Sierra Smart-Trak IM-100 Series, M100L-L-DD-LE-5-OV1-SV1-PV2-V4-S4, C100L-L-DD-LE-5-OV1-SV1-PV1C-V1-S1 Instruction Manual

Series 100 Instruction Manual Table of Contents

Smart-Trak® 100 Series

Mass Flow Meters & Controllers

Instruction Manual

IM-100-C 0-1

IM-100 Series

Rev. C.9, June 2010

Table of Contents Series 100 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

EUROPE HEADQUARTERS

Bijlmansweid 2 1934RE Egmond aan den Hoef
The Netherlands
Phone [phone] Fax [phone]

ASIA HEADQUARTERS

Rm. 618, Tomson Centre, Bldg A, 188 Zhang Yang Road
Pu Dong New District, Shanghai, P.R. China
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 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 2010

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

Smart-Trak
product and company names listed in this manual are trademarks or trade names of their respective manu-

facturers.

®

100 Series and Dial-A-Gas™ is a Registered Trademark of Sierra Instruments, Inc. Other

0-2 IM-100-C

Series 100 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

Definitions Used in This Manual ............................................................ 1-3

The Smart-Trak Flow Sensing Principle ................................................ 1-4

Chapter 2 Installation

Before You Begin Installation ................................................................ 2-1

Smart-Trak Data Labels .......................................................................... 2-1

Pre-Installation Checklist ........................................................................ 2-2

Installing the Instrument-Plumbing ........................................................ 2-3

Compression Fittings ............................................................ 2-3

VCO Fittings ......................................................................... 2-4

VCR Fittings ......................................................................... 2-4

1/4-inch Female NPT Fittings ............................................... 2-4

Installing the Instrument-Mechanical Mounting .................................... 2-5

Installing the Instrument-Electrical Connections ................................... 2-6

D-connector PIN assignments .............................................. 2-7

Power Supply Requirements ................................................. 2-8

RS-232 Wiring ...................................................................... 2-9

Chapter 3 Analog Operation

Introduction ............................................................................................. 3-1

Analog Operation, Mass Flow Meters .................................................... 3-2

Analog Operation, Mass Flow Controllers ............................................. 3-2

Smart-Trak Features ............................................................................... 3-3

Setpoint Adjustment ............................................................. 3-3

Changing the Output or Setpoint Signals ............................. 3-3

Over-Range Condition .......................................................... 3-3

Manual Valve Override-Valve Close ................................... 3-4

Manual Valve Override-Valve Purge ................................... 3-4

Chapter 4 Pilot Module Operation

Introduction to the Pilot Module ............................................................. 4-1

Pilot Module Features and Capabilities .................................................. 4-2

Mass Flow Meters ................................................................................... 4-3

Mass Flow Controllers ............................................................................ 4-4

Pilot Module Menus and User Interface ................................................. 4-5

IM-100-C 0-3

Table of Contents Series 100 Instruction Manual

Map of the User Interface ....................................................................... 4-7

Upper Screens (Display) ............................................................. 4-8

Mass Flow Screen ................................................................. 4-8

Setpoint Screen ..................................................................... 4-8

Valve Position Screen ........................................................... 4-8

Full Scale Screen .................................................................. 4-9

Lower Level Screens (Changing Parameters) .......................... 4-10

Getting to the Lower Level Screens ................................... 4-10

Password ............................................................................. 4-10

Making Changes to the the Lower Level Screens .............. 4-12

Change Setpoint Value Screen ........................................... 4-12

Change Units Screen ........................................................... 4-14

Change Gas (Dial-A-GasTM) Screen ................................... 4-15

Change Valve Operation (Close, Purge) Screen ................. 4-16

Change Setpoint Source Screen .......................................... 4-18

Change Output Signals Screen ........................................... 4-19

Change Full Scale Screen ................................................... 4-20

Change Password Screen .................................................... 4-21

Lost Password ..................................................................... 4-23

Maintenance Functions ....................................................... 4-23

Chapter 5 RS-232 Operation with Smart-Trak Software

Introduction ................................................................................. 5-1

Summary of Smart-Trak Features ............................................... 5-2

Power Up Your Instrument ......................................................... 5-3

Power Up Your Computer .......................................................... 5-3

Loading the Smart-Trak Software .............................................. 5-4

Connecting Smart-Trak to your Computer ................................. 5-4

Running the Smart-Trak Software .............................................. 5-7

Using the Smart-Trak Software ................................................ 5-10

