Fluid Components Intl ST51A Manuel

Doc. No. 06EN003426 Rev. C

06EN003426 Rev. C ST51A/ST75A/ST75AV Mass Flow Meters

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.

ST51A/ST75A/ST75AV Flow Meters 06EN003426 Rev. C

Fluid Components International LLC iii

Table of Contents

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

List of Figures ..........................................................................................................................................................................................vii

List of Tables...........................................................................................................................................................................................viii

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

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

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

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

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

Hardware – Model Descriptions................................................................................................................................................2

Optional Accessories ................................................................................................................................................................2

Specifications....................................................................................................................................................................................3

2INSTALLATION.................................................................................................................................................................................5

Instrument Identification and Outline Dimensions.............................................................................................................................5

Pre-Installation..................................................................................................................................................................................5

Serial Number...........................................................................................................................................................................5

Flow Direction Alignment ..........................................................................................................................................................5

Recommended Straight Run.....................................................................................................................................................7

Installing ST51A Flow Element.........................................................................................................................................................7

Compression Fitting Mounting ..................................................................................................................................................7

Retractable Packing Gland Mounting........................................................................................................................................9

Retraction/Removal Procedure.......................................................................................................................................10

Installing ST75A/ST75AV Flow Element.........................................................................................................................................11

Pipe Tee Installation................................................................................................................................................................11

Tube Tee Installation...............................................................................................................................................................11

NPT Flow Tube Installation.....................................................................................................................................................11

Flanged Installation.................................................................................................................................................................11

Re-positioning the Display..............................................................................................................................................................11

Installing the Remote Flow Meter System.......................................................................................................................................12

Remote Cable.........................................................................................................................................................................13

Local Enclosure.......................................................................................................................................................................14

Remote Enclosure...................................................................................................................................................................15

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

Accessing the Interface Board Connection Terminals............................................................................................................18

ESD Precautions.............................................................................................................................................................18

Interface Board Connections...................................................................................................................................................19

Power Connections.........................................................................................................................................................19

Signal Connections.................................................................................................................................................................21

4-20 mA Analog Outputs.................................................................................................................................................21

HART Connections..........................................................................................................................................................22

06EN003426 Rev. C ST51A/ST75A/ST75AV Mass Flow Meters

iv Fluid Components International LLC

Pulse Output and Alarm (Source/Sink)...........................................................................................................................23

Modbus Connections.......................................................................................................................................................24

Serial Interface Connector J9..................................................................................................................................................25

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

Overview.........................................................................................................................................................................................27

Instrument Configuration and Setup Using the Service Port (RS-232)...........................................................................................27

Main Menu ..............................................................................................................................................................................28

Top Level Menu Commands...................................................................................................................................................28

Secondary Commands: CLI....................................................................................................................................................28

Start-up and Commissioning...........................................................................................................................................................28

Z Menu: Configure Flow Units and 4-20 mA Output Scaling ..........................................................................................................29

Changing Flow Units, Example...............................................................................................................................................30

V Menu: Configure Outputs (4-20 mA and Source/Sink Outputs)...................................................................................................30

4-20 mA Configuration............................................................................................................................................................32

Flow/Temperature Assignment.......................................................................................................................................32

NAMUR Mode.................................................................................................................................................................32

HART Damping Value.....................................................................................................................................................32

Source/Sink Output Configuration...........................................................................................................................................32

Source/Sink Output Functions.........................................................................................................................................32

Source/Sink Output Programming Parameters...............................................................................................................32

Serial Interface Command Reference.............................................................................................................................................33

Top Level Menu Commands...................................................................................................................................................33

CLI Commands.......................................................................................................................................................................34

HART Operation..............................................................................................................................................................................36

Process Data Operation..........................................................................................................................................................36

ST51A/ST75A/ST75AV HART Process Data Organization....................................................................................................36

ST51A/ST75A/ST75AV Process Variable Slots..............................................................................................................36

Primary Variable Classifications......................................................................................................................................36

Device Description Files..........................................................................................................................................................36

