Sierra Top-Trak 820 Series User manual

Sierra 820 Series
Top-Trak™ Mass Flow Meters
Models: 820, 820S, 822, 822S, 824, 824S, 826 and 827
Instruction Manual
Part Number IM-82
Revision H, November 2017

Table of Contents Series 820 Instruction Manual
GLOBAL SUPPORT LOCATIONS: WE ARE HERE TO HELP!
CORPORATE HEADQUARTERS
5 Harris Court, Building L Monterey, CA 93940
Phone [phone] [phone] Fax [phone]
www.sierrainstruments.com
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Bijlmansweid 2 1934RE Egmond aan den Hoef The Netherlands
Phone [phone] Fax [phone]
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 re-
sponsible for determining if this mass flow meter or controller is appropriate for your oxygen appli-
cation. You are responsible for cleaning the mass flow meter or controller to the degree required
for your oxygen flow application.
© COPYRIGHT SIERRA INSTRUMENTS 2016
No part of this publication may be copied or distributed, transmitted, transcribed, stored in a re-
trieval 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 writ-
ten permission of Sierra Instruments. The information contained in this manual is subject to change
without notice.
TRADEMARKS
Top-TrakTM and Cal-Bench TM 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 manu-
facturers.

Series 820 Instruction Manual Table of Contents
Table of Contents
Chapter 1 Introduction
Introduction ......................................................................... 1-1
Using this Manual .............................................................. 1-1
Safety Information ............................................................. 1-2
Receipt of System Components ........................................ 1-2
Technical Assistance .......................................................... 1-2
Top Trak Features .................................................................... 1-3
The 820 Series Flow Sensing Principle ................................... 1-4
Chapter 2 Installation
Installation Overview ............................................................... 2-1
Installing the Transduce
r
.......................................................... 2-2
Compression Fittings ......................................................... 2-2
VCO Fittings ................................................................. 2-2
VCR Fittings .................................................................. 2-3
All 1/2-inch Size Connections ........................................... 2-3
Wiring the Transduce
r
............................................................. 2-4
Standard 0-5 VDC Output Signal Wiring ......................... 2-5
Optional 4-20 mA Output Signal Wiring .......................... 2-5
Remote Display Installation ..................................................... 2-6
Chapter 3 Operation
Transducer Operation ............................................................... 3-1
Transducer Accuracy ......................................................... 3-1
Referencing the Transducer to Non
-
Standard Conditions .... 3-2
Transducer Ove
r
-Ranging ................................................. 3-2
Zero and Span Adjustments ............................................... 3-3
Totalizer Option ................................................................. 3-4
Chapter 4 Maintenance and Repair
Transducer Cleaning ................................................................ 4-1
Flow Path Cleaning Model 822/824 ........................................ 4-2
Inlet and Outlet Screens ..................................................... 4-2
Laminar Flow Elemen
t
...................................................... 4-3
Flow Path Cleaning Model 826/827 ........................................ 4-4
Laminar Flow Elemen
t
...................................................... 4-4
Flow Path Cleaning Model 822-S/824-S ................................ 4-5
Laminar Flow Elemen
t
...................................................... 4-5
Sensor Cleaning and Inspection ........................................ 4-8
Transducer Calibration ............................................................. 4-9
Transducer Troubleshooting .................................................... 4-11
Returning Equipment to the Factory ....................................... 4-13
IM-82 0-3

Table of Contents Series 820 Instruction Manual
Appendix A Conversion Formulas and Gas Tables
Appendix B 822/824 Product Specifications
Appendix C 822S/824S Product Specifications
Appendix D 826/827 Product Specifications
List of Figures
1-1. Top-Trak Features (Typical) ........................................ 1-3
1-2. Flow Paths through the Transduce
r
............................. 1-4
1-3. Flow Measuring Principle ............................................ 1-4
2-1. Pipin
g
Requirements for 1/2-inch Size Connections .. 2-3
2-2. Transducer D-Connector Pin Assignments ................. 2-4
2-3. Standard 0-5 VDC Output Signal Wiring ................... 2-5
2-4. Single Transducer Current Loop Connection .............. 2-5
2-5. Multiple Transducer Current Loop Connections ........ 2-6
2-6. Mounting the Remote Displa
y
..................................... 2-6
4-1. Model 822/824 Flow Components .............................. 4-2
4-2. Correct LFE Position ................................................... 4-3
4-3. Model 826/827 Flow Components ............................... 4-4
4-4. Low Flow Transducer LFE Cleaning .......................... 4-5
4-5. Medium Flow Transducer LFE Cleaning ................... 4-6
4-6. High Flow Transducer LFE Cleaning ......................... 4-7
4-7. Printed Circuit Board Component Locations .............. 4-11
0-4 IM-82

