FCI ST100A Series User manual

06EN003480 Rev. A ST100A Series Flow Meter

Fluid Components International LLC

Notice of Proprietary Rights

This document contains confidential technical data, including trade secrets and proprietary information which is the property of Fluid Components

International LLC (FCI). Disclosure of this data to you is expressly conditioned upon your assent that its use is limited to use within your company

only (and does not include manufacture or processing uses). Any other use is strictly prohibited without the prior written consent of FCI.

ST100A Series Flow Meter 06EN003480 Rev. A

Fluid Components International LLC iii

Table of Contents

Table of Contents......................................................................................................................................................................................iii

List of Figures ...........................................................................................................................................................................................v

List of Tables............................................................................................................................................................................................vii

Typographical Conventions ....................................................................................................................................................................viii

1GENERAL.........................................................................................................................................................................................1

Product Description...........................................................................................................................................................................1

Theory of Operation..........................................................................................................................................................................1

Safety Instructions.............................................................................................................................................................................1

Order Verification..............................................................................................................................................................................1

Technical Specifications....................................................................................................................................................................3

2INSTALLATION.................................................................................................................................................................................7

Specific Conditions of Use................................................................................................................................................................7

Instrument Identificationand Outline Dimensions.............................................................................................................................7

ST100A Insertion Sensor Installation................................................................................................................................................7

STP100A Flow Element Installation................................................................................................................................................14

ST102AA and ST112AA Flow Element Installation ........................................................................................................................14

ST100AL In-Line Process Connection............................................................................................................................................16

Flow Transmitter Electronics Installation.........................................................................................................................................16

Instrument Wiring............................................................................................................................................................................21

Post Installation Check....................................................................................................................................................................33

3OPERATION...................................................................................................................................................................................35

Basic Commissioning and Start-Up................................................................................................................................................35

Configuring the ST100A Series.......................................................................................................................................................35

Verify Engineering Units..................................................................................................................................................................39

System Faults, Alarms and Logging Indication...............................................................................................................................39

ST100A Series ConfigurationSoftware Application (User Password: 2772)..................................................................................40

Real Time Clock..............................................................................................................................................................................41

Totalizer Setup................................................................................................................................................................................42

Process Data Logging.....................................................................................................................................................................43

Configuring for AST™ or Constant Power Measurement Methods ................................................................................................46

Flow Filtering...................................................................................................................................................................................47

NAMUR Setup.................................................................................................................................................................................48

Internal Delta-R Resistor (idR) Check.............................................................................................................................................50

Using Digital Outputs......................................................................................................................................................................53

HART Operation..............................................................................................................................................................................54

Service Data Operation...........................................................................................................................................................55

HART Command List Reference.....................................................................................................................................................59

Modbus Operation...........................................................................................................................................................................77

Extended Operation Modes............................................................................................................................................................84

06EN003480 Rev. A ST100A Series Flow Meter

iv Fluid Components International LLC

4MAINTENANCE..............................................................................................................................................................................89

Introduction.....................................................................................................................................................................................89

General Maintenance......................................................................................................................................................................89

Power Fuse Replacement...............................................................................................................................................................90

Lithium Battery Replacement..........................................................................................................................................................91

5TROUBLESHOOTING....................................................................................................................................................................93

Non-Maintenance Observations......................................................................................................................................................93

General Function Check.................................................................................................................................................................94

Troubleshooting the Flow Element..................................................................................................................................................95

Verification of the Electronics..........................................................................................................................................................97

Constant Power Configuration Troubleshooting .............................................................................................................................99

Defective Parts..............................................................................................................................................................................101

Customer Service..........................................................................................................................................................................101

Reference: Error/Status Register Information...............................................................................................................................102

APPENDIX A DRAWINGS................................................................................................................................................................105

APPENDIX B ADDITIONAL INFORMATION....................................................................................................................................135

Parameters Report from the ST100A Series Configuration Software (Sample)...........................................................................136

HMI Menu Outline.........................................................................................................................................................................145

ST100A Series Configuration Software Menu Outline (v3.2.0.x)..................................................................................................146

