Sierra 780S User Manual
Series 780S Instruction Manual Table of Contents
Sierra 780S Series Flat-Trak
Mass Flow Meter
Instruction Manual
Part Number IM-78S
07/99 Revision B
™
5 Harris Court, Building L Monterey, CA 93940
(831) 373-0200 (800) 866-0200 Fax (831) 373-4402
http://www.sierrainstruments.com
Sierra Instruments b.v. Bolstoen 30A 1046 AV Amsterdam The Netherlands
+31(0)20-6145810 Fax +31(0)20-6145815
IM-78S-B 0-1
Table of Contents Series 780S Instruction Manual
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 for oxygen
gas. You are responsible for determining if this mass flow meter is appropriate for
your oxygen application. You are responsible for cleaning the mass flow meter to
the degree required for your oxygen flow application.
© COPYRIGHT SIERRA INSTRUMENTS 1998
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
Flat-Trak™, Steel-Trak™ and Smart Interface™ software are trademarks of Sierra Instruments, Inc. Other product and company names listed in this manual are trademarks or
trade names of their respective manufacturers.
All Sierra products are Year 2000 compliant.
0-2 IM-78S-B
Series 780S Instruction Manual Table of Contents
Table of Contents
Chapter 1 Introduction
Series 780S Flat-Trak Mass Flow Meters ..........................1-1
Using this Manual.................................................1-1
Note and Safety Information.....................................1-2
Receipt of System Components .................................1-2
Technical Assistance..............................................1-2
The Series 780S Flow Sensing Principle...........................1-3
Smart Electronics Features............................................1-4
Enclosure Options .....................................................1-5
Smart Interface™ Software............................................1-5
Chapter 2 Installation and Wiring
Installation Overview..................................................2-1
Unobstructed Flow Requirements...............................2-2
Installing the Flow Meter .............................................2-2
Changing Display Orientation....................................2-3
Wiring Connections ...................................................2-4
Input Power Wiring...............................................2-5
Output Signal Wiring .............................................2-7
Alarm Output Wiring.............................................2-10
Remote Sensor Probe Wiring...................................2-11
Range Selection Wiring..........................................2-13
Chapter 3 Operating Instructions
Flow Meter Start Up...................................................3-1
Using the Smart Electronics Basic Features........................3-2
Hazardous-Area Enclosure Optional LCD Display............3-2
LCD Display Programming Menu...............................3-3
Single-Digit LED Programming Menu..........................3-4
Entering Alarm Parameters.......................................3-5
K-Factor Adjustment..............................................3-6
User Full Scale Adjustment......................................3-7
Time Response Delay Adjustment...............................3-8
Totalizer Reset.....................................................3-9
Using the Smart Electronics Advanced Features..................3-11
Voltage Zero Adjustment........................................3-11
Voltage Span Adjustment........................................3-11
Current Zero Adjustment........................................3-12
Current Span Adjustment........................................3-12
Instrument Validation.................................................3-13
Electronics Validation Procedure...............................3-14
Sensor Validation Procedure....................................3-15
IM-78S-B 0-3
Table of Contents Series 780S Instruction Manual
Chapter 4 Troubleshooting and Repair
Troubleshooting the Flow Meter.....................................4-1
Returning Equipment to the Factory.................................4-3
Appendix A Product Specifications
List of Figures
1-1. Series 780S Flow Sensing Principle .......................1-3
2-1. Flow Meter Orientation.......................................2-2
2-2. Wiring Access NEMA 4X Enclosures .....................2-4
2-3. Wiring Access Hazardous-Area Enclosures...............2-4
2-4. AC Input Power Connections...............................2-5
2-5. Ferrite Clamp Installation....................................2-5
2-6. DC Input Power Connections (NEMA 4X) ...............2-6
2-7. DC Input Power Connections (Hazardous-Area).........2-6
2-8. DC Output Signal Connections (NEMA 4X)..............2-7
2-9. DC Output Signal Connections (Hazardous-Area)........2-7
2-10. Load Resistance Versus Input Voltage.....................2-8
2-11. Isolated 4-20 mA Loop (NEMA 4X).......................2-9
2-12. Non-isolated 4-20 mA Loop (NEMA 4X).................2-9
2-13. Isolated 4-20 mA Loop (Hazardous-Area).................2-9
2-14. Non-isolated 4-20 mA Loop (Hazardous-Area)...........2-9
2-15. Isolated Alarm Connections (NEMA 4X).................2-10
2-16. Non-Isolated Alarm Connections (NEMA 4X) ..........2-10
2-17. Isolated Alarm Connections (Hazardous-Area) ..........2-11
2-18. Non-isolated Alarm Connections (Hazardous-Area) ....2-11
2-19. Remote Electronics to Sensor (NEMA 4X)...............2-12
2-20. J Box to Remote Enclosure (NEMA 4X).................2-12
2-21. Remote Electronics to Sensor (Hazardous-Area) ........2-12
2-22. J Box to Remote Enclosure (Hazardous-Area)...........2-13
2-23. Range Selection Wiring (NEMA 4X) .....................2-13
2-24. Range Selection Wiring (Hazardous-Area)...............2-13
3-1. Smart Electronics Device Locations ........................3-1
3-2. Magnetic Switch Operation..................................3-2
3-3. Electronics Validation Component Locations.............3-13
3-4. Sensor Validation Component Locations .................3-15
List of Tables
2-1. Pipe Length Requirements for Installation.................2-2
3-1. Electronics Validation Results..............................3-15
3-2. Sensor Validation Results...................................3-16
0-4 IM-78S-B
Series 780S Instruction Manual Table of Contents
Warnings and Cautions
Warning! Agency approval for hazardous location installations varies between flow
meter models. Consult the flow meter nameplate for specific flow meter approvals before any hazardous location installation.
