Sierra 820 User Manual
Series 820 Instruction Manual Table of Contents
Sierra 820 Series
Top-Trakª Mass Flow Meters
Instruction Manual
Part Number IM-82
Revision C 06-99
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-82-C 0-1
Table of Contents Series 820 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 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 SIERRA INSTRUMENTS 1994
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
Top-Trakª and Cal-Benchª 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-82-C
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 Transducer ..............................................2-2
Compression Fittings .............................................2-2
VCO Fittings .......................................................2-2
VCR Fittings .......................................................2-3
All 1/2-inch Size Connections....................................2-3
Wiring the Transducer.................................................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 Over-Ranging ........................................3-2
Zero and Span Adjustments ......................................3-3
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 Element............................................4-3
Flow Path Cleaning Model 826/827 .................................4-4
Laminar Flow Element............................................4-4
Flow Path Cleaning Model 822-S/824-S............................4-5
Laminar Flow Element............................................4-5
Sensor Cleaning and Inspection .................................4-8
Transducer Calibration ................................................4-9
Transducer Troubleshooting............ . . . . . . ...................... 4-11
Returning Equipment to the Factory ............................... 4-12
IM-82-C 0-3
Table of Contents Series 820 Instruction Manual
Appendix A Conversion Formulas and Gas Tables
Appendix B Production Specifications
List of Figures
1-1. Top-Trak Features (Typical)..................................1-3
1-2. Flow Paths through the Transducer..........................1-4
1-3. Flow Measuring Principle.....................................1-4
2-1. Piping 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 Display ................................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 ............. 4-10
0-4 IM-82-C
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 equipment damage.
Caution! Only qualified personnel should perform transducer service, calibration 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-C 0-5
Table of Contents Series 820 Instruction Manual
0-6 IM-82-C
Series 820 Instruction Manual Chapter 1 Introduction
Chapter 1 Introduction
This instruction manual covers the installation, operation and maintenance of SierraÕs 820 Series product line including the following
Top-Trakª 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)
SierraÕs Top-Trak
measurement of gas mass flow. The 820 Series offers a broad range
of sizes and process connections for flexibility and versatility. The
primary standard calibration ensures starting point accuracy and
NIST traceability. The meterÕs 0-5 VDC or 4-20 mA output signal is
provided for recording, data-logging or control. The optional 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 generic
term to represent all models of SierraÕs 820 Series Top-Trak
Mass Flow Meters.
ª
Mass Flow Meters are designed for precise
IM-82-C 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.
This statement appears with information that is
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 without
first contacting Sierra Customer Service.
Technical Assistance
If you encounter a problem with your transducer, review the configuration 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 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, 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-C
Series 820 Instruction Manual Chapter 1 Introduction
Top-Trak Features
Standard Top-Trak Mass Flow Meters require a 12 to 15 VDC external power source (24 VDC input power optional). The transducerÕs
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 additional 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)
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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 instrumentÕs flow body and divides into two
flow paths, one through the sensor tube, the other through the laminar flow element bypass. The laminar flow bypass generates a pressure drop, P1ÐP2, forcing a small fraction of the total flow to pass
through the sensor tube (m1).
Figure 1-2. Flow Paths through the 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 (DT) is
detected by the RTD coils and gives the output signal. Since the
molecules of the gas carry away the heat, the output signal is linearly
proportional to gas mass flow.
Figure 1-3. Flow Measuring Principle
1-4 IM-82-C
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 transducer 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 pa-
rameters recorded on the transducer’s nameplate. Each trans-
ducer 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 advisable 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 tempera-
ture changes, moisture, drafts or near equipment radiating sig-
nificant amounts of heat. Make sure to allow adequate space for
cable connectors and wiring.
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 always recommended. (not
necessary for other models)
4. Horizontal mounting is preferable. Vertical mounting is possible
with best results achieved when the factory calibration is specifi-
cally performed 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-C 2-1
Chapter 2 Installation Series 820 Instruction Manual
Caution!
Only qualified
personnel should install
the transducer.
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.
1. 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 manufacturers.)
2. Hold the body steady with a backup wrench. For 1/2-
inch size, tighten the nut 1-1/4 turns from finger tight. For 1/8inch, 1/4-inch and 3⁄8-inch sizes, tighten only 3/4 turn from finger tight. 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.
Over-exposing the transducer to leak detector fluid may damage
the unit.)
VCO and VCR Fittings
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 manufacturers.)
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. Overexposing the transducer to leak detector fluid may damage the unit.)
2-2 IM-82-C
Series 820 Instruction Manual Chapter 2 Installation
1/4 Inch Female NPT (standard on nylon flow bodies)
1. Position the transducer with the flow direction arrow pointing
downstream in the direction of flow.
2. Use a good quality paste pipe thread sealant.
Apply to the 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.
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.)
1/2-Inch Size NPT Connections (Models 826,827 only)
1. Install a section of straight pipe at least ten pipe diameters in length
upstream of the transducer. Also, allow at least five pipe diameters
downstream 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
downstream 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 liquid 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
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Chapter 2 Installation Series 820 Instruction Manual
Caution!
Do not supply +DC power
at the D-connector while
using a power supply at the
power jack. Both supplies
may be damaged.
Wiring the Transducer
Standard Top-Trak™ transducers require a 12 to 18 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 18 VDC
• PV2 = 24 VDC
Note: operating a 24 VDC transducer at 12 to 18 VDC will result in
unreliable operation.
Caution!
Operating a 12 VDC trans-
ducer at 24 VDC will cause
equipment damage.
The transducer’s standard 0 to 5 VDC (4-20 mA optional) output
signal is available through the D-connector. The mating connector is
included with the transducer. Connection details are given on the
following pages.
When the transducer is configured for a remote display, signal connections are made via the 9-pin connector. Input power connections
are not included in the standard interface cable. Remote display
mounting dimensions are given at the end of this chapter.
Figure 2-2. Transducer D-Connector Pin Assignments
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