Upper Section of Software Window ......................................... 5-10

Password Section ...................................................................... 5-11

Lower Section of Software Window ......................................... 5-11

Change Setpoint Value ....................................................... 5-12

Change Valve Operation (Close, Purge) ............................. 5-12

Change Gas (Dial-A-Gas

Change Units ....................................................................... 5-13

Change Setpoint Source ...................................................... 5-13

Change Output Signal ......................................................... 5-14

Change Full Scale ............................................................... 5-14

Change Password (Lost Passwords) ................................... 5-15

Lost Password ..................................................................... 5-16

Other Useful Features ......................................................... 5-17

Comm Port .......................................................................... 5-17

TM

) ............................................... 5-13

0-4 IM-100-C

Series 100 Instruction Manual Table of Contents

Read Controller Parameters ................................................ 5-17

Chapter 6 Technical Support and Service

Technical Support...………………………………….…………..……6-1

Sierra Website ........................................................................ …6-2

Returning Equipment to the Factory………………….………..6-3

Appendix A Gas Tables

Pre-programmed gas list-Dial-A-Gas……………………………...…..A-1

K-Factor Calculations ……………………………………………...….A-1

Gas Tables with K-factors………………………………………..……A-2

Appendix B Product Specifications

Performance Specifications………………..………………… .B-1

Operating Specifications ………………………………………B-1

Physical Specifications …...…………..………………….……B-3

Optional Accessories……..………………..…………………..B-4

Appendix C Flow Chart for Pilot Module User Interface

Appendix D HD DB-15 PIN Configuration

Appendix E Dimensions and Mounting

Appendix F Micro-Trak Installation and Operation

IM-100-C 0-5

Series 100 Instruction Manual Chapter 1: Introduction

CHAPTER 1: INTRODUCTION

Welcome to the future of gas flow measurement!

The Sierra Instruments’ Smart-Trak Series 100 is an innovation from Sierra, a
company that has designed and manufactured gas mass flow measurement in­struments since the early 1970’s. This manual is your guide to Smart-Trak. Vis-

it the Sierra Instruments website www.sierrainstruments.com any time for

more information about this product.

The Smart-Trak instruments offer a variety of features for ease of operation.
Among these features:

9 Dial-A-Gas: allows a user to change from among 10 gases while maintaining

accuracy.

9 The Optional Pilot Module: control electronics that offers both display and

control options at the user’s fingertips.

9 Digital Electronics: maximum performance with minimum noise plus ex-

ceptional tuning capability.

9 Choice of 4 Analog Communications Options and RS-232 with every

Smart-Trak instrument.

9 Flexible Design with many functions that can be re-configured on-site by the

user.

9 Compact Footprint that allows Smart-Trak to fit almost anywhere.
9 Wide range of sizes for gas flow from 0.1 sccm to 1000 slpm.
9 And many more…visit www.sierrasmarttrak.com

Using This Manual

This manual is organized into six chapters:

• Chapter 1: Introduction and Theory of Operation.

• Chapter 2: Installation, Plumbing & Wiring instructions.

• Chapter 3: Analog Operation.

• Chapter 4: Digital Operation with the Optional Pilot Module.

• Chapter 5: Digital Operation with RS-232 & Smart-Trak Software.

• Chapter 6: Technical Support and Service.

IM-100-C 1-1

Chapter 1: Introduction Series 100 Instruction Manual

There are also 6 Appendices:

• Appendix A: Smart-Trak Pre-Programmed gases, Conversion Formula and

Gas Tables.

• Appendix B: Product Specifications, useful Optional Parts & Accessories

• Appendix C: Flowchart for the Pilot Module.

• Appendix D: PIN Configuration of the mini-D connector

• Appendix E: Dimensional Drawings & Mounting Instructions

• Appendix F: Special Instructions for Installation and Operation of the Mi-

cro-Trak ultra-low flow instruments.

Throughout this manual, we use the word instrument as a generic term to
represent all models of Sierra Instruments’ Smart-Trak Series 100 mass flow

meters and controllers.

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.

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 Sierra’s Technical Support Centers:

1-2 IM-100-C

Series 100 Instruction Manual Chapter 1: Introduction

USA (Headquarters) Customer Service:

TOLL FREE: 800-866-0200

PHONE: [phone]
FAX: [phone]

EMAIL: [e-mail]

European Customer Service:

PHONE: [phone]
FAX: [phone]
EMAIL: [e-mail]

Asia Customer Service:

PHONE: + 8621 5879 8521
FAX: [phone]

EMAIL: www.sierra-asia.com

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
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 Smart-Trak 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
small fraction of the total flow to pass through the sensor capillary tube.

