Sierra MaxTrak 180 Series User manual

Sierra Instruction Manual MaxTrak 180
1
MaxTrak™ 180 Series
Mass Flow Meters & Controllers
Models: 180, 180 + Flanges
Instruction Manual
Version IM-180 Series, Rev. L 11/20
GLOBAL SUPPORT LOCATIONS: WE ARE HERE TO HELP!

Sierra Instruction Manual MaxTrak 180
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For Global Service Centers, go to http://www.sierrainstruments.com/facilities.html
CORPORATE HEADQUARTERS
5 Harris Court, Building L, Monterey, CA 93940
Phone [phone] [phone] Fax [phone]
[email protected]om
www.sierrainstruments.com
EUROPE HEADQUARTERS
Bijlmansweid 2
1934RE Egmond aan den Hoef
The Netherlands
Phone [phone] Fax [phone]
[e-mail]
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]
IMPORTANT CUSTOMER NOTICE: OXYGEN SERVICE
Sierra Instruments, Inc. is not liable for any damage or personal injury, whatsoever, resulting from the use of Sierra
Instruments standard mass flow meters or controllers for oxygen gas. You are responsible for determining if this mass
flow meter or controller is appropriate for your oxygen application. You are responsible for cleaning the mass flow meter
or controller to the degree required for your oxygen flow application
© COPYRIGHT SIERRA INSTRUMENTS 2020
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
MaxTrak™, SmartTrak® 100 Series and Dial-A-Gas™ is a Registered Trademark of Sierra Instruments, Inc. Other product
and company names listed in this manual are trademarks or trade names of their respective manufacturers.

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Warnings in This Manual
“Warning,” “Attention,” and “Note” statements are used throughout this manual to draw your attention to
important information.
Symbol Key
Symbol
Symbol
Meaning
Descripition
Warning
“Warning” statements 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. Failure to comply with
these instructions may damage the meter and cause personal
injury.
Caution
“Attention” indicates that failure to comply with stated instructions
may result in damage or faulty operation of the meter.
Note
“Note” indicates that ignoring the relevant requirements or
precautions may result in flow meter damage or malfunction.
Receipt of System Components
When receiving a Sierra mass flow meter, carefully check the outside packing carton for damage 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 any equipment to the factory
without first contacting Sierra Customer Service .
Technical Assistance
If you encounter a problem with your flow meter, review the configuration information for each step of the
installation, operation, and setup procedures. Verify that your settings and adjustments are consistent with
factory recommendations. Installation and troubleshooting information can be found in the Chapter 2
(Installation) and Chapter 4 (Troubleshooting) of this manual.
If the problem persists after following the troubleshooting procedures outlined in Chapter 4 of this manual,
contact Sierra Instruments by fax or by e-mail (see inside front cover). For urgent phone support you may
call [phone] or [phone] between 8:00 a.m. and 5:00 p.m. PST. In Europe, contact Sierra
Instruments Europe at [phone] . In the Asia-Pacific region, contact Sierra Instruments Asia at + 8621
5879 8521. When contacting Technical Support, make sure to include this information:

Sierra Instruction Manual MaxTrak 180
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• The flow range, serial number, and Sierra order number (all marked on the meter
nameplate)
• The software version (visible at start up)
• The problem you are encountering, and any corrective action taken
• Application information (gas, pressure,temperature and piping configuration)
Register Your Product Today
Warranty Statement
All Sierra products are warranted to be free from defects in material and workmanship and will be repaired or
replaced at no charge to Buyer, provided return or rejection of product is made within a reasonable period but no
longer than one (1) year for calibration and non-calibration defects, from date of delivery. To assure warranty
service, customers must register their products online on Sierra’s website. Online registration of all of your Sierra
products is required for our warranty process. Read complete warranty policy at
www.sierrainstruments.com/warranty.
Register Warranty Online
Register now at www.sierrainstruments.com/register. Learn more about Sierra’s warranty policy at
www.sierrainstruments.com/warranty

