FCI ST80 Series Instruction manual

06EN003490 Rev. B

06EN003490 Rev. B ST80/ST80L 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.

ST80/ST80L Flow Meter 06EN003490 Rev. B

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

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

ST80 Insertion Sensor Installation....................................................................................................................................................7

ST80L In-Line Process Connection................................................................................................................................................12

Flow Transmitter Electronics Installation.........................................................................................................................................12

Instrument Wiring............................................................................................................................................................................17

Post Installation Check....................................................................................................................................................................26

3OPERATION...................................................................................................................................................................................27

Basic Commissioning and Start-Up................................................................................................................................................27

Configuring the ST80/ST80L...........................................................................................................................................................27

Verify Engineering Units..................................................................................................................................................................31

System Faults, Alarms and Logging Indication...............................................................................................................................31

ST80/ST80L ConfigurationSoftware Application (User Password: 2772)......................................................................................32

Real Time Clock..............................................................................................................................................................................33

Totalizer Setup................................................................................................................................................................................34

Configuring for AST™ or Constant Power Measurement Methods................................................................................................35

Flow Filtering...................................................................................................................................................................................36

NAMUR Setup.................................................................................................................................................................................37

Internal Delta-R Resistor (idR) Check.............................................................................................................................................39

Using Digital Outputs ......................................................................................................................................................................42

HART Operation..............................................................................................................................................................................42

HART Command List Reference.....................................................................................................................................................47

Modbus Operation...........................................................................................................................................................................65

4MAINTENANCE..............................................................................................................................................................................75

Introduction.....................................................................................................................................................................................75

General Maintenance......................................................................................................................................................................75

Power Fuse Replacement...............................................................................................................................................................76

Lithium Battery Replacement..........................................................................................................................................................77

06EN003490 Rev. B ST80/ST80L Flow Meter

iv Fluid Components International LLC

5TROUBLESHOOTING....................................................................................................................................................................79

Non-Maintenance Observations......................................................................................................................................................79

General Function Check.................................................................................................................................................................80

Troubleshooting the Flow Element..................................................................................................................................................81

Verification of the Electronics..........................................................................................................................................................83

Constant Power Configuration Troubleshooting.............................................................................................................................85

Defective Parts................................................................................................................................................................................87

Customer Service............................................................................................................................................................................87

Reference: Error/Status Register Information.................................................................................................................................88

APPENDIX A DRAWINGS..................................................................................................................................................................91

APPENDIX B ADDITIONAL INFORMATION....................................................................................................................................123

Parameters Report from the ST80/ST80L Configuration Application (Sample)............................................................................124

HMI Menu Outline.........................................................................................................................................................................129

ST80/ST80L Configuration Software Menu Outline (v3.2.0.x)......................................................................................................130

Instructions: Installing Sun Shield on ST80/ST80L Integral Enclosure.........................................................................................131

Instructions: Installing Sun Shield on ST80/ST80L Remote Enclosure........................................................................................132

APPENDIX C GLOSSARY................................................................................................................................................................133

Abbreviations................................................................................................................................................................................133

Definitions

.....................................................................................................................................................................................133

APPENDIX D APPROVAL INFORMATION......................................................................................................................................135

Safety Instructions.........................................................................................................................................................................139

APPENDIX E CUSTOMER SERVICE..............................................................................................................................................145

ST80/ST80L Flow Meter 06EN003490 Rev. B

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 – Packing Gland Locking Collar................................................................................................................................................11

Figure 7 – ST80L Process Connection...................................................................................................................................................12

Figure 8 – Integral Electronics Installation (Compression Fitting Shown)...............................................................................................13

Figure 9 – Remote Installation, Mounting Bracket on Wall.....................................................................................................................14

Figure 10 – Remote Installation, Mounting Bracket on 1" – 1½" Pipe....................................................................................................15

Figure 11 – Remote Installation, Mounting Bracket on 2" Pipe...............................................................................................................15

Figure 12 – Remote Installation, Optional Stainless Steel Bracket on 2" Pipe.......................................................................................16

Figure 13 – Recommended Wiring Routing, Base Electronics Enclosure..............................................................................................17

Figure 14 – ST80/ST80L I/O Connector Locations.................................................................................................................................18

Figure 15 – ST80/ST80L Electronics Enclosure Label...........................................................................................................................19

Figure 16 – Bus Configuration 2 mm Jumper Headers and DIP Switch.................................................................................................19

Figure 17 – Input Power Wiring ..............................................................................................................................................................20

Figure 18 – ST80/ST80L Ferrite Core Installation..................................................................................................................................20

Figure 19 – Flow Element Connections, TB1 .........................................................................................................................................21

