Vogtlin SmartTrak 100 Series User manual

SmartTrak® Serie 100
Massflowmeasurement
Models: C100, M100, C100 HP, M100 HP, C101, M101, C140
Manual
IM-100, Revision: H.2
Februar 2014
Vögtlin Instruments GmbH –flowtechnology
Langenhagstrasse 1 | 4147 Aesch(Switzerland)
Tel. [phone] | Fax [phone]

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Global Support
Worldwide with exception of China:
Vögtlin Instruments GmbH Phone [phone]
gas flow technology Fax [phone]
Langenhagstrasse 1
CH-4147 Aesch BL [email protected]
Switzerland www.vogtlin.com
China:
KEM flow technology (Beijing) Co., Ltd. Phone [phone]
Rm. 906, Block C, Ruipu Office Bldg, Fax [phone]
No. 15, HongJunYingNan Road,
Chaoyang District, Beijing 100012 [e-mail]
China www.voegtlin.cn
IMPORTANT CUSTOMER NOTICE: OXYGEN SERVICE
Vögtlin Instruments GmbH is not liable for any damage or personal injury, whatsoever, resulting from the use of
Vögtlin 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 VÖGTLIN INSTRUMENTS 2019
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 Vögtlin Instruments. The information
contained in this manual is subject to change without notice.
TRADEMARKS
SmartTrak® 100 Series and Dial-A-Gas® is a Registered Trademark of Vögtlin Instruments, GmbH Other product and
company names listed in this manual are trademarks or trade names of their respective manufacturers.

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Table of Contents
Chapter 1: Introduction .............................................................................................5
Welcome to the future of gas flow measurement!..................................................................5
Using This Manual.................................................................................................................5
Safety Information..................................................................................................................6
Receipt of your instrument.....................................................................................................7
The SmartTrak Flow Sensing Principle .................................................................................9
Chapter 2: Installation ..............................................................................................11
Before You Begin Installation..............................................................................................11
Pre-Installation Check List...................................................................................................12
Installing the Instrument—Plumbing...................................................................................13
Compression Fittings............................................................................................................13
VCO Fittings ........................................................................................................................14
VCR Fittings.........................................................................................................................14
1/4 Inch Female NPT ...........................................................................................................14
Installing your Instrument—Mechanical Mounting.............................................................15
Installing your Instrument—Electrical Connections............................................................15
Figure 2-3: HD DB-15 Connector Pin Configuration (onthe instrument)...........................17
Figure 2-4: Wiring Definitions for Optional Communication Cable...................................17
Figure 2-5: Power Supply Requirements .............................................................................18
Chapter 3: Analog Operation ...................................................................................21
Analog Operation, Mass Flow Controller............................................................................22
SmartTrak Features ..............................................................................................................23
Setpoint Adjustment.............................................................................................................23
Changing the Output or Setpoint Signals.............................................................................23
Over-Range Condition .........................................................................................................23
Manual Valve Override—Valve Close ................................................................................23
Manual Valve Override—Valve Purge Function.................................................................24
Important Notes About Purging...........................................................................................24
Purging Non-Reactive Gases ...............................................................................................24
Purging Reactive Gases........................................................................................................24
Chapter 4: Digital Operation with Pilot Module ......................................................26
Introduction to Pilot Module Features and Capabilities.......................................................26
Pilot Module Operation, Mass Flow Meters........................................................................29
Pilot Module Operation, Mass Flow Controllers .................................................................30
Making Changes Using the Lower Level Screens ............................................................................. 37