Sierra Instruction Manual MaxTrak 180
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Table of Contents
Warnings in This Manual....................................................................................................................................... 3
Register Your Product Today................................................................................................................................. 4
Warranty Statement ....................................................................................................................................................4
Register Warranty Online...........................................................................................................................................4
1Introduction.....................................................................................................8
1.1 Using This Manual..................................................................................................................................... 8
1.2 Definitions Used In This Manual............................................................................................................... 9
1.3 The MaxTrak Flow Sensing Principle ....................................................................................................... 9
2Installation .................................................................................................... 11
2.1 Before You Begin......................................................................................................................................11
2.2 Pre-Installation Check List ...................................................................................................................... 12
2.3 Installing the Instrument-Plumbing ......................................................................................................... 12
2.3.1 Compression Fittings ...................................................................................................................................12
2.3.2 VCO Fittings................................................................................................................................................13
2.3.3 Female NPT .................................................................................................................................................13
2.4 Installing Your Instruments-Mechanical Mounting ................................................................................. 13
2.4.1 Mounting Your Instrument...........................................................................................................................13
2.5 Installing Your Instruments-Electrical Connections ................................................................................ 13
2.5.1 Using Water-Tight (WT) Cables ..................................................................................................................14
2.5.2 Using the Cable Gland or Conduit...............................................................................................................14
2.5.3 Opening the MaxTrak Instrument................................................................................................................14
2.6 Basic Analog Installation......................................................................................................................... 17
2.6.1 Instrument Power.........................................................................................................................................17
2.6.2 Output Signal-Voltage..................................................................................................................................17
2.6.3 Output Signal-Current..................................................................................................................................17
2.6.4 Additional Features for Mass Flow Controllers...........................................................................................17
2.7 Configuring Your Instrument................................................................................................................... 18
2.7.1 Using SmartTrak Software to Configure Your Instrument...........................................................................18
3Analog Operation..........................................................................................19
3.1 Analog Operation, Mass Flow Meters..................................................................................................... 19
3.1.1 Power Your Instrument ................................................................................................................................19
3.2 Analog Operation, Mass Flow Controllers .............................................................................................. 19
3.3 MaxTrak Analog Features........................................................................................................................ 20
3.3.1 Setpoint Adjustment (flow controllers only).................................................................................................20

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3.3.2 Changing the Output or Setpoint Signals.....................................................................................................21
3.3.3 Over-Range Condition .................................................................................................................................21
3.3.4 Manual Valve Override-Valve Close............................................................................................................21
3.3.5 Manual Valve Override-Valve Purge Function ............................................................................................21
3.4 Important Notes About Purging............................................................................................................... 22
3.4.1 Purging Non-Reactive Gases .......................................................................................................................22
3.4.2 Purging Reactive Gases: ..............................................................................................................................22
3.5 Safety Notes When Purging..................................................................................................................... 22
4Digital Operation RS-232 & SmartTrak Software .......................................23
4.1 Summary of the SmartTrak Features ....................................................................................................... 23
4.2 Power Up Your Instruments..................................................................................................................... 24
4.3 Power Up Your Computer........................................................................................................................ 24
4.4 Loading the SmartTrak Software............................................................................................................. 25
4.5 Running the SmartTrak Software ............................................................................................................ 25
4.5.1 Establishing Communication .......................................................................................................................26
4.6 Using the SmartTrak Software................................................................................................................. 27
4.6.1 Upper Section Software Window.................................................................................................................27
4.7 Lower Section of Software Window-Changing Parameters .................................................................... 30
4.7.1 Change Valve Operation-Automatic, Close, Purge ......................................................................................31
4.7.2 Change Gas (Dial-A-Gas®)..........................................................................................................................31
4.7.3 Change Units ...............................................................................................................................................32
4.7.4 Change Analog Out......................................................................................................................................32
4.8 Adjustments ............................................................................................................................................. 33
4.8.1 Change Zero.................................................................................................................................................34
4.8.2 Default Zero.................................................................................................................................................34
4.8.3 Span .............................................................................................................................................................35
4.8.4 Change Full Scale ........................................................................................................................................35
4.9 Other Useful Features.............................................................................................................................. 37
4.9.1 Com Port......................................................................................................................................................37
4.9.2 Read Controller Parameters .........................................................................................................................37
4.9.3 Info...............................................................................................................................................................37
5Technical Support & Service ........................................................................38
5.1 Sierra Customer Service Locations.......................................................................................................... 38
5.2 Returning Equipment to the Factory........................................................................................................ 38
5.2.1 Factory Calibration-All Models...................................................................................................................38
5.2.2 Instructions for Returning Your Instruments for Service .............................................................................39
5.2.3 Please follow these easy steps to return your instrument for factory service:..............................................39

