Sierra Smart-Trak 100 series User manual

Smart-Trak
®
Smart-Trak
®
Smart-Trak
Series 100
INSTRUCTION MANUAL
100L MFC (0-50 slpm)
100M MFC (0-200 slpm)

Series 100 Instruction Manual Table of Contents
IM-100-B0-1
INSTRUCTION MANUAL
IM-100 Rev.B.1
July 2005
CORPORATE HEADQUARTERS
5 Harris Court, Building L Monterey, CA 93940
Phone [phone] [phone] Fax [phone]
www.sierrainstruments.com
EUROPE HEADQUARTERS
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Phone [phone] Fax [phone]
ASIA HEADQUARTERS
100 Jiangnan Dadao Zhong Guang Bldg. Suite 2303 Guangzhou China
Phone + 86203435 4870 Fax: [phone]

Table of Contents Series 100 Instruction Manual
0-2 IM-100-B
IMPORTANT CUSTOMER NOTICE
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 control-
lers 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 2003
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
Smart-Trak™ and Dial-A-Gas™ are trademarks of Sierra Instruments, Inc. Other product
and company names listed in this manual are trademarks or trade names of their respec-
tive manufacturers.

Series 100 Instruction Manual Table of Contents
IM-100-B0-3
TABLE OF CONTENTS
Chapter 1 Introduction
Introduction.............................................................1-1
Using this Manual.................................................1-1
Safety Information ................................................1-2
Receipt of System Components .................................1-2
Definitions Used in This Manual................................1-3
The Smart-Trak Flow Sensing Principle............................1-4
Chapter 2 Installation
Before You Begin Installation........................................2-1
Smart-Trak Data Labels...............................................2-1
Pre-Installation Checklist .............................................2-2
Installing the Instrument-Plumbing..................................2-3
Compression Fittings.............................................2-3
VCO Fittings.......................................................2-4
VCR Fittings.......................................................2-4
1/4-inch Female NPT Fittings ...................................2-4
Installing the Instrument-Mechanical Mounting....................2-5
Installing the Instrument-Electrical Connections...................2-6
D-connector PIN assignments...................................2-7
Power Supply Requirements.....................................2-8
RS-232 Wiring ....................................................2-9
Chapter 3 Analog Operation
Introduction.............................................................3-1
Analog Operation, Mass Flow Meters...............................3-2
Analog Operation, Mass Flow Controllers .........................3-2
Smart-Trak Features...................................................3-3
Setpoint Adjustment...............................................3-3
Changing the Output or Setpoint Signals.......................3-3
Over-Range Condition............................................3-3
Manual Valve Override-Valve Close............................3-4
Manual Valve Override-Valve Purge............................3-4
Chapter 4 Pilot Module Operation
Introduction to the Pilot Module .....................................4-1
Pilot Module Features and Capabilities..............................4-2
Mass Flow Meters.....................................................4-3
Mass Flow Controllers................................................4-4
Pilot Module Menus and User Interface.............................4-5
Map of the User Interface............................................4-7
Upper Screens (Display)..............................................4-8
Mass Flow Screen.................................................4-8
Setpoint Screen....................................................4-8
Valve Position Screen.............................................4-8
Full Scale Screen..................................................4-9

Table of Contents Series 100 Instruction Manual
0-4 IM-100-B
Lower Level Screens (Changing Parameters)......................4-9
Getting to the Lower Level Screens.............................4-9
Password...........................................................4-9
Making Changes to the the Lower Level Screens ............4-12
Change Setpoint Value Screen..................................4-12
Change Units Screen.............................................4-14
Change Gas (Dial-A-GasTM) Screen............................4-15
Change Valve Operation (Close, Purge) Screen..............4-16
Change Setpoint Source Screen ................................4-17
Change Output Signals Screen..................................4-18
Change Full Scale Screen .......................................4-19
Change Password Screen .......................................4-20
Lost Password....................................................4-21
Maintenance Functions ..........................................4-22
Chapter 5 RS-232 Operation with Smart-Trak Software
Introduction.............................................................5-1
Summary of Smart-Trak Features ...................................5-2
Power Up Your Instrument...........................................5-3
Power Up Your Computer............................................5-3
Loading the Smart-Trak Software ...................................5-4
Connecting Smart-Trak to your Computer..........................5-4
Running the Smart-Trak Software...................................5-7
Using the Smart-Trak Software.....................................5-10
Upper Section of Software Window ...............................5-10
Password Section.....................................................5-11
Lower Section of Software Window...............................5-11
Change Setpoint Value...........................................5-12
Change Valve Operation (Close, Purge).......................5-12
Change Gas (Dial-A-GasTM)....................................5-13
Change Units .....................................................5-13
Change Setpoint Source.........................................5-13
Change Output Signal............................................5-14
Change Full Scale................................................5-14
Change Password (Lost Passwords) ..........................5-15
Lost Password....................................................5-16
Other Useful Features............................................5-16
Comm Port........................................................5-17
Read Controller Parameters.....................................5-17
Web Links.........................................................5-17
PDF Information .................................................5-17
Chapter 6 Technical Support and Service
Technical Support ………………………………….…………6-1
Sierra Websites ......................................................…6-2
Returning Equipment to the Factory…………………………….6-3