Series 820 Instruction Manual Table of Contents
Cautions
Caution! Only qualified personnel should install the transducer.
Caution! Do not supply +DC power at the D-connector while using a
power supply at the power jack. Both supplies may be damaged.
Caution! Operating a 12 VDC transducer at 24 VDC will cause equip-
ment damage.
Caution! Only qualified personnel should perform transducer service, ca-
libration or troubleshooting procedures.
Caution! When using toxic or corrosive gases, purge the unit thoroughly
with inert dry gas before disconnecting from the gas line.
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
IM-82 0-5

Series 820 Instruction Manual Chapter 1 Introduction
Chapter 1 Introduction
This instruction manual covers the installation, operation and
maintenance of Sierra’s 820 Series product line including the fol-
lowing Top-Trak
ª
Models:
 822 Mass Flow Meter with display (nylon flow body)
 824 Mass Flow Meter without display (nylon flow body)
 826 Hi-Flow Meter with display (aluminum flow body)
 827 Hi-Flow without display (aluminum flow body)
 822-S Mass Flow Meter with display (stainless steel flow body)
 824-S Mass Flow Meter without display (stainless steel flow body)
Sierra’s Top-Trak
ª
Mass Flow Meters are designed for precise
measurement of gas mass flow. The 820 Series offers a broad
range of sizes and process connections for flexibility and versatili-
ty. The primary standard calibration ensures starting point accura-
cy and NIST traceability. The meter’s 0-5 VDC or 4-20 mA output
signal is provided for recording, data-logging or control. The op-
tional display reads the mass flow rate directly in engineering units
or percentage of full scale.
Using This Manual
This manual is organized into four chapters:
 Chapter 1 includes the introduction and theory of operation
 Chapter 2 provides installation and wiring instructions
 Chapter 3 describes transducer operation and features
 Chapter 4 covers maintenance, calibration and troubleshooting
Gas tables and conversion formulas are found in Appendix A.
The product specifications and dimensional drawings are found
in Appendix B.
Throughout this manual, we use the word transducer as a ge-
neric term to represent all models of Sierra’s 820 Series Top-
Trak Mass Flow Meters.
IM-82 1-1

Chapter 1 Introduction Series 820 Instruction Manual
Safety Information
Caution and warning statements are used throughout this book to
draw your attention to important information.
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.
Thisstatementappearswithinformationthatis
important for protecting your equipment and
performance. Read and follow all cautions that
apply to your application.
Receipt of System Components
When receiving a Sierra transducer, 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 and match your specifications (as ordered).
Make sure any spare parts or accessories are not discarded with the
packing material. Do not return any equipment to the factory with-
out first contacting Sierra Customer Service.
Technical Assistance
If you encounter a problem with your transducer, review the confi-
guration information for each step of the installation, operation and
set up procedures. Verify that your settings and adjustments are
consistent with factory recommendations. Refer to Chapter 4,
Troubleshooting, for specific information and recommendations.
If the problem persists after following the troubleshooting proce-
dures outlined in Chapter 4, 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 bv at +31 20
6145810. When contacting Technical Support, make sure to include
this information:
 the flow range, serial number, Sierra order number and
model number (all marked on the transducer nameplate)
 the problem you are encountering and any corrective action
taken
 application information (gas, pressure, temperature, pipe
and fitting configuration)
1-2 IM-82