Instructions: Installing Sun Shield on ST100A Series Integral Enclosure.....................................................................................147

Instructions: Installing Sun Shield on ST100A Series Remote Enclosure ....................................................................................148

APPENDIX C GLOSSARY................................................................................................................................................................149

Abbreviations................................................................................................................................................................................149

Definitions

.....................................................................................................................................................................................149

APPENDIX D APPROVAL INFORMATION......................................................................................................................................151

Safety Instructions.........................................................................................................................................................................152

APPENDIX E CUSTOMER SERVICE..............................................................................................................................................157

Customer Service/Technical Support....................................................................................................................................157

ST100A Series Flow Meter 06EN003480 Rev. A

Fluid Components International LLC v

List of Figures

Figure 1 – Example Compression Fitting Process Connection.................................................................................................................7

Figure 2 – Compression Fitting Installation, Dimensions..........................................................................................................................8

Figure 3 – Example Flange Mount Installation..........................................................................................................................................9

Figure 4 – Example NPT Pipe Thread Mount Installation.........................................................................................................................9

Figure 5 – Retractable Packing Gland Installation..................................................................................................................................10

Figure 6 – Flow Element Installation Using FCI Retractor Tool 026854-01............................................................................................12

Figure 7 – Packing Gland Locking Collar................................................................................................................................................12

Figure 8 – 2-Point Flow Element Installation (Compression Fitting Shown)...........................................................................................15

Figure 9 – ST100AL Process Connection...............................................................................................................................................16

Figure 10 – Integral Electronics Installation (Compression Fitting Shown).............................................................................................17

Figure 11 – Remote Installation, Mounting Bracket on Wall...................................................................................................................18

Figure 12 – Remote Installation, Mounting Bracket on 1" – 1½" Pipe....................................................................................................19

Figure 13 – Remote Installation, Mounting Bracket on 2" Pipe...............................................................................................................19

Figure 14 – Remote Installation, Optional Stainless Steel Bracket on 2" Pipe.......................................................................................20

Figure 15 – Recommended Wiring Routing, Base Electronics Enclosure..............................................................................................21

Figure 16 – ST100A Series I/O Connector Locations.............................................................................................................................22

Figure 17 – ST100A Series Electronics Enclosure Label.......................................................................................................................23

Figure 18 – Bus Configuration 2 mm Jumper Headers and DIP Switch.................................................................................................24

Figure 19 – Input Power Wiring ..............................................................................................................................................................24

Figure 20 – ST100A Series Ferrite Core Installation (Auxiliary Board Not Shown for Clarity)................................................................25

Figure 21 – Flow Element Connections, TB1 and TB2 (Dual Element Models).....................................................................................26

Figure 22 – HART and Ch. 1 & Ch. 2 4-20 mA Connections, J25..........................................................................................................27

Figure 23 – Single Connection and Multidrop HART Setups..................................................................................................................28

Figure 24 – Ch. 3 4-20 mA Output, J8 (Aux. Board)...............................................................................................................................28

Figure 25 – Modbus/PROFIBUS/Fieldbus Connections, J8...................................................................................................................29

Figure 26 – Modbus Wiring.....................................................................................................................................................................29

Figure 27 – Fieldbus/PROFIBUS Wiring.................................................................................................................................................30

Figure 28 – Source/Sink Outputs, Pressure Input, and Ext. 4-20 mA Input Connections, J9.................................................................31

Figure 29 – Source Output......................................................................................................................................................................32

Figure 30 – Sink Output..........................................................................................................................................................................32

Figure 31 – ST100A Series Service Ports..............................................................................................................................................33

Figure 32 – Hot Key on the Optional HMI Display..................................................................................................................................35

Figure 33 – HMI Display IR Sensor Functions........................................................................................................................................36

Figure 34 – Basic Setup Options, HMI....................................................................................................................................................37

Figure 35 – Instrument Setup Options....................................................................................................................................................37

Figure 36 – Display Setup Options.........................................................................................................................................................38

Figure 37 – Configuration Software Tabs for Basic Setup Functions.....................................................................................................39

Figure38 –ExampleLog, Alarm,andLogging IconsontheOptional Display...............................................................................................40