Series 100 Instruction Manual Table of Contents
IM-100-B0-5
Appendix A Gas Tables
Pre-programmed gas list-Dial-A-Gas …………………………..A-1
K-Factor Calculations ……………………...……..……………A-1
Gas Tables with K-factors ……………...……………………...A-2
Appendix B Product Specifications
Performance Specifications………………..…………………..B-1
Operating Specifications …………………..…………………..B-1
Physical Specifications ………………..………………….……B-3
Optional Accessories……..………………..…………………..B-4
Appendix C Flow Chart for Pilot Module User Interface
Appendix D HD DB-15 PIN Configuration
Appendix E Dimensions and Mounting

Series 100 Instruction Manual Chapter 1 Introduction
IM-100-B1-1
CHAPTER 1: INTRODUCTION
Welcome to the future of gas flow measurement!
The Sierra Instruments’ Smart-Trak Series 100 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 Smart-Trak. Visit the dedicated Smart-
Trak website www.sierrasmarttrak.com any time for more infor-
mation about this product.
The Smart-Trak instruments offer a variety of features for ease of
operation. Among these features:
üDial-A-Gas: allows a user to change from among 10 gases
while maintaining accuracy.
üThe Optional Pilot Module: control electronics that offers
both display and control options at the user’s fingertips.
üTrue Digital Electronics: where the sensor signal feeds di-
rectly to a powerful microprocessor ensuring excellent system
accuracy, stability, and signal-to-noise ratio.
üChoice of 4 Analog Communications Options and RS-232
with every Smart-Trak instrument.
üFlexible Design with many functions that can be re-
configured on-site by the user.
üCompact Footprint that allows Smart-Trak to fit almost any-
where.
üAnd many more…visit www.sierrasmarttrak.com
Using This Manual
This manual is organized into six chapters:
•Chapter 1: Introduction and Theory of Operation.
•Chapter 2: Installation, Plumbing & Wiring instructions.
•Chapter 3: Analog Operation.
•Chapter 4: Digital Operation with the Optional Pilot Module.
•Chapter 5: Digital Operation with RS-232 & Smart-Trak Software.
•Chapter 6: Technical Support and Service.

Chapter 1 Introduction Series 100 Instruction Manual
1-2 IM-100-B
There are also 5 Appendices:
•Appendix A: Smart-Trak Pre-Programmed gases, Conversion
Formula and Gas Tables.
•Appendix B: Product Specifications, useful Optional Parts &
Accessories
•Appendix C: Flowchart for the Pilot Module.
•Appendix D: PIN Configuration of the mini-D connector
•Appendix E: Dimensional Drawings & Mounting Instructions.
Throughout this manual, we use the word instrument as a ge-
neric term to represent all models of Sierra Instruments’ Smart-
Trak Series 100 mass flow meters and controllers.
SAFETY INFORMATION
Caution and warning statements are used throughout this book to
draw your
attention
to impor-
tant infor-
mation.
Warning! Caution!
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 per-
formance. Read and follow all cautions that ap-
ply to your application.
RECEIPT OF YOUR INSTRUMENT
When receiving the instrument, carefully check the outside packing
carton for damage that may have incurred during 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 and match your specifications

Series 100 Instruction Manual Chapter 1 Introduction
IM-100-B1-3
(as ordered). Make sure any spare parts or accessories are not dis-
carded with the packing material. Do not return any equipment to
the factory without first contacting one of Sierra’s Technical Sup-
port Centers:
Email Customer Service: [email protected]
FACTORY USA Customer Service:
TOLL FREE: 800-866-0200
PHONE: [phone]
FAX: [phone]
EMAIL: [email protected]
European Customer Service:
PHONE: [phone]
FAX: [phone]
EMAIL: [email protected]
Asia Customer Service:
PHONE: + 86 203435 4870
FAX: [phone]
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 con-
troller 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 Smart-Trak 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.