EDDL Files......................................................................................................................................................................37

Loading the DD Files to the 475 Field Communicator ............................................................................................................37

Service Data Operation...........................................................................................................................................................37

HART Command List Reference.....................................................................................................................................................40

ST51A/ST75A/ST75AV HART Universal Commands.............................................................................................................40

ST51A/ST75A/ST75AV HART Common Practice Commands...............................................................................................47

ST51A/ST75A/ST75AV HART Device Specific Commands...................................................................................................49

HART Command Bit Assignments..........................................................................................................................................52

Command Status Bytes...................................................................................................................................................52

Command 48, Additional Device Status Bytes................................................................................................................54

HART Engineering Units Codes..............................................................................................................................................55

ST51A/ST75A/ST75AV Flow Meters 06EN003426 Rev. C

Fluid Components International LLC v

Modbus Operation...........................................................................................................................................................................56

Setting Up the ST51A/ST75A/ST75AV for Modbus Operation...............................................................................................56

ST51A/ST75A/ST75AV Modbus Commands..........................................................................................................................57

ST51A/ST75A/ST75AV Process Data Registers....................................................................................................................57

Totalizer Register Description.................................................................................................................................................58

ST51A/ST75A/ST75AV Modbus Service Registers................................................................................................................59

Examples of Totalizer Service Register Access using ModScan32........................................................................................59

Checking the Totalizer Value..........................................................................................................................................59

Resetting the Totalizer Value..........................................................................................................................................61

Starting/Stopping the Totalizer Count .............................................................................................................................61

Checking K Factor Values...............................................................................................................................................62

Changing/Setting K Factor Values..................................................................................................................................62

Modbus Engineering Units Codes Table.................................................................................................................................64

Modbus Device Status Code Table.........................................................................................................................................64

4MAINTENANCE..............................................................................................................................................................................65

Calibration.......................................................................................................................................................................................65

Electrical Connections.....................................................................................................................................................................65

Remote Enclosure...........................................................................................................................................................................65

Electrical Wiring ..............................................................................................................................................................................65

Flow Element Connections.............................................................................................................................................................65

Flow Element Assembly..................................................................................................................................................................65

5TROUBLESHOOTING....................................................................................................................................................................67

Application Verification....................................................................................................................................................................67

Equipment Needed.........................................................................................................................................................................67

Check Serial Numbers....................................................................................................................................................................67

Check the Instrument Installation....................................................................................................................................................67

Check for Moisture..........................................................................................................................................................................67

Check Application Design Requirements........................................................................................................................................67

Verify Standard Versus Actual Process Conditions........................................................................................................................67

Verifying Calibration Parameters (Diagnostics)..............................................................................................................................68

Hardware Verification......................................................................................................................................................................69

Fuse Check.............................................................................................................................................................................69

Sensor Check..........................................................................................................................................................................69

Transmitter Circuit Calibration Check (Delta R Verification)...........................................................................................................70

References..............................................................................................................................................................................70

Equipment...............................................................................................................................................................................70

Procedure................................................................................................................................................................................70

06EN003426 Rev. C ST51A/ST75A/ST75AV Mass Flow Meters

vi Fluid Components International LLC

APPENDIX A DRAWINGS..................................................................................................................................................................73

APPENDIX B GLOSSARY..................................................................................................................................................................91

Abbreviations..................................................................................................................................................................................91

Definitions .......................................................................................................................................................................................91

APPENDIX C APPROVAL INFORMATION........................................................................................................................................93

EU Information........................................................................................................................................................................93

Specific Conditions of Use per FM16ATEX0008X..................................................................................................................94

IEC Information.......................................................................................................................................................................95

APPENDIX D CUSTOMER SERVICE..............................................................................................................................................101

Customer Service/Technical Support....................................................................................................................................101

Warranty Repairs or Returns ................................................................................................................................................101

Non-Warranty Repairs or Returns.........................................................................................................................................101

Extended Warranty ...............................................................................................................................................................101

Return to Stock Equipment...................................................................................................................................................101