Figure 39 – The Configurator Welcome Screen .....................................................................................................................................40

06EN003480 Rev. A ST100A Series Flow Meter

vi Fluid Components International LLC

Figure 40 – Example Process Data Screen............................................................................................................................................41

Figure 41 – Example Date and Time Set Screen ...................................................................................................................................41

Figure 42 – Example Totalizer Display Showing Total Flow Value.........................................................................................................42

Figure 43 – Totalizer Setup Screen........................................................................................................................................................42

Figure 44 – SD Card Data Logging Example Screen (Basic Setup).......................................................................................................43

Figure 45 – Example AST Power Mode Tab (Configuration)..................................................................................................................46

Figure 46 – Flow Filtering Setup Screen.................................................................................................................................................47

Figure 47 – Chart: Flow Output Over Time with Various Flow Damping Values....................................................................................48

Figure 48 – NAMUR Fault.......................................................................................................................................................................48

Figure 49 – NAMUR Output Level Selection (4-20 mA User Tab)..........................................................................................................49

Figure 50 – Example idR Check Results Display ...................................................................................................................................50

Figure 51 – Example Internal Delta R Scheduled Screen (After Clicking "Run test now...")..................................................................51

Figure 52 – idR Log and Process Data Log Files on microSD Card Example........................................................................................51

Figure 53 – Example Internal Delta-R Log File Results (Data Formatted and Titles Added using Microsoft Excel)...............................51

Figure 54 – Internal Delta-R Resistor Check (idR) HMI Display Sequence............................................................................................52

Figure 55 – Digital Bus Deactivation Warning When Enabling HART....................................................................................................53

Figure 56 – Field Communicator Easy Upgrade Utility, Import DD.........................................................................................................55

Figure 57 – ST100A Series Configuration Software Output Tab with Modbus Selected........................................................................77

Figure 58 – ST100A Series Configuration Software Modbus Tab, Serial Interface Configuration..........................................................78

Figure 59 – Extended Operating Mode Status on Front Panel Display (EGS Shown) ...........................................................................84

Figure 60 – Auxiliary Input Configuration................................................................................................................................................84

Figure 61 – Example Extended Op. Mode Tab (Configuration)..............................................................................................................85

Figure 62 – Connections for External Flow Input (EFI)...........................................................................................................................85

Figure 63 – External ST100A Series Flow Input (EFI) Setup Screen.....................................................................................................86

Figure 64 – Example Configurator Process Data Screen with EFI Mode Shown...................................................................................86

Figure 65 – External Control Group Switching (EGS) Setup Screen......................................................................................................87

Figure 66 – Example Process Data Screen with EGS Mode Shown......................................................................................................88

Figure 67 – Fuse Location, Power Supply Board ...................................................................................................................................90

Figure 68 – Instrument Disassembly for Lithium Coin Cell Battery (CR2450N) Replacement...............................................................92

Figure 69 – Example Heater Values Tab (Diagnostics)..........................................................................................................................96

Figure 70 – System Status LED, Main Board (Aux. Board Not Shown for Clarity).................................................................................97

Figure 71 – DMM Hookup to Measure 4-20 mA Output .........................................................................................................................99

Figure 72 – Connecting FES-200 to ST100A Series Transmitter.........................................................................................................100

Figure 73 – ST100A Series Decade Box Wiring...................................................................................................................................100

ST100A Series Flow Meter 06EN003480 Rev. A

Fluid Components International LLC vii

List of Tables

Table 1 – Compression Fitting Material....................................................................................................................................................8

Table 2 – Interconnecting Cable Minimum Conductor Size....................................................................................................................21

Table 3 – Modbus Select Jumpers .........................................................................................................................................................30

Table 4 – Modbus Line Configuration Jumpers......................................................................................................................................30

Table 5 – FOUNDATION Fieldbus/PROFIBUS Select Jumpers.................................................................................................................31

Table 6 – Flow Parameters, HMI............................................................................................................................................................38

Table 7 – Log File Filename Format LGabcdxx.csv ...............................................................................................................................44

Table 8 – Log File Entry Example...........................................................................................................................................................44