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6Appendix A Gas Tables.................................................................................40
6.1 MaxTrak Pre-Programmed Gases: Dial-A-Gas ....................................................................................... 40
6.2 K-Factor Calculations-Using MaxTrak with Other Gases....................................................................... 40
6.3 Gas Tables and K-Factors ........................................................................................................................ 41
7Appendix B: 180 Product Specifications, Dimensions, and Mounting ....... 44
7.1 Optional Parts & Accessories .................................................................................................................. 50
7.2 Ordering Parts & Accessories.................................................................................................................. 50
8Appendix C: PIN Configuration and Wiring Diagram.................................51

Sierra Instruction Manual MaxTrak 180
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1Introduction
The Sierra Instruments’ MaxTrak Series 180 is an innovation from Sierra, a company that has designed and
manufactured gas mass flow measurement instruments since the early 1970’s. This manual is your guide to
MaxTrak, our water-resistant series of mass flow meters and controllers. The Series 180 MaxTrak is the rugged
industrial version of Sierra’s popular Series 100 SmartTrak and the two products share many innovative features.
Visit the Sierra Instruments website www.sierrainstruments.com any time for more information about both of
these products.
The MaxTrak instruments offer a variety of features for ease of operation. Among these features:
•Dial-A-Gas: allows a user to change from among 10 gases while maintaining accuracy.
•Digital Electronics: maximum performance with minimum noise plus exceptional tuning capability.
•Choice of 4 Analog Communications Options and RS-232 with every MaxTrak instrument.
•Flexible Design with many functions that can be re-configured on-site by the user.
•Choice of Electric Connections including our water-tight plug-and-play option
•The Optional Pilot Module: control electronics that offers a large LCD display with convenient instrument
configuration and trouble-shooting options at your fingertips.
•And many more…visit www.sierrainstruments.com
1.1 Using This Manual
This manual is organized into five chapters:
•Chapter 1: Introduction and Theory of Operation.
•Chapter 2: Installation, Plumbing & Wiring instructions.
•Chapter 3: Analog Operation.
•Chapter 4: Digital Operation & SmartTrak 100 Software
•Chapter 5: Digital Operation with RS-232 & MaxTrak Software.
•Chapter 6: Technical Support and Service.
There are also 6 Appendices:
•Appendix A: MaxTrak Pre-Programmed gases, Conversion Formula and Gas Tables.
•Appendix B: Product Specifications, useful Optional Parts & Accessories
•Appendix D: PIN Configuration of the mini-D connector
•Appendix E: Dimensional Drawings & Mounting Instructions.
•Appendix F: Warranty Policy
•
Throughout this manual, we use the word instrument as a generic term to represent all models of Sierra
Instruments’ MaxTrak Series 180 mass flow meters and controllers.