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Lost Passwords and General Customer Service ............................................................................... 47
Chapter 5: Digital Operation RS-232 & SmartTrak Software..................................47
Power Up Your Instrument ..................................................................................................47
Power Up Your Computer....................................................................................................50
Loading the SmartTrak Software.........................................................................................50
Connecting SmartTrak to Your Computer...........................................................................51
If your computer has a serial port.........................................................................................50
If your computer has no serial port, but has a USB port......................................................51
If you plan to control more than one SmartTrak instrument from your computer...............52
Running The SmartTrak Software .......................................................................................53
Chapter 6: Technical Support & Service.................................................................68
FactoryCalibration—All Models.........................................................................................69
Instructions for Returning Your Instrument for Service......................................................69
Appendix A: C100 & M100 SmartTrak® Product Specs, Dimensions and Mounting
Appendix B: C101 & M101 Ultra-Low Flow Product Specs, Dimensions andMounting
Appendix C: C140M Ultra-Low ΔP Product Specs, Dimensions and Mounting
Appendix D: 100HP Ultra-High Pressure Product Specs, Dimensions andMounting
Appendix E: High Pressure Safety Guide for the 100HP
Appendix F: Gas Tables & K-Factors (ALL 100Series)
Appendix G: Flow Chart for Pilot Module User Interface (ALL 100Series)
Appendix H: PIN Configuration (ALL 100 Series)
Appendix I: SmartTrak Basic Commands (ALL 100Series)
Appendix J: Warranty Policy

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CHAPTER 1: INTRODUCTION
Welcome to the future of gas flow measurement!
This manual is your guide to SmartTrak. Visit the Vögtlin Instruments website
www.vogtlin.com any time for more information about this product.
The SmartTrak 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 whilemaintaining
accuracy.
The Optional Pilot Module: control electronics that offers both display andcontrol
options at the user’s fingertips.
Digital Electronics: maximum performance with minimum noise plusexceptional
tuning capability.
Choice of Analog Communications Options and RS-232 with every SmartTrak
instrument.
Flexible Design with many functions that can be re-configured on-site by the user.
Compact Footprint that allows SmartTrak to fit almost anywhere.
Wide range of sizes for gas flow from 0.1 mln/min to 1000 ln/min.
And many more
Using This Manual
This manual is organized into six chapters:
Chapter 1: Introduction and Theory ofOperation.
Chapter 2: Installation, Plumbing & Wiring instructions.
Chapter 3: Analog Operation.
Chapter 4: Digital Operation with the Optional PilotModule.
Chapter 5: Digital Operation with RS-232 & SmartTrakSoftware.
Chapter 6: Technical Support and Service.
Appendix A,B,C,D,E,F,G,H,I,J
Throughout this manual, we use the word instrument as a generic term to represent all
models of Vögtlin Instruments’ SmartTrak Series 100 mass flow meters and
controllers.

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SAFETY INFORMATION
Caution and warning statements are used throughout this book to draw your attention to
important information.
Warning!
This statement appears with information that is important to
protect people and equipment from damage. Pay very close
attention to all warnings that apply to your application.
Caution!
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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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 (as ordered). 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 one of Vögtlin’s Technical Support Centers:
Worldwide with exception of China:
Vögtlin Instruments GmbH Phone [phone]
gas flow technology Fax [phone]
Langenhagstrasse 1
CH-4147 Aesch BL [email protected]
Switzerland www.vogtlin.com
China:
KEM flow technology (Beijing) Co., Ltd. Phone [phone]
Rm. 906, Block C, Ruipu Office Bldg, Fax [phone]
No. 15, HongJunYingNan Road,
Chaoyang District, Beijing 100012 [e-mail]
China www.voegtlin.cn

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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 SmartTrak 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.

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THE CAPILLARY THERMAL OPERATING PRINCIPLE
The operating principle of the SmartTrak instruments isbased 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, and 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 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 SmartTrak microprocessor. From this, SmartTrak 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 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 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 1-4). As a result, the measured flow through the sensor tube is directly proportional
to the gas flow in the main body.
Figure 1-4. Linear Range of the Transducer’s Output Signal

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In the SmartTrak 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 (set point). The result is excellent resolution.
CHAPTER 2 INSTALLATION
Warning!
Before You Begin Installation
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 sample Data Labels in Figure: 2-
1). This is critical because each instrument is configured for a specific application range.
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 35 barg except for SmartTrak100 High Pressure version instruments (refer to
Injury can result if line
pressure exceeds the
maximum rating of
35 barg. for standard
SmartTrak 100.
Warning!
If installing a
SmartTrak 100 HP,
read Appendix E:
SmartTrak 100 High
Pressure Version
Safe Use before
installing instrument.
Warning!
Injury can result if line
pressure exceeds the
maximum rating of
345 barg when using
the SmartTrak 100
High Pressure.
Appendix D). The temperature should not exceed 50°C. The minimum operating
temperature is 0°C and ambient temperature is 0-50°C. If your application exceeds any of
these parameters, contact your Vögtlin Sales Agent before installation. You may also
contact one of Vögtlin’s Technical Support Centers.
Figure 2-1: Examples of SmartTrak Data Label