—The highest flow that an instrument will meter within its specified

—Laminar Flow Element (LFE) or bypass generates pressure drop forcing a

IM-100-C 1-3

Chapter 1: Introduction Series 100 Instruction Manual

THE SMART-TRAK FLOW SENSING PRINCIPLE

The operating principle of the Smart-Trak instruments 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 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
(m

).

1

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 Smart-Trak microprocessor.
From this, Smart-Trak calculates the output signal. Since the molecules of the
gas carry away the heat, the output signal is linearly proportional to gas mass
flow.

Figure 1-2. Flow Measuring Principle

1-4 IM-100-C

Series 100 Instruction Manual Chapter 1: Introduction

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

In the Smart-Trak mass flow controllers, the gas which flows through the moni-

toring 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.

IM-100-C 1-5

Series 100 Instruction Manual Chapter 2: Installation

CHAPTER 2 INSTALLATION

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 La-

Warning!

Injury can result if line
pressure exceeds the

maximum rating of

500 psig (34 barg).

Figure 2-1: Examples of Smart-Trak Data Labels

bel. 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 500 psig (34 barg). The temperature
should not exceed 122°F (50°C). The minimum operating temperature is
32°F (0°C) and ambient temperature is 0-50°C. If your application exceeds
any of these parameters, contact your Sierra Sales Agent before installa­tion. You may also contact one of Sierra’s Technical Support Centers.
FACTORY USA: TOLL FREE: 800-866-0200 or PHONE: [phone]
or FAX: [phone] or EMAIL: [e-mail]

IM-100-C 2-1

Chapter 2: Installation Series 100 Instruction Manual

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 Smart-Trak can be found in the Data
Label. See Appendix A for a table of elastomer compatibility with
a wide variety of gases.

2. Sierra strongly recommends you install an in-line filter up-

stream of the instrument. Recommended filter size: 10 micron.

A 10 micron filter is available from Sierra as an accessory. See
Appendix B or contact your local Sierra distributor.

3. Do not locate the instrument in areas subject to sudden tem-

perature changes, 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.

5. Output Signals: The Smart-Trak has two analog outputs that are

linearly proportional to the gas mass flow rate. These are a 4-20
mA signal plus your choice of one voltage signal: 0-5 VDC or 0­10 VDC or 1-5 VDC. The voltage signal specified at time of order
will be indicated on the data label. You may change between the
current and the voltage output signal at your discretion after receipt
of the instrument using the Pilot Module or the Smart-Trak Soft­ware (see Chapters 4 & 5). Changing the voltage output has no
fluence on the instrument’s accuracy.

6. The CAT-5 connector on the side of the Smart-Trak 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.

7. The instrument has specific power supply requirements. See

the table later in this chapter for a complete listing of power re­quirements.

in-

2-2 IM-100-C

Series 100 Instruction Manual Chapter 2: Installation

Installing the Instrument—Plumbing

Smart-Trak instruments are supplied with compression, VCO®, VCR®, or
female NPT process connections. To ensure a successful installation, inlet
and outlet tubing should be in a clean state 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 leak­tested 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 Smart-Trak. 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, tigh-

ten 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. Ex-

posing the instrument to leak detector fluid may cause damage.

IM-100-C 2-3

Chapter 2: Installation Series 100 Instruction Manual

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. Ex-

posing 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. Ex-

posing the instrument to leak detector fluid may cause damage.

1/4 Inch Female NPT

1. Position the transducer with the flow direction arrow pointing the

direction of flow.

2. Use a good quality Teflon tape. Apply to the male fittings. Alter-

natively, use a high quality paste pipe thread sealant suitable for
the application and gas and apply this 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. Ex-

posing the instrument to leak detector fluid may cause damage.

2-4 IM-100-C

Series 100 Instruction Manual Chapter 2: Installation

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 E.

Your Smart-Trak instrument is made from premium quality 316 stainless
steel. As a result, it may require mounting brackets to 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 screw the 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 Pilot Module.

2. Rack mounting—to mount your Remote Pilot Module to a stan-

dard 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.

IM-100-C 2-5

Chapter 2: Installation Series 100 Instruction Manual

Installing your Instrument—Electrical Connections

All electrical connections for your Smart-Trak instrument are
made on the left (inlet) side panel. See Figure 2-2: Smart-Trak

Connections below for the location of all connections. Note that
the CAT-5 connector is not an ethernet connector.