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1.2 Definitions Used In This Manual
The following terms are used frequently in this manual. They are presented here with their definitions for your
information.
Setpoint—The command or control signal supplied to a flow controller is called its setpoint. The controller will
maintain the flow at this value.
Full scale—The highest flow that an instrument will meter within its specified accuracy. It is often possible for
an instrument to measure a flow beyond its full scale value, but the accuracy of this measurement may be outside
of published specifications.
Purge—The MaxTrak Mass Flow Controller is supplied with the ability to open the valve far beyond the full scale
position to allow them to be cleaned. This is usually accomplished by blowing clean, dry nitrogen through the
instrument. When the valve is opened to this cleaning position, it is said to be in the Purge mode.
LFE—Laminar Flow Element (LFE) or bypass generates pressure drop forcing a small fraction of the total flow to
pass through the sensor capillary tube.
1.3 The MaxTrak Flow Sensing Principle
The operating principle of the MaxTrak instruments is based on heat transfer and the first law of thermodynamics.
During operation process gas enters the instrument’s flow body and divides into two flow paths, one through the
sensor tube, the other through the laminar flow bypass. The laminar flow bypass (often called LFE which stands for
“laminar flow element”) generates a pressure drop, P1–P2, forcing a small fraction of the total flow to pass through
the sensor tube (m1).
Figure 1. Flow Paths Through the Instrument.
Two resistance temperature detector (RTD) coils around the sensor tube direct a constant amount of heat (H) into
the gas stream. During operation, the gas mass flow carries heat from the upstream coil to the downstream coil. The
resulting temperature difference (∆T) is measured by the MaxTrak microprocessor. From this, MaxTrak calculates
the output signal. Since the molecules of the gas carry away the heat, the output signal is linearly proportional to
gas mass flow.

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Figure 2. Flow Measuring Principle
Figure 3. Sensor Temperature Distribution
Figures 2 and 3 show the mass flow through the sensor tube as inversely proportional to the temperature difference of
the coils. The coils are legs of a bridge circuit with an output voltage in direct proportion to the difference in the coils’
resistance; the result is the temperature difference (∆T). Two other parameters, heat input (H) and coefficient of
specific heat (Cp) are both constant. Through careful design and attention to these parameters, this output signal is
made linear over the transducer’s normal operating range (Figure 4). As a result, the measured flow through the
sensor tube is directly proportional to the gas flow in the main body.
Figure 4. Linear Range of the Transducer's Output Signal
In the MaxTrak mass flow controllers, the gas which flows through the monitoring section is precisely regulated
by the built-in electro-magnetic valve. The normally closed valve is similar to an on/off solenoid valve, except
that the current to the valve coil, and hence the magnetic field, is modulated so that the ferromagnetic valve
armature, or valve plug, assumes the exact height above the valve’s orifice required to maintain the valve’s
command flow (set point). The result is excellent resolution.

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2Installation
2.1 Before You Begin
WARNING: Injury can result if line pressure exceeds the maximum rating of 500 psig (34 barg).
Before installing the instrument, ensure that the installation site conforms to the specific operating parameters
recorded on the instrument’s Data Label. The Data Label is mounted on the back of the instrument electronics
enclosure (see samples below). Should the data label on the back of the instrument become illegible due to
exposure or age, a duplicate of this label in included INSIDE the enclosure for reference. Because each
instrument is con-figured for a specific application range it is critical to verify these details be-fore operation.
Please review the gas or gases, the mounting orientation, the maximum flow range(s), the inlet and outlet
pressure(s), and the operating temperature(s). The line pressure should not exceed 500 psig (34 barg). The
temperature should not exceed 50°C (122°F). The minimum operating gas temperature is 0°C (32°F) and ambient
temperature must remain between -20 to 50°C. If your application exceeds any of these parameters, contact your
Sierra Sales Agent before installation. You may also contact one of Sierra’s Technical Support Centers. FACTORY
USA: TOLL FREE: 800-866-0200 or PHONE: [phone] or FAX: [phone] or EMAIL:
[e-mail].
Figure 5. Examples of Data Labels