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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
SmartTrak can be found in the Data Label. See Appendix A for a table of elastomer
compatibility with a wide variety ofgases.
2. Vögtlin strongly recommends you install an in-line filter upstream of the
instrument. Recommended filter size: 10 micron. A 10 micron filter is available
from Vögtlin as an accessory. See Appendix B or contact your local Vögtlin
distributor.
3. Do not locate the instrument in areas subject to sudden temperaturechanges,
excessive moisture or near equipment radiating 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 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. If restricted, controller will not reach full scale.
5. Output Signals: The SmartTrak has two analog outputs that are linearly
proportional to the gas mass flow rate, one voltage and one current. Choose from 0-
20 mA or 0/0/4-20 mA for current plus one voltage signal: 0-5 VDC or 0-10 VDC
or 1-5 VDC. The output signals specified at time of order will be indicated on the
data label. You may change among the current and the voltage output signal at
your discretion after receipt of the instrument using the Pilot Module or the
SmartTrak Software (see Chapters 4 & 5). Changing the output signals has no
influence on the instrument’s accuracy.
NOTE: For the SmarTrak 100 plus Compod, the 0-5 VDC I/O cannot be used. Only
0/4-20 mA I/O is available.
6. The CAT-5 connector on the side of the SmartTrak 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. Keep this connector covered if possible whenever it is
not in use.

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7. The instrument has specific power supply requirements. See the table later in
this chapter for a complete listing of power requirements.
Installing the Instrument—Plumbing
SmartTrak instruments are supplied with compression, VCO®, VCR®, or female NPT
process connections. To ensure a successful installation, inlet and outlet tubing should be
clean 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. It is not a
requirement to leak test your instrument. Do not use liquid leak detectors such as
Snoop® to search for leaks inside or outside the SmartTrak. 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. 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.
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)
5. Check the system’s entire flow path thoroughly for leaks. Do not use liquid leak
detectors. Instead, monitor pressure decay. Exposing the instrument to leak
detector fluid may cause damage.

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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. Exposing the instrument to leak
detector fluid may cause damage.
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. Exposing the instrument to leak
detector fluid may cause damage.
1/4 Inch Female NPT
1. Position the instrument with the flow direction arrow pointing the direction of
flow.
2. Apply high quality Teflon tape to the maleNPT fitting. Alternatively, use a high
quality paste pipe thread sealant suitable for the application and gas, and applythis
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. Do not use liquid leak
detectors. Instead, monitor pressure decay. Exposing the instrument to leak
detector fluid may cause damage.

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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 A.
Your SmartTrak instrument is made from premium 316 stainless steel. As a result, it may
require substantial mounting brackets to properly support its weight. Exercise caution when
installing to avoid damage or injury.
Mounting the Optional Remote Pilot Module
If you have the optional Remote Pilot Module control unit, you have several 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 screwthe
shoulder screws into the plate. Then, attach the plate to the wall by driving 2
screws (not included) 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 PilotModule.
2. Rack mounting—to mount your Remote Pilot Module to a standard 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 cable 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.
Installing your Instrument—Electrical Connections
All electrical connections for your SmartTrak instrument are made on the left (inlet) side
panel. See Figure 2-2: SmartTrak Connections below for the location of all connections.
Note that the CAT-5 connector is not an ethernet connector.