Figure 2-2: Smart-Trak connections

Smart-Trak is provided with a high density 15-pin D Connector called the
“HD DB-15” located on the side of the enclosure and either an empty mat­ing connector or an optional pre-assembled communications cable (speci­fied when ordering). See Appendix B to purchase pre-assembled commu­nications cables from Sierra. Power must be supplied to the HD 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 2­3: 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 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.

2-6 IM-100-C

Series 100 Instruction Manual Chapter 2: Installation

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

2. Red 0-5 VDC Output (or 0-10, 1-5 VDC)

3. Orange Analog Ground

4. Pink Valve Override Purge

5. Yellow Power Return (-)

6. Dark Green Power Input (+)

7. Light Green RS-232 Transmit (out)

8. Blue Setpoint

9. Purple Not Used

10. Gray Analog Ground

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 4-20 mA Output

15. Red/Black Chassis (Earth) Ground

Note: Pins 1, 3, 5, and 10 are connected together inside the
instrument. Sierra recommends individual wires.

IM-100-C 2-7

Chapter 2: Installation Series 100 Instruction Manual

For Basic Analog Installation of the Instrument:

• Instrument Power: The Smart-Trak requires a 15-24 VDC power supply.

If you are using the power supply supplied by Sierra, 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.

Figure 2-5: Power Supply Requirements

Instrument Type Recommended Input

Voltage

Minimum Current

Required (mA)

M100L Meter 15-24 VDC (+ 10%) 130

M100M Meter

M100H Meter

15-24 VDC (+
15-24 VDC (+

10%)
10%)

130
130

C100L Controller 24 + 10% VDC* 400

C100M Controller 24 + 10% VDC 700

C100H Controller 24 + 10% VDC 1260

*Note: A Smart-Trak C100L Mass Flow Controller may be powered

by less than 24 VDC if Sierra’s Multi-adapter is used (See Appendix B
for Parts and Accessories ordering information). For operation of a
C100L with 12-22 VDC, the minimum current required is 800 mA.

CAUTION: This instrument is not a loop-powered device! Do NOT apply
power to the 4-20 mA output or input connections.

• 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.

• Output Signal—Current: Measure the current output signal, 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.

2-8 IM-100-C

Series 100 Instruction Manual Chapter 2: Installation

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 any of the
analog grounds: pin 1, 3, or 10.

 Valve Close: To force the valve closed, connect the black (pin 12) wire to one

of the analog grounds.

 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 Smart-Trak 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.

Figure 2-6: Digital Communication

RS-232 Transmit (pin7) to DB-9 pin #2

RS-232 Receive (pin 13) to DB-9 pin #3

Analog ground (pin 1,3, or10) to DB-9 pin #5

With the connections in Figure 2-6 in place, plug the DB-9 connector into an
appropriate serial port on your PC.

If you are in an environment with high RF interference, it may be necessary to shield
these wires. In this case, use a metal DB-9 connector and connect one end of the
shield to the DB-9 shell and the other end to the outer shell of the Smart-Trak HD
DB-15 connector.

For your convenience, the RS-232 communication may also be accessed using the
mini-RCA jack located on the side of the instrument below the D-connector. Use
Sierra Instruments’ cable number “CRS.” This cable is included with your instru­ment. Additional cables may be purchased separately from Sierra or its agents.

CAUTION: The CAT-5 connector on the side of the Smart-Trak 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.

IM-100-C 2-9

Series 100 Instruction Manual Chapter 3 Analog Operation

CHAPTER 3: ANALOG OPERATION

Your Smart-Trak instrument may be operated in three different
ways:

This chapter will discuss the first of these—Analog Operation. Please see

subsequent chapters for other options.

Regardless of control options, the standard output for all Smart-Trak in­struments are two linear analog output signals corresponding to 0% to
100% of the mass flow full-scale range. Please note that one of these output
signals is always a current signal of 4-20 mA. The other is a user­configurable voltage signal of either 0-5 VDC, 0-10 VDC or 1-5 VDC.

For mass flow controllers, one input signal of 4-20 mA, 0-5 VDC, 0-10
VDC or 1-5 VDC (selectable by user) may be chosen to set the gas mass
flow rate to any desired value within the range of the device. This input
signal must be a direct linear representation of 0% to 100% of the desired
gas mass flow full-scale value. For the location of these signals on the HD
DB-15 connector, refer to Figure 2-4: Wiring Definitions for Optional

Communication Cable in Chapter 2 or Appendix D.