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2.2 Pre-Installation Check List
1. Double-check to be sure that the o-ring material used in your instrument is compatible with the gas
to be measured. The o-ring material used in your MaxTrak can be found in the Data Label. See
Appendix A for a table of elastomer compatibility with a wide variety of gases.
2. Sierra strongly recommends you install an in-line filter upstream of the instrument. Recommended
filter size: 10 micron.
3. Do not locate the instrument in areas subject to sudden temperature changes or near equipment
radiating significant amounts of heat. Be sure to allow adequate space for cable connectors and
wiring. MaxTrak weighs up to 30 lbs (14 kg) so make certain mounting hardware is properly designed.
4. For controllers, use a properly sized pressure regulator. Make sure the pressure regulator is not too
small or too big. There can be no restrictions (such as valves, tubing or pipe internal diameters, reducers,
etc.) upstream or downstream of the controller with a dimension that is less than the valve orifice
diameter. To determine orifice diameter, consult the calibration certificate included with your
instrument.
5. Output Signals: The MaxTrak has two analog outputs that are linearly proportional to the gas mass flow
rate. These are a 4-20 mA signal plus your choice of one voltage signal: 0-5 VDC or 0-10 VDC or 1-5
VDC. The voltage signal specified at time of order will be indicated on the data label. You may
change between the current and the voltage output signal at your discretion after receipt of the instrument
using the Remote Pilot Module or the SmartTrak Software (see Chapters 4 & 5). Changing the voltage
output has no influence on the instrument’s accuracy.
6. The instrument has specific power supply requirements. See the table later in this chapter for a
complete listing of power requirements.
2.3 Installing the Instrument-Plumbing
MaxTrak instruments are supplied with compression, VCO®, VCR®, or female NPT process connections. To ensure
a successful installation, inlet and outlet tubing should be in a clean state prior to plumbing the instrument into the
system. The shipping caps covering the inlet/outlet fittings should not be removed until immediately before
installation.
Follow the installation instructions that are applicable to your instrument’s process connection. Ensure that the
tubing is free from burrs, or sharp rims that may result from cutting.
CAUTION: Before use, all plumbing should be checked carefully for leaks, especially at the connecting fittings. All
instruments are leak-tested prior to shipping. If you choose to leak-check your new instrument, you may either
monitor pressure decay or use liquid leak detectors such as Snoop® to search for leaks.
2.3.1 Compression Fittings
1Position the instrument with the flow direction arrow pointing in the direction of flow.
2Verify the position of the front and back ferrule. Insert the tubing into the fitting. Be sure that the tubing
rests firmly on the shoulder of the fitting and that the nut is finger-tight. Scribe the nut at the six o’clock
position.

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3While holding the fitting body steady with a backup wrench, tighten the nut 1-1/4 turns, watching the
scribe mark make one complete revolution and continue to the nine o’clock position. For 1/16-inch, 1/8-
inch and 3/16-inch (2, 3 and 4 mm) sizes, tighten only 3/4 turns from finger-tight. Do not over-tighten!
4If you use flexible tubing (Example: Polyflow) use an “Insert” (see www.swagelok.com)
5Check the system’s entire flow path thoroughly for leaks.
2.3.2 VCO Fittings
1Position the instrument with the flow direction arrow pointing in the direction of flow.
2Tighten the nut finger-tight, and then 1/8 turn tighter with a wrench. Do not over-tighten!
3Check the system’s entire flow path thoroughly for leaks.
2.3.3 Female NPT
1. Position the transducer with the flow direction arrow pointing the direction of flow.
2. Use a good quality Teflon tape. Apply to the male fittings. Alternatively, use a high quality paste pipe
thread sealant suitable for the application and gas and apply this compound to the inlet and outlet fittings.
Avoid getting the tape or the thread sealant onto the first two threads to keep it out of your process gas.
3. Tighten each fitting by hand. Then, tighten no more than one (1) turn. Do not over-tighten.
4. Check the system’s entire flow path thoroughly for leaks
2.4 Installing Your Instruments-Mechanical Mounting
2.4.1 Mounting Your Instrument
The base plate or bottom of the instrument has 4 mounting holes. Two are SAE thread and two are metric thread.
For location and dimensions, please see Appendix B. Remember to properly support the weight of your instrument.
2.5 Installing Your Instruments-Electrical Connections
WARNING: Do not apply power to the output loop on units equipped and calibrated for a 4-20 mA output signal.
This is not a loop-powered device. Damage will occur.
All electrical connections for your MaxTrak instrument are made on the left (inlet) side panel. There are 3 options

