0.0 °F
TmpLo=0.0 °F
Pwr_Cycl=24
Err_tot=0
FloHi=0.00 SCFM
FloLo=0.00 SCFM
BioCal= 0.1
Press F1 tonavigate up
Press F2 tonavigate down
Press F4 toreturn tonormalmode
Flow rate measured bythe meter
Current Sense Voltage of sensor circuit
Digitalcontrol counts of Pulse output
Digitalcontrol count of 4-20mA output
Elapsed me of meter opera on
Meter funcon and opera on status code
Meter’s acve alarms
Firmware version of meter
Main board serial number
Bridge board serial number
Meter serial number
Sensor serial number
Alarm Seng
Alarm Seng
Alarm
Alarm
Totalnumber of power cycles
Number of errors in totalflow measuremen
t
BioCalTM measurement value
Press NXT (F1) tonavigate down
Press PRV (F2) tonavigate back up
1014.1 BTU/Ft3
NXT PRV EXIT
DNS=0.6800 Kg/M3
PRV EXIT
Methane
Air
Methane
Digester Mix
100%
OK
Flow: SCFM
NXT PRV EXIT
Temp: °F
NXT PRV EXIT
Ref Press: Psia
NXT PRV EXIT
Ch1: Flow
NXT PRV EXIT
20 Ma=706.29
NXT PRV EXIT
4 Ma=0.00
NXT PRV EXIT
FloHi=0.00 SCFM
NXT PRV EXIT
FloLo=0.00 SCFM
NXT PRV EXIT
TmpHi=0.0 °F
NXT PRV EXIT
TmpLo=0.0 °F
NXT PRV EXIT
RefP=14.73 psia
NXT PRV EXIT
RefT=60.00 °F
NXT PRV EXIT
Kfact=0.0%
NXT PRV EXIT
Cutoff=12.5 SCFM
NXT PRV EXIT
PipeID=4.03 In
NXT PRV EXIT
Flt=0.80 Sec
NXT PRV EXIT
MTR_Sn=123456
NXT PRV EXIT
645i v8.2
NXT PRV EXIT
Release: 02_28_23
PRV EXIT
ENG Screen 1
GAS CFG VAL EXIT
ENG Screens
ENG1 ENG2 EXIT
BioCal=0.1
NXT PRV EXIT
BioCal=Pass
NXT PRV EXIT
NXT PRV EXIT
PRV EXIT
P BioCal=Pass
P BioCal=0.14
Fig. 1.8: 645i/745i Menu Tree - Engineering Screens
Fig. 1.9: 645i/745i Menu Tree - Reset Flow Total
F3 & F4 pressed at the same time will
initiate a "Total" reset
Reset Total?
NO YES
Resetting total

Welcome
Thank you for purchasing the BioTrak 645i/745i Thermal Gas Mass Flow Meter from Sierra


performance and outstanding reliability.
This instruction manual contains the electrical and mechanical installation instructions as well as
details for programming, maintaining and troubleshooting the meter. This manual is divided into
the following sections: Introduction, Installation, Wiring, Operation, Communications, Maintenance,

Theory of Operation


that gases absorb heat. A heated sensor placed in an air or gas stream transfers heat in proportion
to the stream’s mass velocity. There are two sensor elements. One sensor element detects the
gas temperature and a second element is maintained at a constant temperature above the gas


pressure range.
Mass Flow



and pressure. As temperature and pressure changes, the gas volume changes but not its mass.


units (SCFM, SLPM) or normal units (NM3/hr, NLPM) with no additional temperature or pressure
measurements required.
BioTrak 645i/745iBioTrak 645i/745i
Introduction | 19
Introduction

Calibration Validation

Validation is to provide operators with the ability to verify that the meter is capturing accurate data
at scheduled recalibration times - or at any time - instead of sending the meter back to the factory

accurately by testing the functionality of the sensor and its associated signal processing circuitry. This
test can be done in the pipe under normal process conditions.
Flow Calibration







I/O Description
The 645i/745i features two galvanically isolated 4-20mA analog outputs, HART communication
(optional), a pulse output, switch input and Modbus RTU (RS485) (optional). There is also a USB


temperature and can be scaled by the user. The pulse output can be used for pulse or alarm and is

and elapsed time.
BioView™ software interfaces to the USB port and is a free Sierra Instruments PC-based software

available for download on the Sierra Instruments website.
BioTrak 645i/745iBioTrak 645i/745i
Introduction | 20
Introduction