Field Service Procedures......................................................................................................................................................102

Field Service Rates...............................................................................................................................................................102

ST51A/ST75A/ST75AV Flow Meters 06EN003426 Rev. C

Fluid Components International LLC vii

List of Figures

Figure 1 – Probe Serial Number, Reference Flat and Flow Direction Mark..............................................................................................5

Figure 2 – Serial Number Location on Interface Board (AC Version Shown) with Blind Cover Removed................................................6

Figure 3 – ST51A Flow Arrow Alignment..................................................................................................................................................6

Figure 4 – Recommended Straight Run (ST75A Shown).........................................................................................................................7

Figure 5 – Flow Element Installation, Compression Fitting ST51A...........................................................................................................8

Figure 6 – Flow Element Installation, Retractable Packing Gland ST51A................................................................................................9

Figure 7 – Retractable Packing Gland Locking Collar Detail..................................................................................................................10

Figure 8 – Display Re-positioning...........................................................................................................................................................12

Figure 9 – Typical Remote Flow Meter System (ST51A with ½" NPT Cable Port Shown).....................................................................12

Figure 10 – Remote Cable, Interconnecting...........................................................................................................................................13

Figure 11 – Remote Cable Installation, Local Enclosure........................................................................................................................14

Figure 12 – Local Enclosure Remote Cable Wiring................................................................................................................................14

Figure 13 – Remote Cable/Bracket Installation, Remote Enclosure.......................................................................................................16

Figure 14 – Remote Enclosure Interface Board Connector J4 Detail (AC Version Shown)....................................................................16

Figure 15 – ST51A/ST75A/ST75AV Wiring Access................................................................................................................................17

Figure 16 – Recommended Wire Routing/Internal Ground Screw..........................................................................................................18

Figure 17 – Power and Signal Wiring Terminals.....................................................................................................................................19

Figure 18 – Input Power Fuse Locations................................................................................................................................................20

Figure 19 – Single Connection and Multidrop HART Setups..................................................................................................................22

Figure 20 – Sink Output..........................................................................................................................................................................23

Figure 21 – Source Output......................................................................................................................................................................23

Figure 22 – Modbus Wiring.....................................................................................................................................................................24

Figure 23 – Serial Cable Adapter 025859-01 Plugged Into Flow Meter J9 Header................................................................................25

Figure 24 – Block Diagram: Flow Meter Serial Port Connections, FC88 and Computer........................................................................26

Figure 25 – Z Menu Command Structure: Units and Scaling Setup.......................................................................................................29

Figure 26 – V Menu Command Structure: Output Configuration Setup..................................................................................................31

Figure 27 – Field Communicator Easy Upgrade Utility, Import DD.........................................................................................................37

Figure 28 – Reference and Active Sensor Resistance Check (AC Version Shown) ..............................................................................69

Figure 29 – Transmitter Circuit Calibration Diagram...............................................................................................................................71

Figure 30 – Basic Instrument Assembly: ST51A, ST75A and ST75AV..................................................................................................74

06EN003426 Rev. C ST51A/ST75A/ST75AV Mass Flow Meters

viii Fluid Components International LLC

List of Tables

Table 1 – Optional Accessories................................................................................................................................................................2

Table 2 – Compression Fitting Material....................................................................................................................................................8

Table 3 – Power and Signal Wiring Summary........................................................................................................................................21

Table 4 – Serial Port J9 Pinout...............................................................................................................................................................25

Table 5 – Serial (COM) Port Configuration.............................................................................................................................................27

Table 6 – Typical Serial Interface Top Level Commands for Flow Meter Configuration.........................................................................29

Table 7 – Flow Unit Example..................................................................................................................................................................30

Table 8 – Top Level Menu Commands...................................................................................................................................................33

Table 9 – List of CLI Commands ............................................................................................................................................................34

Table 10 – ST51A/ST75A/ST75AV HART Process Variables................................................................................................................36

Table 11 – ST51A/ST75A/ST75AV HART Device Registration Information...........................................................................................37

Table 12 – HART Universal Commands.................................................................................................................................................40