Series 820 Instruction Manual Chapter 1 Introduction
Top-Trak Features
Standard Top-Trak Mass Flow Meters require a 12 to 15 VDC ex-
ternal power source (24 VDC input power optional). The transduc-
er’s 0 to 5 VDC output signal allows for flow recording, data-logging
or control. A 4 to 20 mA output signal is optionally available. Input
power and output signal connections are made via the 9-pin sub-
type D-connector located on the side of the transducer. An addi-
tional input power jack is located just below the D-connector. (It is
important to connect input power at only one location.)
The transducer shown below is a typical example of a 822 Series
Top-Trak Mass Flow Meter. Other models may vary slightly in
their appearance but are operationally equivalent.
Figure 1-1. Top-Trak Features (Typical)
IM-82 1-3

Chapter 1 Introduction Series 820 Instruction Manual
The 820 Series Flow Sensing Principle
The operating principle of Top-Trak transducers 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 la-
minar flow element bypass. The laminar flow bypass generates a
pressure drop, P 1 –P 2 , forcing a small fraction of the total flow to
pass through the sensor tube (m 1 ).
Figure1-2.FlowPathsthroughthe Transducer
Two resistance temperature detector (RTD) coils around the sensor
tube direct a constant amount of heat (H) into the gas stream. In
actual operation, the gas mass flow carries heat from the upstream
coil to the downstream coil. The resulting temperature difference
(?T) is detected by the RTD coils and gives the output signal.
Since the molecules of the gas carry away the heat, the output sig-
nal is linearly proportional to gas mass flow.
Figure1-3.Flow MeasuringPrinciple
1-4 IM-82

Series 820 Instruction Manual Chapter 2 Installation
Chapter 2 Installation
Installation Overview
To ensure a successful installation, inlet and outlet tubing should be clean
and free from burrs or rims caused by cutting prior to plumbing the transduc-
er into the system. The protective caps covering the inlet/outlet fittings
should not be removed until immediately prior to installation.
Before installing the transducer, verify the following:
1. Make sure the installation site meets the specific operating parameters
recorded on the transducer’s nameplate. Each transducer is factory-
configured for a specific gas and flow range. If the operating pressure is
more than 50 psi (3.4 bar) away from the calibration pressure, it is advis-
able to return the unit to the factory for re-calibration. (Adjusting zero
may be sufficient to remain within specification.)
2. Do not locate the transducer in areas subject to sudden temperature
changes, moisture, drafts or near equipment radiating significant amounts
of heat. Make sure to allow adequate space for cable connectors and wir-
ing.
3. For 1/2-inch size inlet/outlet process connections on models 826 and 827
make sure the location meets the minimum number of recommended pipe
diameters upstream and downstream of the transducer. A minimum of 5
inches (127 mm) upstream and 2-1/2 inches (64 mm) downstream is al-
ways recommended. (not necessary for other models)
4. Horizontal mounting is preferable. Vertical mounting is possible with
best results achieved when the factory calibration is specifically per-
formed for vertical mounting. In vertical positions zero shift will occur
depending on the gas pressure at zero flow.
5. If the gas contains any particulate matter, install an in-line filter prior to
the transducer. Recommended filter size: 15 micron for flows of 10
sccm to 30 slpm, 30 micron for above 30 slpm.
6. If a potential over-flow condition exists, insert a valve or critical orifice
in the line to limit flow to approximately 25 percent above the full scale
range of the meter.
7. Confirm that the transducer o-ring material is compatible with the gas to
be measured.
8. For remote displays, confirm the supplied cable is of sufficient length to
connect the components.
IM-82 2-1

Caution!
Only qualified personnel
should install the
transducer.
Chapter 2 Installation Series 820 Instruction Manual
Installing the Transducer
Follow the installation instructions that apply to your transducer’s
process connection. For all 1/2-inch size process connections, observe
the piping recommendations given on page 2-3. Before operation, all
plumbing should be checked carefully for leaks and the transducer
purged with dry nitrogen.
Compression Fittings
1. Position the transducer with the flow direction arrow pointing
downstream in the direction of flow.
2. Verify the position of the front
and back ferrule. Insert the
tubing into the fitting. Make
sure that the tubing rests firmly
on the shoulder of the fitting
and that the nut is finger tight.
(Do not mix or interchange
parts of tube fittings made by different manufactur- ers.)
3. Hold the body steady with a backup wrench. For 1/2-inch size,
tighten the nut 1-1/4 turns from finger tight. For 1/8-inch, 1/4- inch
and 3∕8-inch sizes, tighten only 3/4 turn from finger tight. 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. Over-
exposing the transducer to leak detector fluid may damage the unit.)
VCOFittings
1. Position the transducer with the flow direction arrow pointing
downstream in the direction of flow.
2. Install new o-rings compatible with the gas to be used. (Do not mix
or interchange parts of tube fittings made by different manu-
facturers.)
3. Hold the body steady with a backup wrench. Tighten the nut
finger tight and then 1/4 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. Over- exposing
the transducer to leak detector fluid may damage the unit.)
2-2 IM-82