Table 9 – Fatal Faults that Trigger NAMUR............................................................................................................................................49

Table 10 – ST100A Series HART Process Variables.............................................................................................................................54

Table 11 – ST80/ST80L HART Field Device Registration Information...................................................................................................55

Table 12 – HART Universal Commands.................................................................................................................................................59

Table 13 – HART Common Practice Commands...................................................................................................................................66

Table 14 – ST100A Series HART Device Specific Command Groupings..............................................................................................68

Table 15 – HART Device Specific Commands.......................................................................................................................................68

Table 16 – Command Status Bytes, Bit Assignments ............................................................................................................................74

Table 17 – Command-Specific Response Codes...................................................................................................................................74

Table 18 – Command 48, Additional Device Status Bytes Bit Assignments...........................................................................................75

Table 19 – HART Engineering Units Codes ...........................................................................................................................................76

Table 20 – ST100A Series Modbus Function Codes..............................................................................................................................78

Table 21 – ST100A Series Modbus Process Data .................................................................................................................................79

Table 22 – Modbus Service Data – Service and Setup Functions..........................................................................................................80

Table 23 – ST100A Series Modbus Engineering Unit Codes.................................................................................................................82

Table 24 – ST100A Series Modbus Exception Codes............................................................................................................................83

Table 25 – ST100A Series Modbus Variables and Registers Map.........................................................................................................83

Table 26 – Power Fuse Summary ..........................................................................................................................................................90

Table 27 – Lithium Coin Cell Battery Summary......................................................................................................................................91

Table 28 – Flow Element Resistance Measurements (In Ohms) Taken From Remote/Integral Electronics..........................................95

Table 29 – Flow Element Resistance (In Ohms) at the Local Enclosure................................................................................................95

Table 30 – Nominal Heater Parameter Ranges......................................................................................................................................96

Table 31 – System Status LED D3 States..............................................................................................................................................97

Table 32 – Instrument Power Supply Voltages.......................................................................................................................................98

Table 33 – Basic CORE Fault Register (CORE CY Command)...........................................................................................................102

Table 34 – Detailed CORE Fault Register (CORE 2V Command).......................................................................................................103

Table 35 – FE Fault Register (FE DF Command).................................................................................................................................104

Table 36 – ST100A Series Drawings in Appendix A.............................................................................................................................105

06EN003480 Rev. A ST100A Series Flow Meter

viii Fluid Components International LLC

Typographical Conventions

Important notes or warnings are shown like the following:

Note:

A note is additional information that adds to or supplements the topic.

Caution:

A caution indicates an action that can cause equipment damage, loss of data or software, or minor injury.

Warning:

A warning indicates an action that can cause equipment damage, or serious injury/death, or both.

Caution symbols that may be marked on the product or its packaging are explained below:

Risk of Danger symbol (observe all warnings and cautions in manual).

Hot Surface Caution symbol (risk of burn from probe heater).

ESD (Electrostatic Discharge) Susceptibility symbol (do not touch without

appropriate precautions).

Static-sensitive Devices symbol (use ESD handling procedures).

ST100A Series Flow Meter GENERAL

Fluid Components International LLC 1

1 GENERAL

Product Description

The ST100A Series is a thermal dispersion, industrial process grade air/gas flow meter. It is suitable for all air and gas flow measurement

applications in line sizes from 1" to 100" [25 to 2500 mm] and larger. The instrument provides direct mass flow measuring and measures flow rate,

totalized flow and temperature, and the STP versions add pressure measurement.

The measurements are made available to the user by way of 4-20 mA analog output channels with HART or pre-selected digital bus protocols. The

optional graphics display provides real-time process variable values along with flow range and process description information.

There are no moving parts to clean or maintain. A wide selection of process connections are offered to fit with any process piping. Versions are

available for temperature service from -40 °F [-40 °C] to 850 °F [454 °C].