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! Do not power the flow meter with the sensor jumper wires disconnected. This
could cause over-heating of the sensors and/or damage to the electronics.
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.
Caution! Changing the length of cables or interchanging sensors or sensor wiring
will affect the accuracy of the flow meter. You cannot add or subtract wire length without returning the meter to the factory for re-calibration.
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 exceed 71°C (158°F).
Caution! Before making adjustments to the Smart Electronics device, verify the flow meter
is not actively monitoring or reporting to any master control system. Adjustments to the
electronics will cause direct changes to flow control settings.
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-78S-B 0-5
Table of Contents Series 780S Instruction Manual
0-6 IM-78S-B
Series 780S Instruction Manual Chapter 1 Introduction
Chapter 1 Introduction
Series 780S Flat-Trak™ Mass Flow Meters
Sierra’s Series 780S Flat-Trak Mass Flow Meter provides a reliable
solution for monitoring gas mass flow rate. Low-flow sensitivity,
fast response and outstanding rangeability have made this model the
instrument of choice for many critical gas flow applications. The
Series 780S meter solves the problems associated with monitoring
flow in installations where long runs of straight pipe are not available. The instrument’s built-in flow conditioner creates a uniform
velocity profile by means of two stainless-steel perforated plates
welded into the body between the sensor and the inlet connection.
With flow conditioning, upstream piping requirements are reduced
to less than three diameters after most common flow disturbances.
The flow meter’s versatile microprocessor-based transmitter integrates
the functions of flow-range adjustment, meter validation and diagnostics in a probe-mounted or remotely mounted housing. Mass flow rate
and totalized flow, as well as other configuration variables are displayed on the meter’s optional LCD display. The meter provides an
optical/galvanic isolated flow output, two alarm outputs and one contact input for range or gas selection. The programmable transmitter is
easily configured via RS-232 and Sierra’s Smart Interface™ software
or through three push buttons built into the device.
The Series 780S Mass Flow Meter’s simple installation combines
with an easy-to-use interface that provides quick set up, long term
reliability and accurate mass flow measurement over a wide range of
flows and conditions.
Using This Manual
This manual provides the information you need to install and operate
the Series 780S Mass Flow Meter. The four chapters of this manual
cover the following areas:
• Chapter 1 includes the introduction and product description
• Chapter 2 provides installation and wiring instructions
• Chapter 3 describes system operation and programming
• Chapter 4 covers troubleshooting and repair
The product specifications are found in Appendix A.
IM-78S-B 1-1
Chapter 1 Introduction Series 780S Instruction Manual
Note and Safety Information
We use note, caution and warning statements throughout this book
to draw your attention to important information.
Warning! Caution! Note
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.
This statement appears with
a short message to alert you
to an important detail.
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. Remove the packing slip and check that all ordered components are present. Make sure any spare parts or accessories are not discarded with
the packing material. Do not return any equipment to the factory
without first contacting Sierra Customer Service.
Technical Assistance
If you encounter a problem with your flow meter, review the configuration information for each step of the installation, operation and
setup procedures. Verify that your settings and adjustments are consistent with factory recommendations. Refer to Chapter 4, Troubleshooting, for specific information and recommendations.