Chapter 1 Introduction Series 100 Instruction Manual
1-4 IM-100-B
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.
THE SMART-TRAK FLOW SENSING PRINCIPLE
The operating principle of the Smart-Trak instruments is based on
heat transfer and the first law of thermodynamics. During opera-
tion 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 1-1. Flow Paths through the Instrument
Two resistance temperature detector (RTD) coils around the sen-
sor 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 Smart-Trak microprocessor. From this,
Smart-Trak calculates the output signal. Since the molecules of the
gas carry away the heat, the output signal is linearly proportional
to gas mass flow.

Series 100 Instruction Manual Chapter 1 Introduction
IM-100-B1-5
Figure 1-2. Flow Measuring Principle
Figure 1-3. Sensor Temperature Distribution
Figures 1-2 and 1-3 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 pro-
portion 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 care-
ful design and attention to these parameters, this output signal is
made linear over the transducer’s normal operating range (Figure 1-4).
As a result, the measured flow through the sensor tube is directly
proportional to the gas flow in the main body.

Chapter 1 Introduction Series 100 Instruction Manual
1-6 IM-100-B
Figure 1-4. Linear Range of the Transducer’s Output Signal
In the Smart-Trak mass flow controllers, the gas which flows
through the monitoring section is precisely regulated by the built-in
electromagnetic 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. The
result is excellent resolution.

Chapter 2 Installation Series 100 Instruction Manual
2-2 IM-100-B
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 Smart-Trak can be found in the Data La-
bel. 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 up-
stream of the instrument. Recommended filter size: 10 micron.
Smart-Trak is supplied with a 10 micron filter installed inside the
instrument.
3. Do not locate the instrument in areas subject to sudden tem-
perature changes, excessive moisture or near equipment ra-
diating significant amounts of heat. Be sure to allow adequate
space for cable connectors and wiring.
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 di-
ameters, reducers, etc.) upstream or downstream of the controller
with a dimension that is less than the valve orifice diameter. To de-
termine orifice diameter, consult the calibration certificate included
with your instrument or contact Sierra.
5. Output Signals: The Smart-Trak 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 cur-
rent and the voltage output signal at your discretion after receipt of
the instrument using the Pilot Module or the Smart-Trak Software
(see Chapters 4 & 5). Changing the voltage output has no influence
on the instrument’s accuracy.
6. The CAT-5 connector on the side of the Smart-Trak is NOT an
Ethernet connector. It is for use with the optional Remote Pilot
Module. Do not plug an Ethernet cable here as damage may result.
The instrument has specific power supply requirements. See the
table later in this chapter for a complete listing of power requirements.

Series 100 Instruction Manual Chapter 2 Installation
IM-100-B2-3
Installing the Instrument—Plumbing
Smart-Trak 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 instru-
ment 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. It is not a requirement to leak test your in-
strument. Do not use liquid leak detectors such as Snoop®to search
for leaks inside or outside the Smart-Trak. Instead, monitor pressure
decay.
Compression Fittings
1. Position the instrument with the flow direction arrow pointing in
the direction of flow.
2. Verify the position of the
front and back ferrule. In-
sert the tubing into the fit-
ting. Be sure that the tub-
ing rests firmly on the
shoulder of the fitting and
that the nut is finger-tight.
Scribe the nut at the six
o’clock position.
3. While 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!
4. If you use flexible tubing (Example: Polyflow) use an “Insert” (see
www.swagelok.com)

Chapter 2 Installation Series 100 Instruction Manual
2-4 IM-100-B
5. Check the system’s entire flow path thoroughly for leaks. Do not
use liquid leak detectors. Instead, monitor pressure decay. Ex-
posing the instrument to leak detector fluid may damage the unit.
VCO Fittings
1. Position the instrument with the flow direction arrow pointing in
the direction of flow.
2. Tighten the nut finger-tight, and then 1/8 turn tighter with a
wrench. Do not over-tighten!
3. Check the system’s entire flow path thoroughly for leaks. Do not
use liquid leak detectors. Instead, monitor pressure decay. Ex-
posing the instrument to leak detector fluid may damage the unit.
VCR Fittings
1. Position the instrument with the flow direction arrow pointing the
direction of flow.
2. Install new gaskets that are compatible with the gas to be used.
3. Tighten the nut finger-tight, and then 1/8 turn tighter with a wrench.
Do not over-tighten!
4. Check the system’s entire flow path thoroughly for leaks. Do not
use liquid leak detectors. Instead, monitor pressure decay. Ex-
posing the instrument to leak detector fluid may damage the unit.
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. Alter-
natively, 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.