Table 13 – HART Common Practice Commands...................................................................................................................................47

Table 14 – HART Device Specific Commands.......................................................................................................................................49

Table 15 – Command Status Bytes, Bit Assignments ............................................................................................................................53

Table 16 – Command-Specific Response Codes...................................................................................................................................53

Table 17 – Command 48, Additional Device Status Bytes Bit Assignments...........................................................................................54

Table 18 – HART Engineering Units Codes ...........................................................................................................................................55

Table 19 – ST51A/ST75A/ST75AV Modbus Function Codes.................................................................................................................57

Table 20 – ST51A/ST75A/ST75AV Modbus Process Data....................................................................................................................58

Table 21 –Modbus Service Data.............................................................................................................................................................59

Table 22 – Modbus Engineering Units Codes ........................................................................................................................................64

Table 23 – Device Status Code Bit Assignments, Register #4025.........................................................................................................64

Table 24 – Diagnostic Test Sequence....................................................................................................................................................68

Table 25 – Appendix A, List of Drawings................................................................................................................................................73

ST51A/ST75A/ST75AV Mass Flow Meters GENERAL

Fluid Components International LLC 1

1 GENERAL

Product Description

The ST51A and ST75A/ST75AV Series are thermal dispersion, industrial process grade air/gas flow meters. They are suitable for all air

and gas flow measurement applications. The ST51A is an insertion type flow meter for line sizes ranging from 2″ to 24″ [51 to 610 mm].

The ST75A is an in-line type flow meter for line sizes ranging from ¼″ to 2″ [6 mm to 51 mm]. Both ST51A and ST75A/ST75AV flow meters

provide direct mass flow measuring and measures flow rate, totalized flow and temperature.

The measurements are made available to the user throughdual 4-20 mA analog output channels, a separate source and sink channel (pulse

output for totalizer or level output for alarm) and HART. The optional alphanumeric LCD display provides real-time process variable values, flow

range and process description information. There are no moving parts to clean or maintain. These flow meters are offered in a wide selection of

process connections to fit with any process piping and versions are available for temperature service from -0°F [-18 °C] to 350°F [177 °C].

ST51A and ST75A/ST75AV’s electronics/transmitter can be integrally mounted with the flow sensor or remote mounted up to 100′[30 m]

from the sensor element. All ST51A and ST75A/ST75AV flow meters are precision calibrated in FCI’s world-class, NIST traceable

calibration facility on one ofour flow stands matched to the customer’s gas application and actual installation conditions.

Theory of Operation

The instrument is functionally based on the thermal dispersion operating principal. Alow powered heater produces a temperature

differential (ΔT) between two Resistance Temperature Detectors (RTDs) by heating one of the RTDs above process temperature. As the

process mass flow rate increases, the temperature differential (ΔT) between the RTDs decreases. The ΔT between the RTDs is

proportional to the process mass flow. The flow transmitter converts the RTD’s ΔT signal into a scaled flow output signal. The signal from

the unheated RTD is used to provide the process temperature value.

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) for Division 2 hazardous locations and CEC (CSA C22.1) for division 2

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 (i.e., local electrical codes) must be met and maintained. Install an input

power circuit breaker or power disconnect switch and fuse near the flow meter to interrupt power during installation and maintenance.

A switch or circuit breaker is required if installation 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. See Agency Approvals, page 3and APPENDIX C, page 93 for a

complete listing of the instrument’s safety/hazardous areas approvals.

Order Verification

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

number on the instrument I.D. tag matches the purchased model number 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 ST51A/ST75A/ST75AV Mass Flow Meters

2 Fluid Components International LLC

Hardware – Model Descriptions

ST51A – Single point insertion element with flow and temperature process output

ST75A – In-line element with flow and temperature process output

ST75AV – Vortab In-line element with flow and temperature process output

Optional Accessories

Table 1 – Optional Accessories

Part Number

Description

FC88

Portable Hand-held Communicator

014108-03

PC Interface Communications Kit, for RS-232 serial port connection

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