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for making electrical connection which must be specified at time of order: a waterproof electrical connector (WT in
the model code), a cable gland (GLAND in the model code) or an open port for conduit connection (COND in the
model code). These will be discussed separately.
2.5.1 Using Water-Tight (WT) Cables
If your instrument has the WT option, attach the water-tight cable to the electrical connector on the inlet side of the
instrument. Connect the wires in this cable per the diagram below. You do not need to open the instrument if you
have ordered the WT option.
2.5.2 Using the Cable Gland or Conduit
If your instrument has our 1/2 FNPT conduit port (code COND) or a cable gland (code GLAND), you must remove
the top of the instrument for installation. All electrical connections, including power, are applied via the terminal
strip which is located INSIDE the waterproof enclosure. Access is through the port or cable located on the inlet
side of the enclosure.
2.5.3 Opening the MaxTrak Instrument
1. Remove the top section of the enclosure by unscrewing the 4 mounting bolts on the top of the instrument
(bolt size SAE 7/16”). Gently pry the top section off the instrument (not the complete cover, just the top
section). Do not remove the O-ring seal around the perimeter of the enclosure.
2. If using conduit, run your wires through the conduit, connect the conduit to our ½” FNPT port on the inlet
side of the instrument with Teflon tape or pipe thread sealant, then pass your wires into the instrument
toward the terminal strip (at the top). If using the cable gland, run your shielded cable with a diameter of
0.20-0.35” (5-9 mm) through the special gland on the side of the enclosure (cable with a smaller ID may
allow liquid to enter the instrument and cause permanent damage). Do not remove the cable gland.
3. Separate your individual wires (16-28 gauge required) and connect to the terminal strip on the top of the
upper circuit board. Wire per the diagrams below. Note that this terminal strip is unique to the MaxTrak
180 Series instruments.
4. When wiring is completed, secure the conduit to the enclosure in a water-tight fashion or tighten the cable
gland fitting so that it grasps your cable securely. Failure to seal the conduit to the enclosure or to tighten
the fitting can permit liquid to enter the electronic compartment and damage the instrument.
5. Install the top section of the enclosure taking care not to pinch the O-ring seal or any of your wires. Insert
and tighten the 4 mounting bolts. Failure to install these bolts correctly can permit liquid to enter the
electronic compartment and damage the instrument.

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Terminal Strip PCA Pin Configuration (inside the enclosure)
8
7
6
5
4
3
44-0206/52-0193 Rev A
www.sierrainstruments.com
9
10
11
12
13
14
15
8
7
6
5
4
3
2

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Wiring Functions, Locations and Color Codes
#
Function
Wire Color with
Optional WT Cable
1
Analog Ground
Brown
2
0-5 VDC Output (or 0-10, 1-5 VDC)
Red
3
Analog Ground
Orange
4
Valve Override (purge)
NOT CONNECTED
5
Power Return (-)
Yellow
6
Power Input (+)
Green
7
RS-232 Transmit (out)
Purple
8
Setpoint
Blue
9
Not Used
NOT CONNECTED
10
Analog Ground
Gray
11
Reference Voltage
(5 VDC External Setpoint & Valve
Purge)
NOT CONNECTED
12
Valve Override (close)
Black
13
RS-232 Receive (in)
Pink
14
4-20 mA Output
White
15
Chassis (Earth) Ground
Tan (Light Brown)
16
Not Used
NOT CONNECTED
NOTE: Sierra recommends individual wires from pins 1, 3, 5, and 10 to power supply ground.

