Sierra CalTrak XL User manual

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CalTrak®XL
High Accuracy High Flow
Primary Standard Gas Flow Calibrator
Up to 1500 slpm
Instruction Manual
Model: XL
PartNumber:IM-Cal-XLRev.I,7-17

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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
EUROPE HEADQUARTERS
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]
© COPYRIGHT SIERRA INSTRUMENTS 2017
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
CalTrak®, CalTrak™, CalSoft™, and SmartTrak®are trademarks 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 and Cautions
Note and Safety Information
We use caution and warning statements 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.
This statement appears with information that is
important for protecting your equipment and
performance. Read and follow all cautions that apply
to your application.
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Warning! All wiring procedures must be performed with the power off.
Warning! To avoid potential electric shock, follow National Electric Code safety practices or your local code when wiring this unit
to a power source and to peripheral devices. Failure to do so could result in injury or death. All AC power connections must be in
accordance with published CE directives.
Warning!
Before attempting any flow meter repair, verify that the line is de-pressurized.
Warning! Always remove main power before disassembling any part of the mass flow meter/controller.
Caution! Before making adjustments to the device, verify the flow meter/controller is not actively monitoring or reporting to any
master control system. Adjustments to the electronics will causedirect changes to flow control settings.
Caution! When using toxic or corrosive gases, purge the line with inert gas for a minimum of four hours at full gas flow
before installing the meter.
Caution! The AC wire insulation temperature rating must meet or exceed80°C (176°F).
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

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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
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TechnicalAssistance
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 information can be found in Chapter 2 of this manual.
If the problem persists after following the troubleshooting procedures outlined in this manual, contact Sierra
Instruments by fax or by E-mail
(see inside front cover). For urgent phone support you may call (800)
866-0200 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 + 86-21-
58798521.
When contacting Technical Support, make sure to include this information:
 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)

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Table of Contents
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Table of Contents............................................................................................................................5
Chapter 1: Introduction...................................................................................................................6
Chapter 2: Operating Your CalTrak XL..........................................................................................8
Chapter 3: Notes............................................................................................................................ 12
Chapter 4: Annual Maintenance and Calibration........................................................................14
Chapter 5: Product Specifications............................................................................................... 16
Chapter 6: CalSoft™Software.......................................................................................................19
Appendix A: Warranty Policy.........................................................................................................19

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Chapter 1: Introduction
Bring world class accuracy to your facility. Sierra’s CalTrak® XL is the leading high flow primary gas flow calibrator
on the market today. With increased demand for higher flows of process gas, there is a requirement to validate and
calibrate high flow gas meters and controllers. Designed to replace aging bell provers, the XL meets that need with an
impressive standardized accuracy of +/- 0.25% of reading over a flow range of 5 slpm to 500 slpm or +/- 0.45 % from
15 slpm to 1500 slpm.
The flow cell is fitted with low mass borosilicate glass pistons with a low friction coating that oscillate between two
detectors to quickly and accurately measure gas flow rates. The design of the CalTrak allows for increased flexibility
and speed of reading.
Flow measurements can be taken manually (one reading at a time), or automatically in continuous mode. CalTrak
calibrators offer digital communications via RS-232 and USB and come with our CalSoft™ data collection software
suite.
This manual will provide the information needed to operate your CalTrak XL. If at any time you have questions
regarding its operation, please contact Sierra through our web site (www.sierrainstruments.com) or call us at
800.866.0200 to speak with a member of our professional customer service staff.
In Your CalTrak XL Shipment
Your CalTrak XL is a laboratory primary standard, and has been shipped in Sierra’s rugged, reusable shipping con-
tainer.
The CalTrak XL weighs 90 lbs (41 kilograms). Unpacking by two people is recommended. The CalTrak XL can be
lifted from the shipping container by verifying the nuts on the large inlet and outlet fittings are tight and lifting the
CalTrak XL by grasping these fittings. While lifting the CalTrakXL from the shipping container, the top of the
CalTrak XL should be supported to prevent tipping.
Your CalTrak XL has been packaged with care and includes all components necessary for complete operation.
Please take a moment to check that you have received the following items. If you believe you have not received a
full shipment or if you have any questions, please contact Sierra immediately.
Your CalTrak XL comes with the following:
 AC Power Adapter
 PC Serial Cable (RS-232)
 Instruction Manual
 Calibration Certificate
 Reusable shipping container