If the problem persists after following the troubleshooting procedures
outlined in Chapter 4, contact Sierra Instruments by fax or by E-mail
(see inside front cover). For urgent phone support you may call (800)
866-0200 or (831) 373-0200 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 and Sierra order
• the software version (visible at start up)
• the problem you are encountering and any corrective
• application information (gas, pressure, temperature
number (all marked on the meter nameplate)
action taken
and piping configuration)
1-2 IM-78S-B
Series 780S Instruction Manual Chapter 1 Introduction
The Series 780S Flow Sensing Principle
Sierra’s unique Steel-Trak™ sensor probe is responsible for the unsurpassed accuracy, ruggedness and reliability of Sierra industrial
flow meters. The immersible Steel-Trak sensor consists of two
sensing elements–a velocity sensor and a temperature sensor that
automatically corrects for changes in gas temperature.
When power is applied to the flow meter, the transducer electronics
heats the velocity sensor to a constant temperature differential above
the gas temperature and measures the cooling effect of the gas flow.
The electrical power required to maintain a constant temperature differential is directly proportional to the gas mass flow rate.
Both sensors are reference-grade platinum resistance temperature
detectors (RTDs). The platinum RTD wire is wound on a rugged ceramic mandrel for strength and stability. Steel-Trak sensors are clad
in a rugged, sealed 316 stainless steel encasement.
Figure 1-1. Series 780S Flow Sensing Principle
IM-78S-B 1-3
Chapter 1 Introduction Series 780S Instruction Manual
Smart Electronics Features
Instrument Validation
Two simple tests offer full “field-validation” of your Smart mass
flow meter. The first test checks the system electronics, linearization
and microprocessor functionality and is performed by injecting a
known input value and confirming that the flow meter outputs the
expected value. The second test verifies that the instrument’s primary sensing elements have not drifted or shifted from their original
calibration and is accomplished by measuring the resistance of the
velocity and temperature sensors and comparing the results to the
NIST-traceable calibration data provided with the flow meter. Together, these tests confirm that your meter is working correctly and
the calibration variables did not drift, shift or change values.
Dual Range or Dual Gas Calibration (Optional)
Select one of two factory calibrated flow ranges using a simple external customer-supplied single contact closure.
User Full Scale Flow Rate
Field-configure from 50% to 100% of the factory full scale setting
(factory full scale is normally set to 125% of the user-specified maximum flow rate). This adjustment can be made for each flow range.
Alarms
Program high and low or window alarm limits independently for
each flow range. The solid state contacts are optically isolated.
K-Factor Correction
Change the calibration correction factor to compensate for flow profile disturbances or specific application conditions. The K-factor is a
multiplication factor applied to the linearized flow signal. You may
set the K-factor individually for each flow range.
Dual Output Signals
The flow meter offers two separate linear output signals proportional to flow, 0-5 VDC (0-10 VDC optional) and 4-20 mA. The
4-20 mA output can be field-configured as an active loop powered
by the flow meter or an optically isolated passive loop requiring an
external power supply.
1-4 IM-78S-B
Series 780S Instruction Manual Chapter 1 Introduction
Totalizer
With the optional LCD display, actual mass flow appears on line 1
and the totalized flow on line 2 both in the user-specified engineering units. The totalizer counts only the selected range and when
ranges are switched, the value of the non-selected range is stored in
memory. You may reset the totalizer using the membrane buttons or
by using a hand-held magnet.
Zero and Span Outputs
Validate and adjust the settings to ensure output circuits are correct.
Time Response Delay
Select from a low response for faster tracking to a high response
for a smoother output.
Enclosure Options
Flow meter electronics are available mounted directly to the flow
body, or remotely mounted up to 200 feet away. The electronics
housing may be used indoors or out, including wet environments.
Display options include a 2 x 12 character LCD display of mass flow
rate including totalized mass, or a single-digit LED located on the device printed circuit board. Local operation and reconfiguration is accomplished using the three push buttons operated via finger touch.
Smart electronics include nonvolatile memory that stores all configuration information. The memory allows the flow meter to function
immediately upon power up, or after an interruption in power.
Smart Interface™ Software
Sierra’s Smart Interface Windows™-based software is available for
connecting your PC directly to the mass flow meter. An RS-232 serial cable along with floppy disks containing the program and system files are available from the factory. See the Smart Interface User
Guide included with the software package for operating instructions.
(Order code for this package is 780-SIP.)
IM-78S-B 1-5
Chapter 1 Introduction Series 780S Instruction Manual
1-6 IM-78S-B
Series 780S Instruction Manual Chapter 2 Installation
Warning!
Agency approval for hazardous
location installations varies
between flow meter models.