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

Figure 21 – Single Connection and Multidrop HART Setups..................................................................................................................23

Figure 22 – Modbus/PROFIBUS/Fieldbus Connections, J8...................................................................................................................24

Figure 23 – Modbus Wiring.....................................................................................................................................................................24

Figure 24 – Fieldbus/PROFIBUS Wiring.................................................................................................................................................25

Figure 25 – Hot Key on the Optional HMI Display..................................................................................................................................27

Figure 26 – HMI Display IR Sensor Functions........................................................................................................................................28

Figure 27 – Basic Setup Options, HMI....................................................................................................................................................29

Figure 28 – Instrument Setup Options....................................................................................................................................................29

Figure 29 – Display Setup Options.........................................................................................................................................................30

Figure 30 – Configuration Software Tabs for Basic Setup Functions.....................................................................................................31

Figure31 –ExampleLog,Alarm,andLogging Iconson theOptionalDisplay...............................................................................................32

Figure 32 – The Configurator Welcome Screen .....................................................................................................................................32

Figure 33 – Example Process Data Screen............................................................................................................................................33

Figure 34 – Example Date and Time Set Screen ...................................................................................................................................33

Figure 35 – Example Totalizer Display Showing Total Flow Value.........................................................................................................34

Figure 36 – Totalizer Setup Screen........................................................................................................................................................34

Figure 37 – Example AST Power Mode Tab (Configuration)..................................................................................................................35

Figure 38 – Flow Filtering Setup Screen.................................................................................................................................................36

Figure 39 – Chart: Flow Output Over Time with Various Flow Damping Values....................................................................................37

06EN003490 Rev. B ST80/ST80L Flow Meter

vi Fluid Components International LLC

Figure 40 – NAMUR Fault.......................................................................................................................................................................37

Figure 41 – NAMUR Output Level Selection (4-20 mA User Tab)..........................................................................................................38

Figure 42 – Example idR Check Results Display ...................................................................................................................................39

Figure 43 – Example Internal Delta R Scheduled Screen (After Clicking "Run test now...")..................................................................40

Figure 44 – Example Internal Delta R Test Logs Screen........................................................................................................................40

Figure 45 – Internal Delta-R Resistor Check (idR) HMI Display Sequence............................................................................................41

Figure 46 – Digital Bus Deactivation Warning When Enabling HART....................................................................................................42

Figure 47 – Field Communicator Easy Upgrade Utility, Import DD.........................................................................................................44

Figure 48 – ST80/ST80L Configuration Software Output Tab with Modbus Selected............................................................................65

Figure 49 – ST80/ST80L Configuration Software Modbus Tab, Serial Interface Configuration .............................................................66

Figure 50 – ModScan32, Data Definition................................................................................................................................................68

Figure 51 – ModScan32, Serial Interface and Transmission Mode Configuration..................................................................................69

Figure 52 – ModScan32 Connected to Modbus Device with Registers 4111 and 4112 on Display (Totalizer 1 Count)........................69

Figure 53 – ModScan32 Connected to Modbus Device with Registers 4113 and 4114 on Display (Rollover Count)............................70

Figure 54 – ModScan32 Connected to Modbus Device with Register 4115 on Display (Ceiling Value)................................................70

Figure 55 – ModScan32 Connected to Modbus Device with Register 4117 on Display (Totalizer Reset).............................................71

Figure 56 – ModScan32 Connected to Modbus Device with Register 4118 on Display (Totalizer Start/Stop).......................................71

Figure 57 – Fuse Location, Power Supply Board ...................................................................................................................................76

Figure 58 – Instrument Disassembly for Lithium Coin Cell Battery (CR2450N) Replacement...............................................................78

Figure 59 – Example Heater Values Tab (Diagnostics)..........................................................................................................................82

Figure 60 – System Status LED, Main Board.........................................................................................................................................83

Figure 61 – DMM Hookup to Measure 4-20 mA Output..........................................................................................................................85

Figure 62 – Connecting FES-200 to ST80/ST80L Transmitter...............................................................................................................86

Figure 63 – ST80/ST80L Decade Box Wiring.........................................................................................................................................86

Figure 64 – Tag, Unit Certification, FM (Canada/US), ST80/ST80L.....................................................................................................136

Figure 65 –Tag, Unit Certification, ATEX, IECEx, ST80/ST80L Integral Configuration........................................................................137

Figure 66 –Tags, Unit Certification, ATEX, IECEx, ST80/ST80L Remote Configuration......................................................................138

ST80/ST80L Flow Meter 06EN003490 Rev. B

Fluid Components International LLC vii

List of Tables

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

Table 2 – Interconnecting Cable Minimum Conductor Size....................................................................................................................17