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Warnings!
 The CalTrak XL is not intrinsically-safe and is not for use with explosive or
flammable gases, or for use in explosive environments. If you choose to calibrate
explosive or flammable gases with your CalTrakCalTrak XL, please follow your
organization’s laboratory safety procedures, which typically require operation within
an inert atmosphere. To enable use in an inert atmosphere, your CalTrak XL has
two (2) 1/4” gas Purge fittings, located on its right side, and its electronics are
isolated from the gas flow stream, contained within an internal, partitioned
compartment. The CalTrak 800 is not designed for gas flows above the rated
specifications of the flow cell in use. Please consult the product specification on the
inside front cover of the manual for more information regarding acceptable gas flow
ranges or visit our website at www.sierrainstruments.com for the most current
product specifications
 The CalTrak XL is not designed to be pressurized above 45 psiA (3102 mbarA) or
for gas flows above 1500 Lpm. If pressurization reaches 45 psiA (3102 mbarA), the
following warning will appear on the display on the main control panel:
OVERPRESSURE! If this occurs, remove the overpressure situation, then choose
“Reset” from the LCD display to clear this warning.
 The CalTrak XL does not contain user-serviceable parts and must be returned to
Sierra for maintenance.

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Chapter 2: Operating Your CalTrak XL
Connections
Your CalTrak XL should be placed on a steady, secure work surface. For optimum stability, the CalTrak XL has
self- adjusting feet at its base.
Locate both the Inlet (pressure) and Outlet (suction) fittings (see Figure 1) and remove their protective caps.
Maintain only minimum amount of tubing necessary between your CalTrak XL and the flow source. As with any
primary standard, the more internal (“dead”) volume between your CalTrak XL and the flow restrictor (MFC, needle
valve, or sonic nozzle), the more uncertainty (error) is added to the calibration process.
You’re now ready to make the following connections (as needed), using Figures 1 and 2 as reference.
Power
Plug your AC power adapter (supplied) into an AC wall outlet, and attach its DC output cord to your CalTrak XL’s
rear DC Power 12VDC, 3A connection.
Valve Actuation Air Source
Your CalTrak XL’s internal valve actuates by air pressure, and must be connected to a filtered oil free air source of at
least 80 psi (5516 mbar) and no higher than 100 psi (6895 mbar). Using tubing (not supplied) and the 1/4 inch
(6.35mm) Swagelok Valve Actuation Fitting on the rear of the unit, connect your laboratory air to your CalTrak XL.
Turn on the air source, and verify that the pressure is between 80 and 100 psi (5516 and 6895 mbar) (pressure gauge not
supplied).
Inlet (Pressure) and Outlet (Suction) Fittings
When using a pressure flow source, connect the gas flow to the 1.5 inch (38.1 mm) Swagelok®
fitting labeled Inlet – Pressure.
When using a suction flow source, connect the gas flow to the 1.5 inch (38.1 mm) Swagelok®
fitting labeled Outlet – Suction.
Your CalTrak XL’s internal pressure transducer is rated at 45 pisa (3102 mbara) maximum, or 5.3 psi (365 mbar)
more than typical ambient pressure. When taking standardized flow measurements, we recommend that any tubing
or exhaust system connected to your CalTrak XL’s outlet fitting have a maximum pressure drop of 3 psi (207 mbar).
When taking volumetric flow measurements, there should be no significant pressure difference (such as the pressure
drop of restrictive tubing or filters) between your CalTrak XL and the point in the flow stream that is of interest (i.e.,
at its inlet or outlet fitting). If there is a significant pressure difference, there will also be a corresponding volumetric
flow difference (from the Ideal Gas Law). In that case, your CalTrak XL’s indicated volumetric flow should be
adjusted by a factor of the absolute pressure at your CalTrak XL, divided by the absolute pressure at the point of
interest.