The ST100A Series electronics/transmitter can be integrally mounted with the flow sensor or remote mounted up to 1000' [300m] from the sensor

element. Additional patented or FCI exclusive features include VeriCal® in-situ calibration verification, AST™ (patent pending) adaptive sensing

technology measuring technique, dual sensor/single transmitter models, and a built-in data logger capable of storing more than 20M readings. All

ST100A Series instruments are precision calibrated in FCI’s world-class, NIST traceable calibration facility on one of our flow stands matched to your

gas application and actual installation conditions.

Theory of Operation

The instrument is functionally based on the thermal dispersion operating principal. With AST™, power to the active RTD sensor’s heater is varied to

maintain a constant Delta T with the reference (unheated) RTD sensor. The flow rate and the heater power needed to maintain Delta T is

proportional. Once the heater current reaches a set maximum, the heater current is maintained as the instrument reads the varying sensor

resistance (Delta R). This resistance is proportional to flow rate. The transition between reading the heater power (constant Delta T) and reading the

sensor resistance (constant power) is seamless and automatic and is the key to the AST™ feature. The differential signal, whether it’s from the

sensor heater power (constant Delta T) or the sensor resistance (constant power) is scaled to drive a 4-20 mA flow output. A second temperature

output, from the unheated reference sensor, drives a second 4-20 mA output. A third 4-20 mA output is optional.

Safety Instructions

Warning:

Explosion Hazard. Do not disconnect equipment when flammable or combustible atmosphere is present.

●Field wiring shall be in accordance with NEC (ANSI-NFPA 70) or CEC (CSA C22.1) locations as applicable.

●Theinstrumentmust beinstalled,commissionedandmaintainedby qualifiedpersonneltrained inprocessautomationand control

instrumentation.Theinstallationpersonnel mustensure the instrument has been wired correctlyaccording tothe applicable wiringdiagram.

●All location specific installation and wiring requirements must be met and maintained. FCI recommends an input power circuit breaker

be installed between the power source and the flow meter. This facilitates easy power disconnection during commissioning and

maintenance procedures. Use a switch or circuit breaker if the instrument is in a hazardous area.

●The flow meter contains electrostatic discharge (ESD) sensitive devices. Use standard ESD precautions when handling the circuit

board assemblies.

●Hazardous Areas: The instrument is designed for use in hazardous areas. The approved area classification is identified on the

nameplate along with the temperature and pressure limitations. The USB port and the optional Ethernet port do not support the

hazardous area requirements and should only be used when the area is declassified. Remove any non-certified parts such as plastic

protection caps from cable entry ports and replace by suitable wiring and cabling system certified by notified bodies for use in

hazardous areas.

●When mounting the flow element into the process pipe, it is important that a lubricant/sealant is applied to the mating threads. Use a

lubricant/sealant that is compatible with the process media. Tighten all connections firmly. To avoid leaks do not overtighten or cross-

thread connections.

Order Verification

●Verify the received hardware matches the purchased hardware and application requirements. Verify the model/part number on the

instrument I.D. tag (e.g., ST100AL – 43E8000…) matches the purchased model/part number.

●Review the Calibration requirements as specified on the Engineering Data Sheet in the documentation package. Verify the flow,

temperature and pressure limits meet the application requirements.

GENERAL ST100A Series Flow Meter

2 Fluid Components International LLC

Hardware - Model Descriptions

ST100A – Single point insertion element with flow and temperature process output

ST100AL – In Line element with flow and temperature process output

ST102AA – Dual point insertion elements with flow and temperature process output

ST110A – Single point insertion element with flow and temperature process output, VeriCal option

ST112AA – Dual point insertion elements with flow and temperature process output, VeriCal option

STP100A – Single point insertion element with flow, temperature and pressure process output

STP110A – Single point insertion element with flow and temperature process output, VeriCal option

Documentation and Accessories

06EN003480 ST100A Series Installation, Operation, & Maintenance Manual

06EN003481 ST100A Series Configuration Software Manual

Calibration Certification Documentation

PC Configuration Software and USB Cable

Supplemental Manuals, optional

06EN003482 ST100A Series FOUNDATION™ Fieldbus Manual

06EN003483 ST100A Series PROFIBUS PA Manual

Supplemental Software, optional

HART DD Files

FOUNDATION Fieldbus

PROFIBUS DD File

PDM/DTMs

This manual suits for next models

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