Table 3 – Modbus Select Jumpers .........................................................................................................................................................25

Table 4 – Modbus Line Configuration Jumpers......................................................................................................................................25

Table 5 – FOUNDATION Fieldbus/PROFIBUS Select Jumpers.................................................................................................................26

Table 6 – FOUNDATION Fieldbus/PROFIBUS Line Configuration Jumpers..............................................................................................26

Table 7 – Flow Parameters, HMI............................................................................................................................................................30

Table 8 – Fatal Faults that Trigger NAMUR............................................................................................................................................38

Table 9 – ST80/ST80L HART Process Variables...................................................................................................................................43

Table 10 – ST80/ST80L HART Field Device Registration Information...................................................................................................43

Table 11 – HART Universal Commands.................................................................................................................................................47

Table 12 – HART Common Practice Commands...................................................................................................................................54

Table 13 – ST80/ST80L HART Device Specific Command Groupings..................................................................................................56

Table 14 – HART Device Specific Commands.......................................................................................................................................56

Table 15 – Command Status Bytes, Bit Assignments ............................................................................................................................62

Table 16 – Command-Specific Response Codes...................................................................................................................................62

Table 17 – Command 48, Additional Device Status Bytes Bit Assignments...........................................................................................63

Table 18 – HART Engineering Units Codes ...........................................................................................................................................64

Table 19 – ST80/ST80L Modbus Function Codes..................................................................................................................................66

Table 20 – ST80/ST80L Modbus Process Data .....................................................................................................................................67

Table 21 – Modbus Service Data............................................................................................................................................................68

Table 22 – ST80/ST80L Modbus Engineering Unit Codes.....................................................................................................................72

Table 23 – ST80/ST80L Modbus Exception Codes................................................................................................................................73

Table 24 – ST80/ST80L Modbus Variables and Registers Map.............................................................................................................73

Table 25 – Power Fuse Summary ..........................................................................................................................................................76

Table 26 – Lithium Coin Cell Battery Summary......................................................................................................................................77

Table 27 – Flow Element Resistance Measurements (In Ohms) Taken From Remote/Integral Electronics..........................................81

Table 28 – Flow Element Resistance (In Ohms) at the Local Enclosure................................................................................................81

Table 29 – Nominal Heater Parameter Ranges......................................................................................................................................82

Table 30 – System Status LED D3 States..............................................................................................................................................83

Table 31 – Instrument Power Supply Voltages.......................................................................................................................................84

Table 32 – CORE Fault Register Definitions ..........................................................................................................................................88

Table 33 – Devices (Sensor x) Status Codes #1 Register......................................................................................................................89

Table 34 – Devices (Sensor x) Status Codes #2 Register......................................................................................................................89

Table 35 – Devices (Sensor x) Status Codes #3 Register......................................................................................................................90

Table 36 – ST80/ST80L Drawings in Appendix A...................................................................................................................................91

06EN003490 Rev. B ST80/ST80L 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).

ST80/ST80L Flow Meter GENERAL

Fluid Components International LLC 1

1 GENERAL

Product Description

The ST80/ST80L 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.

The measurements are made available to the user by way of 4-20 mA analog output channels with HART or Modbus (standard) or other pre-selected

digital bus options. 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 ST80/ST80L electronics/transmitter can be integrally mounted with the flow sensor or remote mounted up to 1000’ [300m] from the sensor

element. The ST80/ST80L features the FCI exclusive AST™ (patent pending) adaptive sensing technology measuring technique that provides for

improved response time and accurate flow measurement. All ST80/ST80L instruments are precision calibrated in FCI’s world-class, NIST traceable

calibration facility on one ofour flow stands matched to your gas application and actualinstallation 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.

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.

●The instrument must be installed, commissioned and maintained by qualified personnel trained in process automation and control

instrumentation. The installation personnel must ensure the instrument has been wired correctly according to the applicable wiring

diagram.

●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 USBport does 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., ST80L – 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 ST80/ST80L Flow Meter

2 Fluid Components International LLC

Hardware - Model Descriptions

ST80 – Single point insertion element with flow and temperature process output

ST80L – In Line element with flow and temperature process output

Documentation and Accessories

06EN003490 ST80/ST80L Installation, Operation, & Maintenance Manual

06EN003491 ST80/ST80L Configuration Software Manual

Calibration Certification Documentation

PC Configuration Software and USBCable

Supplemental Manuals, optional

06EN003492 ST80/ST80L FOUNDATION™ Fieldbus Manual

06EN003493 ST80/ST80L 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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