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Overpressure Exhaust
When your CalTrak XL completes a flow measurement, its internal valve opens, releasing the gas from the flow cell and
enabling the piston to drop to the bottom (reset). If for any reason the valve doesn’t open, the piston will move to the top
of the flow cell and a safety switch will automatically reset the CalTrak XL. If for any reason the valve doesn’t open, the
piston will remain at the top of the flow cell and pressure will build. To prevent over-pressurization of the flow cell, your
CalTrak XL’s has an overpressure sensor that will reset the unit. Additionally the CalTrak XL has a mechanical pressure
relief valve that exhausts the gas if over pressurization occurs through a 1/2-inch Swagelok® fitting (Overpressure
exhaust). If this fitting is currently open to ambient and you don’t want the gas to vent to atmosphere, you should connect
a direct line from this fitting to your exhaust system; or, if your CalTrak XL is already directly connected to your exhaust
system, you can “tee” a line from the Overpressure Exhaust fitting to your exhaust line.
Purge Fittings
Your CalTrak XL is not intrinsically-safe for use with explosive or flammable gases (see About Your CalTrak XL
– Warnings). If you choose to calibrate explosive or flammable gases with your CalTrak XL, please follow your
organization’s laboratory safety procedures, which typically require operation within an inert atmosphere. To
enable use in an inert atmosphere, your CalTrak XL has two (2) ¼-inch (6.25 mm) gas Purge fittings, located on
its right side, and its electronics are isolated from the gas flow stream, contained within an internal, partitioned
compartment.
Please note that electric current is still present within your CalTrak XL’s gas flow stream, at the pressure sensor
and temperature transducer.

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Getting Started
To turn on your CalTrak XL, press the On/Off button in the lower right corner of the control panel for one
second. To turn it off, press and hold the On/Off button for three seconds.
When turned on, your CalTrak XL’s LCD displays an opening screen indicating the product name, model number
and flow range, and its cooling fan will turn on.
Navigating through your CalTrak XL’s menu screens is easy and intuitive – simply use the four directional arrows on
the control panel for toggling between menu options (right, left, up, down). Your location within each menu or menu
item is highlighted (shaded). A menu item in angle brackets (< >) indicates that multiple options exist for that item;
these options are displayed when that item is selected. To select highlighted or bracketed items, press ENTER at the
center of the navigational display on the control panel.
When you’re ready, visit the SETUP menu and take some time to explore your CalTrak XL’s many user-definable
settings (see Setup).
Customizing Your Calibration
Your CalTrak XL’s calibrations may be customized and automated for your convenience. To customize each option,
move between menu selections using the up and down arrows. When a selection is highlighted, use the right and left
arrows to toggle between your choices for that selection. Press CONFIRM to save any changes and return to SETUP,
or press EXIT to return to SETUP without saving any changes.
Setup
From the initial screen, choosing SETUP gives you access to many customizable options. If at any time you’d like to
return your CalTrak XL to its factory default settings, navigate to Preferences, set Default Settings to “Yes” and then
Confirm the changes. In each setup sub-menu, selecting CONFIRM applies the settings and returns to the main setup
menu. Selecting EXIT returns to the main menu retaining the settings as they were originally.
Readings. Select Volumetric flow or Standardized flow (volumetric flow corrected to specified temperature and
pressure conditions, for calibrating instruments that read in mass flow, such as MFCs). Choose your preferred
number of measurements in the average, from 1 to 100. If you’d like a delay between flow measurements (i.e., in
order to time-profile MFCs to verify their long-term performance), set the “Time Between” from 1 to 60 minutes.
As applicable, change the Sensor Factor from its default value of 1.000 to the value provided by the MFC or
MFM manufacturer (see Using Sensor Factors).
Units. Depending on whether you’ve selected Volumetric or Standardized flow in the Readings menu, you may
view flow measurements in liters or cubic feet (all units are per minute). Choose to view pressure in mmHg, kPa or
psi, and choose to view temperature in Celsius or Fahrenheit. If you’re measuring standardized flow, enter the
temperature to which the gas flow volume will be standardized depending on the application. Pressure
standardization is not adjustable, and is always 101.325 kPa, 760 mmhg, or 14.696 PSI of absolute pressure.
Time: Set the current time in the format you prefer.
Date: Set the month/date/year in the format you prefer.
Preferences: Read Default offers a choice of Single, Continuous or Burst measurements; choose the type of flow
measurement you will normally use. Once selected, your CalTrak XL always defaults to this setting when Measure is
selected. Default Settings allows you to reset your CalTrak XL to the factory defaults. Magnification controls the