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2.6 Basic Analog Installation
WARNING: This instrument is not a loop-powered device! Do not apply power to the 4-20 mA output or
input connections.
2.6.1 Instrument Power
The MaxTrak requires a 24 VDC power supply. If you are using the power supply supplied by Sierra, connect it
as noted above. If you are supplying your own power source, it must be a regulated source with ripple not to
exceed 100 mV peak-to-peak. Refer to the table below for voltage and current requirements. MaxTrak is polarity
sensitive. If you reverse this wiring, the instrument will not be damaged, but it will not function.
Power Supply Requirements
Instrument Type
Recommended Input
Voltage
Minimum Current Required
(mA)
M180M Meter
15-24 VDC (+/- 10)
130
M180H Meter
15-24 VDC (+/- 10)
130
C180M Controller
24 VDC (+/- 10)
700
C180H Controller
24 VDC (+/- 10)
1260
2.6.2 Output Signal-Voltage
Measure the voltage output signal across the red (pin 2) wire and any of the analog grounds: brown (pin 1), orange
(pin 3) or gray (pin 10). The minimum load is 1000 Ohms.
2.6.3 Output Signal-Current
Measure the current output signal, 4-20 mA across the white (pin 14) wire and any of the analog grounds: pin 1, 3,
or 10. The maximum load is 500 Ohms.
2.6.4 Additional Features for Mass Flow Controllers
•Setpoint: To transmit an analog setpoint, supply the voltage or current signal (user selectable) across the
blue (pin 8) wire and any of the analog grounds: pin 1, 3, or 10. Note that the setpoint signal you supply must
match the signal type your instrument is configured for. See Chapters 4 for how to change the type of
setpoint source.

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•Valve Close: To force the valve closed, connect the black (pin 12) wire to one of the analog grounds.
•Purge: To force the valve to its maximum open position which we call “Purge,” connect pin 4 to pin 11.
Note that this will allow much greater flow than the rated full-scale value.
2.7 Configuring Your Instrument
The MaxTrak instruments have many features which can be changed by the user. You may wish to review these
features and modify some of them prior to operation of your instrument. This must be accomplished using Digital
Communication with the supplied SmartTrak software. If you prefer to use your instrument as delivered, please
proceed to Chapter 3: Analog Operation.
2.7.1 Using SmartTrak Software to Configure Your Instrument
You can communicate with your instrument using the SmartTrak Software package (provided with your purchase)
and your PC running the Windows operating system. Simply connect the purple (pin 7) wire, the pink (pin 13)
wire and one of the analog grounds: brown, orange or gray wires (pin 1, 3, or 10) to a standard DB-9 connector
according to the chart on the next page.
RS-232 Wiring Configuration
RS-232 Transmit (pin 7)
To
DB-9 pin #2
RS-232 Transmit (pin 13)
To
DB-9 pin #3
Analog Ground (pin 1,3, or 10)
To
DB-9 pin #5
With the connections above in place, plug the DB-9 connector into an appropriate serial port on your PC. If you are
in an environment with high RF interference, it may be necessary to shield these wires. Should your computer not
have a serial port, you will need a serial to USB adapter. See Chapter 4 for details.
You are now ready to configure your MaxTrak instrument. Proceed to Chapter 4 for a discussion of the use of the
SmartTrak software