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Figure 2-2: SmartTrak connections
SmartTrak is provided with a high density 15-pin D Connector called an “HD DB-15”
located on the side of the enclosure and either one of our optional pre-assembled
communications cables or an empty mating connector. Power must be supplied to the HD
CAT 5
HD DB 15

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DB-15 connector. Other features may be accessed there as well. The pin numbers and
assignments for the HD DB-15 connector are shown in Figure 2-3: HD DB-15 Connector
Pin Configuration (on the instrument). The corresponding colors of the optional
communication cable wires and the functions of each are listed in Figure 2-4: Wiring
Definitions for Optional Communication Cable. The connections for input power, analog

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output signal and analog input signal (controllers only) are all made at the HD DB-15
connector. There is a second copy of these 2 figures in Appendix D for your convenience
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/Output
2.
Red
0-5 VDC Output (or 0-10, 1-5 VDC)
3.
Orange
Analog Ground/RS232
4.
Pink
Valve Override Purge
5.
Yellow
Power Return (-)
6.
Green
Power Input (+)
7.
Green/White
RS-232 Transmit (out)
8.
Blue
Setpoint
9.
Purple
Not Used
10.
Gray
Analog Ground/Setpoint
11.
White
Reference Voltage
(5 VDC External Setpoint & Valve Purge)
12.
Black
Valve Override Close
13.
Brown/white
RS-232 Receive (in)
14.
Red/white
0/4-20 mA Output
15.
Red/Black
Not Used
Shield Wire
(no insulation)
Chassis (Earth) Ground

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NOTE: Pins 1, 3, and 10 are connected
together inside the instrument. Do not tie these
grounds together outside the instrument. Must
have one connection per analog ground.
Recommended use listed.
Instrument Power:
The SmartTrak requires a 15-24 VDC power supply. If you are using the power supply
supplied by Vögtlin, 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 15-24 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.
Instrument Grounding:
The SmartTrak has very high levels of RFI and EMI shielding built into the metal electronics
cover (meets or exceeds the CE Standard EN 61326-1; 2006). To maintain the integrity of
this CE rating, it is critical that a path be provided for any residual internal noise to exit the
instrument or it may register on the outputs. Grounding provides this path.
To properly ground your instrument, secure the chassis to solid earth ground using the
mounting holes on the bottom of the flow body. If the instrument will be used without
permanent mounting (on a laboratory bench, for instance) then, using the provided cable,
connect the shield wire (no insulation) to earth ground in your facility. If you purchased a
Vögtlin power supply, a ground wire is provided for your convenience.
Figure 2-5: Power Supply Requirements
Instrument Type
Recommended Input
Voltage
Minimum Current
Required (mA)
M100L Meter
15-24 VDC (+ 10%)
230
M100M Meter
15-24 VDC (+ 10%)
230
M100H Meter
15-24 VDC (+ 10%)
230
C100L Controller
24 + 10% VDC
500
C100M Controller
24 + 10% VDC
800
C100H Controller
24 + 10% VDC
1260
NOTE: The Compod™ adds an additional 100mA to the ST2 current ratings.

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CAUTION: This instrument is not a loop-powered
device! Do NOT apply power to the 0/4-20 mA output
or input connections.
Analog Output Signals:
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. We recommend pin 1. DO NOT USE THE SAME ANALOG GROUND
FOR CURRENT OUTPUT, SETPOINT OR RS232.
Output Signal—Current: Measure the current output signal, 0/4-20 mA or 0-20 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. We recommend pin 1. DO NOT USE THE SAMEANALOG
GROUND FOR VOLTAGE OUTPUT, SETPOINT OR RS232.
For Mass Flow Controllers, the following analog features are also available
at the HD DB-15 connector:
Setpoint: To transmit an analog setpoint, supply the voltage or current signal (check the data
label and/or setting) across the blue (pin 8) wire and pin 10.
Valve Close: To force the valve closed, connect the black (pin 12) wire to pin 10
Purge: To force the valve to its maximum open position which we call “Purge,” connect the
pink (pin 4) wire to the white (pin 11) wire. Note that this will allow much greater flow than
the rated full-scale value.
For Digital Communication Using Your Personal Computer:
You can communicate with your instrument using the SmartTrak Software package and your PC
running the Windows operating system. Simply connect the light green (pin 7) wire, the
brown/white stripe (pin 13) wire and one of the analog grounds (pin 1,3, or 10) to a standard DB-
9 connector according to Figure 2-6: Digital Communication.