THREE CONTROL OPTIONS

A. Analog Input/Output Operation (This Chapter): Using analog in-

put/output signals at the 15-pin mini-D connector.

B. Digital Operation with Pilot Module (Chapter 4): Using the optional

Pilot Module.

C. Digital Operation with RS-232 and Smart-Trak Software (Chapter 5):

Using the RS-232 link, the supplied Smart-Trak Software package
and a PC-style computer running the Windows operating system.

IM-100-C 3-1

.

Chapter 3 Analog Operation Series 100 Instruction Manual

Analog Operation, Mass Flow Meter (see below for Controllers)

After your instrument is installed and the system has undergone a com­plete leak check as discussed in detail in Chapter 2, you are ready to
supply power.

Power Up Your Instrument: See Chapter 2, Figure 2-5: Power Supply

Requirements. Apply power using Sierra’s power supply or your own
power source. The green LED at the top of the left side will light to con­firm power. If your instrument has a Pilot Module, it will begin its start­up cycle. See Chapter 4 for details on Pilot Module operation. Let the in­strument warm up for at least 15 minutes for optimal performance.

Your Smart-Trak instrument is now ready for use!

Analog Operation, Mass Flow Controller

After your instrument is installed and the system has undergone a com­plete leak check as discussed in detail in Chapter 2, follow these steps:

1. The valve will remain closed until power is supplied. See Chap-

ter 2 for wiring instructions. Remember that the valve in the
Smart-Trak is not a positive shut-off device. When power is ap­plied, the flow control valve will operate per any instructions it
receives. When the Smart-Trak is delivered, the valve will be in
the Automatic (Normal) state and the Pilot Module or analog sig­nal will provide the correct zero setpoint reference for the instru­ment. As a result, the valve will be closed. However, upon subse­quent power-ups, the valve will return to the state it was in the last
time the instrument was operated.

CAUTION: If you do not know the value of the setpoint or the valve

state given to the Smart-Trak when it was last operated, you must as­sume that the valve will open when power is applied. Take necessary
precautions. You may use the Pilot Module or the Smart-Trak Soft­ware to check the setpoint or the valve state currently on your instru­ment. See Chapter 4 or Chapter 5 for information on Setpoint and
Valve State.

2. Power Up Your Instrument: See Chapter 2, Figure 2-5: Power

Supply Requirements. Apply power using Sierra’s power supply
or your own input power source. The green LED at the top of the
left side will light. If your instrument has a Pilot Module, it will

3-2 IM-100-C

Series 100 Instruction Manual Chapter 3 Analog Operation

begin its start-up cycle. See Chapter 4 for details on Pilot Module
operation.

3. Adjust the controller setpoint to the desired flow rate by sup-

plying an appropriate signal (mA or VDC). The effective control

range of the unit is 2% to 100% of the calibrated full scale flow
range. Automatic shut-off occurs at 1.9% of the factory full scale
calibrated range unless specifically modified at time of order.
Smart-Trak will immediately begin accurately monitoring and con­trolling the gas mass flow rate. Let the instrument warm up for at
least 15 minutes for optimal performance.

Your Smart-Trak instrument is now ready for use!

Smart-Trak Features

Caution!

Setpoint Adjustment

The setpoint (command) input signal you supply to Smart-Trak must be a
direct linear representation of 0% to 100% of the mass flow full-scale val­ue. Apply the setpoint signal from pin 8 to any of the analog grounds (see
Chapter 2 for wiring details). A setpoint value of 0 VDC (or 1 VDC or 4
mA) will regulate the flow to 0% and a setpoint value of 5.00 VDC (or 10
VDC or 20 mA) will adjust the flow to 100% of the instrument’s full scale
range.

When the setpoint (command) signal is applied, the flow controller will
reach the setpoint value within two seconds to within ±2% of the selected
flow rate.

CAUTION: DO NOT LEAVE A SETPOINT APPLIED FOR AN
EXTENDED PERIOD OF TIME TO A CONTROLLER WHEN THE GAS
SUPPLY IS SHUT OFF OR BLOCKED. Damage may result and the instru-

ment will become hot to the touch. Instead, see below for use of the “Valve
Close” feature which allows you to disable the valve while maintaining the
setpoint signal. This may be set by the Pilot Module, the Smart-Trak Software,
or an external analog signal.