Consult the flow meter name-
plate for specific flow meter
approvals before any hazard-
ous location installation.
Chapter 2 Installation
Installation Overview
The Series 780S Flat-Trak™ is available with ANSI or DIN flanges,
NPT or butt-weld connections. For ease of installation, the meter is
pre-assembled with the sensor probe installed in the flow body.
When selecting an installation site, make sure that:
1. Line pressure and temperature will not exceed the flow meter
rating. Temperature should not vary more than 200°F (100°C)
around the calibration temperature. Line pressure should not
vary more than 50 psi (3.4 bar) around the calibrated pressure.
2. The location meets the required minimum number of pipe
diameters upstream and downstream of the sensor head (see
Table 2-1).
3. Safe and convenient access with adequate clearance. Also, verify
the meter is located where the gas is clean and dry and the meter
is calibrated for the gas to be measured.
4. When using a CSA, FM or EEx approved flow meter, verify that
the cable entry into the instrument meets the specific standard required for that approval.
5. For remote installations, verify the supplied cable length is suffi-
cient to connect the flow meter sensor to the remote electronics.
(Do not extend or shorten the supplied cable between the probe
and the electronics.)
Also, before installation check your flow system for anomalies
such as:
• leaks
• valves or restrictions in the flow path that could create dis-
turbances in the flow profile that might cause unexpected
flow rate indications
• heaters that might cause rapid excursions in the measured
temperature
IM-78S-B 2-1
Chapter 2 Installation Series 780S Instruction Manual
Unobstructed Flow Requirements
Select an installation site that will minimize possible distortion in the
flow profile. Valves, elbows, control valves and other piping components may cause flow disturbances. Check your specific piping condition against the examples shown below. To achieve accurate and repeatable performance, install the flow meter using the recommended
number of straight run pipe diameters upstream of the sensor.
Piping Condition Upstream
Single 90° elbow or T-piece 1 D
Reduction (4:1) 3 D
Expansion 3 D
After a control valve 3 D
Two 90° elbows (in same plane) 3 D
Two 90° elbows (different planes) 5 D
(1) Number of diameters (D) of straight pipe required between upstream disturbance and the flow meter sensor.
Table 2-1. Pipe Length Requirements for Installation
Installing the Flow Meter
Enclosure
adjustable to any
viewing position
FLOW
SIERRA
(1)
Requirements
Flow direction indicator
should point downstream
in the direction of flow
Figure 2-1. Flow Meter Orientation (Flange Connection Shown)
When positioning the flow meter, refer to the flow direction indicator
attached to the probe. For proper operation, install the meter with the
flow direction indicator pointing downstream in the direction of flow.
Installing the meter opposite this direction may result in inaccurate
flow measurement.
2-2 IM-78S-B
Series 780S Instruction Manual Chapter 2 Installation
To install the flow meter:
1. Turn off the flow of process gas. Verify that the line is not pres-
Caution!
When using toxic or cor-
rosive gases, purge the
line with inert gas for a
minimum of four hours at
full gas flow before in-
stalling the flow meter.
surized. Confirm that the installation site meets the minimum up-
stream pipe diameter requirements shown in Table 2-1.
2. Prepare the fluid connection fittings or flanges in the pipeline.
(Fitting components should be blown clean with filtered gas be-
fore use.) Mount in a vertical position. For horizontal pipelines
having a process gas temperature above 300° F (130°C), mount the
flow meter at a 90-degree angle to avoid overheating the electron-
ics enclosure.
3. Seat the flow meter level and square on the mating fluid connec-
tions with a gasket in place for each side for flange types. (Make
sure both gaskets are smooth and even with no gasket material
protruding into the flow profile; obstructions in the pipeline could
cause inaccurate flow measurement.) Make sure that the flow di-
rection indicator is pointing downstream in the direction of flow.
4. Secure the fluid connections as specified in the technical guidelines
furnished by the fitting or flange manufacturer.
5. If needed, adjust the optional display to the desired orientation,
as follows.
Changing Display Orientation (Hazardous-Area Enclosures Only)
Depending on installation requirements, you may need to change the
position of the optional display. To rotate the display board:
1. Use a 1/16-inch hex key to loosen the set screw securing the
larger end of the enclosure. Turn cover counterclockwise and
remove.
2. Remove 4 screws and standoffs from the display. Release the
latch securing the display ribbon cable connector from the dis-
play board.
3. Rotate the display board to the desired position. Re-connect the
ribbon cable to the display board.
4. Replace the 4 screws and standoffs. Replace the enclosure
cover. Tighten set screw.
IM-78S-B 2-3
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