Series 820 Instruction Manual Chapter 2 Installation
1/4 inch Female NPT Connections (standard on nylon flow bodies )
1. Position the transducer with the flow direction arrow pointing in the di-
rection of flow.
2.
Use a good quality paste pipe thread sealant. Apply to pipe threads.
3. Tighten the pipe no more than 1 turn past hand-tight. Caution! Do not
over-tighten. Damage to the instrument may result.
1/2-Inch Size NPT Connections
1. Install a section of straight pipe at least ten pipe diameters in length up-
stream of the transducer. Also, allow at least five pipe diameters down-
stream for accurate operation. DO NOT use reducers. If the preceeding
components in the flow path create disturbances extend the upstream pipe
length.
2. Position the transducer with the flow direction arrow pointing down-
stream in the direction of flow.
3. Tighten fittings until leak tight (refer to published standards for specific
recommendations).
4. Check the system’s entire flow path thoroughly for leaks. (Do not use liq-
uid leak detectors, instead monitor pressure decay. Over-exposing the
transducer to leak detector fluid may damage the unit.)
Figure 2-1 Piping Requirements for all 1/2-Inch Size Process Connections
IM-82 2-3

Chapter 2 Installation Series 820 Instruction Manual
Wiring the Transducer
Standard Top-Trak
rm
transducers require a 12 to 15 VDC power supply
(15 VDC nominal, 100 mA maximum). 24 VDC input power is
optional. Transducers are connected to the power supply through
either the dedicated DC power jack or through the 9-pin D-connector
located on the side of the enclosure. Before powering the unit, check
the transducer’s nameplate to confirm input power:
 PV1 = 12 to 15 VDC
 PV2 = 24 VDC
Note: operating a 24 VDC transducer at 12 to 15 VDC will result in unreliable
operation.
The transducer’s standard 0 to 5 VDC (4-20 mA optional) output sig- nal is
available through the D-connector. The mating connector is in- cluded with the
transducer. Connection details are given on the fol- lowing pages.
When the transducer is configured for a remote display, signal con-
nections are made via the 9-pin connector. Input power connections
are not included in the standard interface cable. Power connections
for the display and the transducer are shared when the connector is
wired for a remote display. Optionally the input power can be applied
at the power jack (either 12 volts (PV 1) or 24 volts (PV2). Remote
display mounting dimensions are given at the end of this chapter.
2-4 IM-82
Do not supply +DC powe
r
at the D-connector whil
e
using a power supply a
t
thepowerjack.Bothsup-
plies may be damaged.
Caution!
Operating a 12 VDC trans-
ducer at 24 VDC will cause
equipment damage.
Caution!

Series 820 Instruction Manual Chapter 2 Installation
Figure 2-2. Transducer D-Connector Pin Assignments
Note:Thepowerjackrequires aplugthathasa2.5mminnerdiameteranda 5mmouter
diameter. The center is positive (+).
IM-82 2-5

Chapter 2 Installation Series 820 Instruction Manual
Standard 0-5 VDC Output Signal Wiring
The standard 0-5 VDC output signal flows from Pin 3 (0-5 VDC Out)
through the load (1K Ohm minimum) to Pin 7 (Power Common). The
figure below is a typical example of input power and output signal
connections.
Figure 2-3. Standard 0-5 VDC Output Signal Wiring
Optional 4-20 mA Output Signal Wiring
The optional 4-20 mA output signal flows from Pin 9 (4-20 mA Out)
through the load (50 to 500 Ohms maximum) to Pin 7 (Power Com-
mon). The figure below is a typical example of input power and output
signal connections. (Multiple transducer current loop output connec-
tions are given on the next page.)
Figure 2-4. Single Transducer Current Loop Connection
2-6 IM-82-E