Series 100 Instruction Manual Chapter 2 Installation
IM-100-B2-5
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. Do not
use liquid leak detectors. Instead, monitor pressure decay. Ex-
posing the instrument to leak detector fluid may damage the unit.
Installing your Instrument—Mechanical Mounting
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 E.
Mounting the Optional Remote Pilot Module
If you have the optional Remote Pilot Module control unit, you have sev-
eral mounting options.
1. Wall or Panel mounting—your Remote Pilot Module may be
mounted to a flat surface using the supplied plate and 2 special
“shoulder” screws. Simply screw the shoulder screws into the
plate. Then, attach the plate to the wall by driving 2 screws (not in-
cluded) through the 2 large central holes. MAKE SURE THE
UP ARROW IMPRINTED ON THE MOUNTING
BRACKET POINTS UPWARD. Your Remote Pilot Module
will slip onto the shoulder screws. Push against the plate and then
down. To remove, push up and pull. Attach the CAT-5 cable to the
socket on the bottom of the Remote Pilot Module.
2. Rack mounting—to mount your Remote Pilot Module to a stan-
dard 19” laboratory rack, first purchase a “blank” panel from your
industrial supplier. Decide where the Remote Pilot Module will be
attached, then follow the procedure listed above for wall mounting.
When you are ready, insert the CAT-5 cable into the socket in the
Remote Pilot Module.
3. Desktop mounting—the Remote Pilot Module will sit on a desk
in a fashion that makes it convenient to view and operate. Insert the
CAT-5 cable into the socket in the back of the Module. Use the ca-
ble as a “kickstand.” Gently bend the cable to recline the Remote
Pilot Module to an angle suitable for easy viewing. Alternately, you
can lay the Remote Pilot Module on its back and insert the CAT-5
cable into the socket in the bottom.

Series 100 Instruction Manual Chapter 2 Installation
IM-100-B2-7
Figure 2-3: HD DB-15 Connector Pin Configuration (on the instrument)
Figure 2-4: Wiring Definitions for Optional Communication Cable
Pin #
Wire Color in Cable
Function
1.
Brown
Analog Ground
2.
Red
0-5 VDC Output (or 0-10, 1-5 VDC)
3.
Orange
Analog Ground
4.
Pink
Valve Override (purge)
5.
Yellow
Power Return (-)
6.
Dark Green
Power Input (+)
7.
Light Green
RS-232 Transmit (out)
8.
Blue
Setpoint
9.
Purple
Not Used
10.
Gray
Analog Ground
11.
White
Reference Voltage
(5 VDC External Setpoint & Valve Purge)
12.
Black
Valve Override (shut)
13.
Brown/white
RS-232 Receive (in)
14.
Red/white
4-20 mA Output
15.
Red/Black
Chassis (Earth) Ground
Note: Pins 1, 3, 5, and 10 are connected together inside the
instrument. Sierra recommends individual wires.

Chapter 2 Installation Series 100 Instruction Manual
For Basic Analog Installation of the Instrument:
•Instrument Power: The Smart-Trak requires a 12-30 VDC power supply. If
you are using the power supply supplied by Sierra, connect it to the 15-pin HD
DB-15 connector on the side of the instrument. If you are supplying your own
power source, it must be a regulated 12-30 VDC with ripple not to exceed 100
mV peak-to-peak. It must be capable of producing the current specified for the
appropriate voltage shown in Figure 2-5: Power Supply Requirements. Apply
power as follows: positive (+) to the green (pin 6) and negative (-) to the
yellow (pin 5) wires. The instrument is polarity sensitive. If you reverse this
wiring, the instrument will not be damaged, but it will not function.
Figure 2-5: Power Supply Requirements
Instrument Type Recommended
Input Voltage Minimum Current Required (mA)
M100L Meter 12-30 Vdc 250
M100M Meter 12-30 Vdc 250
C100L Controller 24-30 Vdc* 400
C100M Controller 24-30 Vdc* ±5% 500
*Note: A Smart-Trak Mass Flow Controller may be powered by less
than 24 VDC if Sierra’s Multi-adapter is used (See Appendix B for
Parts and Accessories ordering information). For operation of a
controller with 12-24 VDC, the minimum current required is 800 mA.
CAUTION: This instrument is not a loop-powered device! Do
NOT apply power to the 4-20 mA output or input connections.
•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.
•Output Signal—Current: Measure the current output signal, 4-20 mA,
across the red/white stripe (pin 14) wire and any of the analog grounds: pin
1, 3, or 10. The maximum load is 500 Ohms.
2-8 IM-100-B