Changing the Output or Setpoint Signals

To modify the analog output or setpoint signals (from 4-20mA to 0­10Vdc, for example), you must use the Pilot Module or the Smart-Trak
Software. The data label will indicate the form these signals had when the
instrument was last calibrated. We strongly recommend that you adapt the

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Chapter 3 Analog Operation Series 100 Instruction Manual

data label if the configuration is changed for future reference. See Chapter
4 or 5 for the necessary procedure. Remember that the Smart-Trak will
always output a current signal of 4-20mA. The other output signal and the
setpoint signal may be changed using this procedure.

Over-Range Condition

If the mass flow rate exceeds the full-scale range listed on the Smart-Trak
data label (see samples of the data label in Chapter 2, page 2-1), the output
signal will measure above full-scale. However, the device has not been
calibrated for flows in excess of the calibrated full scale value and will be
both non-linear and inaccurate if an over-range condition exists. Please be
aware that the analog outputs can exceed full scale by as much as 20%, or
more.

Once the over-range condition has been removed, it may take up to 30
seconds for the Smart-Trak to recover and resume normal operation. An
over-range condition will not harm the instrument.

Manual Valve Override—Valve Close

Manual valve override is provided for all Sierra mass flow controllers.
This feature includes both a valve close command and a valve maximum
open command (called purge). When the valve is directed to close or to
purge, it will no longer respond to a setpoint command.

FOR VALVE CLOSE: connect pin 12 to analog ground

Remember that the valve in the Smart-Trak is not a positive shut-off device.

The Controller will return to normal automatic operation about 4 seconds after
pin 12 is left floating.

Manual Valve Override—Valve Purge Function

The purge function opens the controller valve completely for the purpose
of quickly flushing unwanted gas from the flow path. When the valve is
opened for purging, it allows flows far in excess of the rated full scale of
the controller.

FOR VALVE PURGE: connect pin 4 to pin 11.

IMPORTANT NOTES ABOUT PURGING

Purging Non-Reactive Gases:

Purge your Smart-Trak with clean, dry nitrogen for a minimum of
two hours.

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Series 100 Instruction Manual Chapter 3 Analog Operation

Purging Reactive Gases:

One of the following methods may be used:

 Cycle purge. This is done by alternately evacuating and

purging the instrument for 2 to 4 hours with clean, dry ni-

Caution!

Always fully neutralize

any toxic gas trapped in-

side the instrument before

removing it from the gas

line.

trogen.

 Purge the instrument with clean, dry nitrogen for 18 to 24

hours.

 Evacuate the instrument for 18 to 24 hours.

IMPORTANT SAFETY NOTES ABOUT PURGING

WARNING: When toxic or corrosive gases are used,
purge unit thoroughly with inert dry gas before dis­connecting from the gas line to prevent personnel
from being injured when coming in contact with the
instrument. Chapter 3 discusses how to purge your
instrument.

WARNING: If an instrument used with a toxic or cor­rosive gas is returned to the factory, a Material Safety
Data Sheet (MSDS) must be enclosed & attached to
the outside of the box to alert Sierra personnel of the
potential hazard. Also, make sure the inlet & outlet
are securely sealed.

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Series 100 Instruction Manual Chapter 4 Operation with Pilot Module

CHAPTER 4: Digital Operation with Pilot Module

Your Smart-Trak instrument may be operated in three different
ways:

This chapter will discuss the second of these—Digital Operation with the

optional Pilot Module. Please see alternate chapters for other options.

Although you have chosen to use the optional Pilot Module, please note
that all the Analog control functions are still available on your instrument.
Consult Chapter 3 for details on Analog operation. Also, computer control
using the RS-232 communication is available. See Chapter 5 for details on
operation with a computer.

THREE CONTROL OPTIONS

A. Analog Input/Output Operation (Chapter 3): Using analog

input/output signals at the HD DB-15 connector.

B. Digital Operation with Pilot Module (This Chapter): Using

the optional Pilot Module.

C. Digital Operation with RS-232 and Smart-Trak Software

(Chapter 5): Using the RS-232 Smart-Trak Software package and

a computer running the Windows operating system.

CAUTION—If RS-232 digital communication is to be used in conjunction with the

Pilot Module, the RCA mini-plug connection at the bottom of the inlet side of the in­strument must be used with the supplied CRS cable. Do NOT use the RS-232 con­nections on the mini-D connector when a Pilot Module (local or remote) is function­ing. DAMAGE TO THE INSTRUMENT CAN RESULT.

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