Remote Display Installation
Mount the remote display at a convenient location within reach of the
supplied interface cable. The maximum cable length is 100 feet (30 m).
Figure 2-6. Mounting the Remote Display
Series 820 Instruction Manual Cha
p
ter 2 Installation
Fi
g
ure
2
-5. Multi
p
le Transducer Current Loo
p
Connection
s
IM-82 2-7

Series 820 Instruction Manual Chapter 3 Operation
Chapter 3 Operation
The output signal of the transducer is either 0-5 VDC (standard) or
4-20 mA (optional). The output signal is linear and proportional to
the gas mass flow rate. For example, for a 0-5 VDC output signal,
5.00 VDC is the output signal for the full scale listed on the trans-
ducer’s nameplate, 2.50 VDC is for one-half of full scale, and 0.00
VDC is for zero flow. For a 4-20 mA output signal, 20.00 mA is
the output signal for the full scale, 12.00 mA is for one-half of full
scale, and 4.00 mA is for zero flow.
Transducer Operation
When the transducer is installed and the system has undergone a
complete leak check:
1. Apply power. The output signal will be at a high level for the
first 10 to 20 seconds while the sensor warms up to its normal
operating temperature range. Assuming zero flow, the output
signal will then drop to zero (or 4 mA, depending on output
configuration). Allow at least thirty minutes of warm-up time.
2. For first-time start ups, perform an initial zero output check as
described on page 3-3. After checking the initial zero setting,
the transducer is ready to monitor the gas mass flow rate.
Transducer Accuracy
The standard accuracy of Top-Trak is ±1.5% of full scale. The
±1.5% of full scale accuracy means that the 0-5 VDC output sig-
nal is accurate to within ±.075 VDC. The 4-20 mA output is ac-
curate to within ±0.24 mA.
For example, the output signal for zero flow can be as much as
±.075 VDC or +0.24 mA. If the transducer has an output signal at
zero flow, as long as it is within either of these two ranges, it does
not mean it is malfunctioning.
For transducers with a digital display, the accuracy is simply .015
times the full scale flow rate stated on the nameplate. For exam-
ple, if the full scale is 10 slpm, the digital display will be accurate
to ±0.15 slpm. The reading at zero flow may be as much as +0.15
slpm and still be within the stated accuracy specification.
IM-82 3- 1

Chapter 3 Operation Series 820 Instruction Manual
Referencing the Transducer to Non-Standard Conditions
The gas flow rate output of your transducer is referenced to
“normal” conditions of 21 °C (70°F) and 760 mm of mercury (1
atmosphere) unless otherwise specified on the certificate of
calibration. Check the stated reference conditions of your transducer.
If you are comparing your transducer’s output with another type of flow
meter, different reference conditions could cause a discrepancy
between the flow readings.
For example, the output reading of a Top-Trak will be approximately
7% lower when referenced to 0°C rather than 21°C. To find the flow
rate referenced to other standard conditions or the actual temperature
and pressure conditions in the pipe where your transducer is located,
see Appendix A.
Transducer Over-Ranging
If the flow rate exceeds the full scale value listed on the transducer
nameplate, the output signal and digital display (if so equipped)
will read a higher value. The transducer is not calibrated for over-
ranged flows and will probably be both non-linear and inaccurate.
Over-range conditions are indicated by the display and/or output
signal going to a level above the full scale range. When the over-
range condition is removed, it may take several seconds for the
transducer to recover and resume normal operation.
If the supply voltage is only 12 VDC, the over-ranged reading may
exceed the full scale value by 10% maximum. If the supply voltage
is higher, as with the 24 VDC option, then the output can exceed
the full scale by as much as 50%, or more. Digital displays cannot
exceed 3-1/2 digits (1999). If the flow rate exceeds 1999, the right-
most digits will blank and only the left-hand “1” will appear on the
display.
3-2 IM-82