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3Analog Operation
Your MaxTrak instrument may be operated in two different ways:
1. Analog Input/Output Operation (this chapter): Using analog input/output signals at the 15-pin mini-D
connector.
2. Digital Operation with RS-232 and SmartTrak Software (Chapter 4): Using the RS-232 link, the supplied
SmartTrak Software package and a PC-style computer running the Windows operating system.
This chapter will discuss the first of these—Analog Operation. Please see Chapter 4 for digital operation.
Regardless of control options, the standard output for all MaxTrak instruments are two linear analog output signals
corresponding to 0% to 100% of the mass flow full-scale range. Please note that one of these output signals is always
a current signal of 4-20 mA. The other is a user-configurable voltage signal of 0-5 VDC, 0-10 VDC or 1-5 VDC.
For mass flow controllers, one input signal of 4-20 mA, 0-5 VDC, 0-10 VDC or 1-5 VDC (selectable by user) may
be chosen to set the gas mass flow rate to any desired value within the range of the device. This input signal must
be a direct linear representation of 0% to 100% of the desired gas mass flow full-scale value.
For the location of these signals on the WT connector or the Terminal Strip, refer to Chapter 2.
3.1 Analog Operation, Mass Flow Meters
After your instrument is installed and the system has undergone a complete leak check as discussed in detail in
Chapter 2, you are ready to supply power.
3.1.1 Power Your Instrument
Apply power using Sierra’s power supply or your own power source. See Chapter 2 for complete power supply
requirements. Let the instrument warm up for at least 15 minutes for optimal performance. Check the con-
figuration of your instrument by reviewing the data label details.
WARNING: The MaxTrak is not a loop-powered device. Do not apply power to the 4-20 outputs.
If the configuration is not correct for your present application, you can alter it. See Chapter 4 or 5 for details on how
to change the configuration of your MaxTrak instrument.
If the configuration is correct, your MaxTrak instrument is now ready for use.
3.2 Analog Operation, Mass Flow Controllers
After your instrument is installed and the system has undergone a complete leak check as discussed in detail in
Chapter 2, follow these steps:

Sierra Instruction Manual MaxTrak 180
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1. The valve will remain closed until power is supplied. See Chapter 2 for wiring instructions. Remember
that the valve in the Max-Trak is not a positive shut-off device. When power is applied, the flow control
valve will operate per any instructions it receives. When the MaxTrak is delivered, the valve will be in
the Automatic (Normal) state and the analog or digital command signal will pro-vide the correct zero
setpoint reference for the instrument. As a result, the valve will be closed. However, upon subsequent
power-ups, the valve will return to the state it was in the last time the instrument was operated.
WARNING: If you do not know the value of the setpoint or the valve state given to the MaxTrak when it
was last operated, you must assume that the valve will open when power is applied. Take necessary
precautions. You may use the MaxTrak Software to check the setpoint or the valve state currently on your
instrument. See Chapter 4 for information on Setpoint and Valve State.
2. Power Your Instrument: Apply power using Sierra’s power sup-ply or your own power source. See
Chapter 2 for complete Power Supply requirements.
3. Adjust the controller setpoint to the desired flow rate by supplying an appropriate signal (mA or VDC).
The effective control range of the unit is 2% to 100% of the calibrated full scale flow range. Automatic
shut-off occurs at 1.9% of the factory full scale calibrated range. MaxTrak will immediately begin
accurately monitoring and controlling the gas mass flow rate. Let the instrument warm up for at least 15
minutes for optimal performance.
NOTE: You must supply the setpoint in the configuration the MaxTrak is looking for. If the instrument does
not respond to your setpoint, check the configuration on the data label and re-configure the instrument as
needed (see Chapter 4).
4. Your MaxTrak instrument is now ready for use.
3.3 MaxTrak Analog Features
3.3.1 Setpoint Adjustment (flow controllers only)
The setpoint (command) input signal you supply to MaxTrak must be a direct linear representation of 0% to 100%
of the mass flow full-scale value. Apply the setpoint signal from pin 8 to any of the analog grounds (see Chapter 2
for wiring details). A setpoint value of 0 VDC (or 1 VDC or 4 mA) will regulate the flow to 0% and a setpoint
value of 5.00 VDC (or 10 VDC or 20 mA) will adjust the flow to 100% of the instrument’s full scale range.
When the setpoint (command) signal is applied, the flow controller will reach the setpoint value within two seconds
to within ±2% of the selected flow rate.
WARNING: Do not leave a setpoint applied for an extended period of time to a controller when the gas
supply is shut off or blocked. This will overheat your instrument which will become hot to the touch and
damage may result. Instead, drive the set point to zero or use the “Valve Close” feature which allows you
to disable the valve while maintaining the current setpoint signal. Valve Close may be activated from an
external analog signal (see below) or digitally (see Chapter 4).